Service and Repair Manual

Serial Number Range

S-80
from S8015-12264 to
S8016H-13999
This manual includes:
from S8515-12264 to Repair procedures
S8516H-13999
Fault Codes
S-85
from S80X15-12264 to
S80X16H-13999 Electrical and
from S8015D-101 to
S8016D-339 Hydraulic Schematics

S-80X
from S80X15D-101 to
S80X16D-339

from S80H-14000
from S85H-14000
from S80XH-14000
from S80D-340
from S85D-340
from S80XD-340 For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.

Part No. 1269074

Rev A3
October 2016
Service and Repair Manual October 2016

Introduction
Intr oducti on Intr oducti on

Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that Contact Us:
maintenance and repair be performed at an
authorized Genie dealer service center. Internet: www.genielift.com
E-mail: [email protected]

Compliance Find a Manual for this Model

Go to http://www.genielift.com
Machine Classification
Use the links to locate Service Manuals,
Group B/Type 3 as defined by ISO 16368
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.

Copyright © 2015 by Terex Corporation

1269074 Rev A, September 2015
First Edition, First Printing
"Genie" and "S" are registered trademarks of Terex South
Dakota, Inc. in the USA and many other countries.

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Introduction

Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 7/2016 Repair Procedures Added 4-7, Primary Boom Angle Sensor, S80X
A2 9/2016 Introduction Serial Number Legend
A3 10/2016 Repair; Schematics Hydraulic Drive Manifolds, Hydraulic Schematics

Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics

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Service and Repair Manual October 2016

Introduction

Serial Number Legend

To August 31, 2016

1 Model 4 Sequence number

2 Model year 5 Serial label (located under cover)
3 Facility code 6 Serial number (stamped on chassis)
From September 1, 2016

1 Model 4 Serial label (located under cover)

2 Facility code 5 Serial number (stamped on chassis)
3 Sequence number

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October 2016 Service and Repair Manual

Safety Rules
Section 1 Safety R ules

Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine 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.

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Safety Rules

Personal Safety Workplace Safety

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

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

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Table of Contents

Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules .......................................................................................................... v

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

Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 2
Hydraulic Specification ........................................................................................... 2
Hydraulic Component Specifications...................................................................... 5
Manifold Component Specifications ....................................................................... 6
Continental TME27 Engine Specifications ............................................................. 7
Deutz TD2011L04i Engine Specifications .............................................................. 8
Deutz TD 2.9 Engine Specifications ....................................................................... 9
Perkins 804D-33 Engine Specifications ............................................................... 10
Perkins 404F-22T Engine Specifications ............................................................. 11
Machine Torque Specifications ............................................................................ 12
Hydraulic Hose and Fitting Torque Specifications ............................................... 13
Torque Procedure ................................................................................................ 14

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Table of Contents

Section 3 Repair Procedures ............................................................................................. 16

Introduction .......................................................................................................... 16

Platform Controls ............................................................................................... 18

1-1 ALC-500 Circuit Board ................................................................................... 18
How to Remove the ALC-500 Circuit Board ................................................... 18
1-2 Joysticks ........................................................................................................ 19
How to Adjust the Joystick Max-out Setting ................................................... 20
How to Adjust the Joystick Ramp Rate Setting .............................................. 21
How to Adjust the Joystick Threshold Setting ................................................ 22
How to Calibrate the Boom Angle Sensor ...................................................... 23

Platform Components ....................................................................................... 25

2-1 Platform.......................................................................................................... 25
2-2 Platform Leveling Slave Cylinder ................................................................... 26
How to Remove the Platform Leveling Slave Cylinder ................................... 26
How to Bleed the Slave Cylinder .................................................................... 26
2-3 Platform Rotator ............................................................................................. 27
How to Remove the Platform Rotator ............................................................. 27
How to Bleed the Platform Rotator ................................................................. 28
2-4 Platform Overload System ............................................................................. 29

Jib Boom Components ...................................................................................... 32

3-1 Jib Boom ........................................................................................................ 32
3-2 Jib Boom Lift Cylinder .................................................................................... 33

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Boom Components ............................................................................................ 34

4-1 Cable Track .................................................................................................... 34
How to Remove the Cable Track, S-80 .......................................................... 34
How to Repair the Cable Track ....................................................................... 36
4-2 Boom .............................................................................................................. 36
How to Shim the Boom ................................................................................... 36
How to Remove the Boom .............................................................................. 37
4-3 Boom Lift Cylinder .......................................................................................... 39
4-4 Boom Extension Cylinder ............................................................................... 41
4-5 Boom Extend/Retract Cables ......................................................................... 43
How to Adjust the Extend/Retract Cables ....................................................... 43
How to Replace the Boom Extend/Retract Cables ......................................... 45
4-6 Platform Leveling Master Cylinder ................................................................. 47
4-7 Primary Boom Angle Sensor, S-80X .............................................................. 48

Engines ................................................................................................................ 50
5-1 RPM Adjustment ............................................................................................ 50
5-2 Flex Plate ....................................................................................................... 50
How to Remove the Flex Plate........................................................................ 50
How to Install the Flex Plate............................................................................ 53
How to install the Pump and Bell Housing Assembly ..................................... 54

Ground Controls ................................................................................................. 55

6-1 Control Relays ................................................................................................ 55

Hydraulic Pumps ................................................................................................ 56

7-1 Function Pump ............................................................................................... 56
7-2 Drive Pump..................................................................................................... 57
How to Prime the Pump .................................................................................. 58

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Table of Contents

Manifolds ............................................................................................................ 59
8-1 Function Manifold .......................................................................................... 59
8-2 Valve Adjustments - Function Manifold ......................................................... 61
How to Adjust the System Relief Valve .......................................................... 61
How to Adjust the Boom Down Relief Valve ................................................... 61
How to Adjust the Boom Extend Relief Valve ................................................. 62
8-3 Brake/Two-Speed Manifold Components ...................................................... 63
8-4 Turntable Rotation Manifold Components ..................................................... 64
8-5 Platform Rotate Manifold Components .......................................................... 65
8-6 Platform Manifold Components, S-80 ............................................................ 66
8-7 Platform Manifold Components, S-85 ............................................................ 67
8-8 2WD Traction Manifold Components ............................................................. 68
8-9 4WD Traction Manifold Components ............................................................. 69
8-10 Drive Oil Diverter Manifold Components (welder option) ............................ 71
8-11 Valve Adjustments - Traction Manifold ........................................................ 72
8-12 Valve Coils ................................................................................................... 73
Valve Coil Resistance Specifications ............................................................. 73

Fuel and Hydraulic Tanks ................................................................................. 75

9-1 Fuel Tank ....................................................................................................... 75
9-2 Hydraulic Tank ............................................................................................... 76

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Table of Contents

Turntable Rotation Components ...................................................................... 78

10-1 Turntable Rotation Drive Hub Assembly ...................................................... 78
How to Remove the Turntable Rotation Drive Hub Assembly ........................ 78
How to Remove the Turntable Rotation Hydraulic Motor ............................... 79
How to Adjust the Turntable Rotation Gear Backlash .................................... 80

Steer Axle Components ..................................................................................... 82

11-1 Yoke and Drive Hub ..................................................................................... 82
11-2 Drive Motors ................................................................................................. 83
11-3 Drive Hubs.................................................................................................... 83
11-4 Steer Cylinders ............................................................................................. 84

Non-steer Axle Components ............................................................................. 85

12-1 Drive Motor ................................................................................................... 85
12-2 Drive Hub ..................................................................................................... 85

Oscillating Axle Components ........................................................................... 86

13-1 Oscillate Axle Cylinders ............................................................................... 86
13-2 Oscillate Directional Valve ........................................................................... 87
How to Adjust the Oscillate Relief Valve ......................................................... 87
How to Set Up the Directional Valve Linkage ................................................. 88

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Table of Contents

Section 4 Fault Codes......................................................................................................... 89

Introduction .......................................................................................................... 89

Control System Fault Codes ............................................................................. 90

How to Retrieve Control System Fault Codes ................................................ 90
Control System Fault Codes ........................................................................... 91

Fault Code Display - Deutz and Perkins Models............................................. 95

How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins
404F-22 Models ...................................................................................... 95
Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins
404F-22 Models ...................................................................................... 96
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models
................................................................................................................ 97
Main Menu Structure - Deutz D 2.9 L4 Models .............................................. 98
Main Menu Structure - Perkins 404F-22 Models ............................................ 99

Deutz D 2.9 L4 Engine Fault Codes ................................................................ 100

Perkins 404F-22 Engine Fault Codes ............................................................. 111

Continental TME27 Engine Fault Codes ........................................................ 113

How to Retrieve Continental Engine Fault Codes ........................................ 113
How to Clear Engine Fault Codes from the ECM ......................................... 113
Continental TME27 Engine Fault Codes ...................................................... 114

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Table of Contents

Section 5 Schematics........................................................................................................ 119

Introduction ......................................................................................................... 119
Electrical Symbol Legend ................................................................................... 120
Hydraulic Symbols Legend ................................................................................. 121
Relay and Fuse Panel Legend - Deutz TD2011L04i.......................................... 122
Relay and Fuse Panel Legend - Deutz TD2.9 L4 .............................................. 122
Relay and Fuse Panel Legend - Perkins 404F-22T ........................................... 122
Relay and Fuse Panel Legend - Perkins 804D-33 ............................................. 123
Relay and Fuse Panel Legend - Continental TME27 ......................................... 123
Connector Pin Legends ...................................................................................... 124
Continental TME27 Engine Harness .................................................................. 129
S-80X Ground Control Box Wiring Diagram ....................................................... 130
Deutz TD2.9 L4 Engine Harness........................................................................ 133
Perkins 404F-22T Engine Harness .................................................................... 134

Electrical Schematics, S-80X – ANSI and CSA Models ................................ 136

Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) .......... 137
Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) ........... 141
Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) ......... 143
Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ..... 146
Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ...... 150
Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) .... 151
Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA) ....... 154
Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) ....... 158
Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) ...... 159
Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA) ........ 162
Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA) ......... 166
Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA) ........ 167
Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA) .... 170
Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA) ..... 174
Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA) .... 175

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Table of Contents

Electrical Schematics, S-80, S-85 – ANSI and CSA Models ........................ 177
Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models
(ANSI / CSA) ......................................................................................... 178
Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models
(ANSI / CSA) ......................................................................................... 182
Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models
(ANSI / CSA) ......................................................................................... 183
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models
(ANSI / CSA) ......................................................................................... 186
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models
(ANSI / CSA) ......................................................................................... 190
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models
(ANSI / CSA) ......................................................................................... 191
Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models
(ANSI / CSA) ......................................................................................... 194
Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models
(ANSI / CSA) ......................................................................................... 198
Platform Control Box, S-80 • S-85 - Perkins 404F-22T Models
(ANSI / CSA) ......................................................................................... 199
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models
(ANSI / CSA) ......................................................................................... 202
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models
(ANSI / CSA) ......................................................................................... 206
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models
(ANSI / CSA) ......................................................................................... 207
Electrical Schematic, S-80 • S-85 - Continental TME27 Models
(ANSI / CSA) ......................................................................................... 210
Ground Control Box, S-80 • S-85 - Continental TME27 Models
(ANSI / CSA) ......................................................................................... 214
Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
.............................................................................................................. 215

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Table of Contents

Electrical Schematics, S-80, S-85 – CE Models............................................. 217

Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ............... 218
Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ................ 222
Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ............... 223
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE) ........... 226
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE) ........... 230
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE) .......... 231
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE) .............. 234
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE) .............. 238
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE) ............. 239
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE) .......... 242
Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE) .......... 246
Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE) ......... 247

Electrical Schematics, S-80, S-85 – AS Models............................................. 249

Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS) ........... 250
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)............ 254
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS) .......... 255
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS) .............. 258
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) ............... 262
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) ............. 263
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS) .......... 266
Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS) ........... 270
Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS) ......... 271

Schematics - Options ....................................................................................... 273

Continental Options Schematic ..................................................................... 274
Deutz and Perkins Options Schematic ......................................................... 275
Platform Level Cutout, CTE Option ............................................................... 278
12 kW Hydraulic Generator Wiring Diagram ................................................. 279
12 kW Hydraulic Generator Electrical Schematic ......................................... 282
Belt Driven Generator Option ........................................................................ 283

Hydraulic Schematics ...................................................................................... 285

Hydraulic Schematic, 2WD Models ............................................................... 286
Hydraulic Schematic, 4WD Models ............................................................... 287

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Specifications
Section 2 Specific ati ons

Machine Specifications Fluid capacities

Fuel tank, 35 gallons
Tires and wheels Deutz and Perkins models 132.5 liters
Rough Terrain and Non Marking
Fuel tank, 30 gallons
Tire size 18-625 FF Continental model 113.5 liters
Tire ply rating 16 ply LPG tank 33.5 lbs
Overall tire diameter 40.7 in 15.2 kg
103.3 cm Hydraulic tank 40 gallons
Tire pressure Foam filled 151.4 liters

Wheel diameter 24.5 in Hydraulic system (including tank) 50 gallons

62.2 cm 189.3 liters

Wheel width 15 in Turntable rotation drive hub 40 fl oz

38.1 cm (single fill port) 1183 cc

Tire weight, new foam filled 622 lbs Turntable rotation drive hub 43 fl oz
(minimum) 282 kg (dual fill port) 1262 cc
Drive hubs 30.5 fl oz
Tires and wheels High Flotation
four wheel drive 902 cc
Tire size 41/18LLx22.5 Drive hubs 23 fl oz
two wheel drive 680 cc
Tire ply rating 14 ply
Tire pressure 70 psi Drive hub oil type: SAE 90 multipurpose hypoid
4.8 bar 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 11 @ 3/4 - 16
Lug nut torque, dry 420 ft-lbs
569 Nm
Lug nut torque, lubricated 320 ft-lbs
434 Nm

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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
Stowed position, 40 ft / 11 - 13 sec systems, have the ability to perform over a wide
High Flotation tires 12.2 m / 11 - 13 sec temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
Raised or Extended 40 ft / 40 - 45 sec oxidation prevention, corrosion inhibition, seal
12.2 m / 40 - 45 sec conditioning, and foam and aeration suppression
Braking distance, maximum properties.

High range on paved surface 6 ft / 1.8 m Cleanliness level, ISO 15/13

minimum
Gradeability Refer to Operator's Manual
Water content, 250 ppm
Boom function speeds, maximum from platform maximum
controls
Recommended Hydraulic Fluid
Jib Boom up (S-85) 25 - 35 sec
Hydraulic oil type Chevron Rando HD Premium
Jib Boom down (S-85) 15 - 25 sec
Viscosity grade 32
Boom up (ANSI, CSA, models) 57 - 65 sec
Viscosity index 200
Boom up (CE, AS models) 75 - 83 sec
Optional Hydraulic Fluids
Boom down (ANSI, CSA, models) 61 - 69 sec
Mineral based Shell Tellus S2 V 32
Boom down (CE, AS models) 75 - 83 sec Shell Tellus S2 V 46
Boom extend 59 - 67 sec Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Boom retract 57 - 65 sec Chevron 5606A
Turntable rotate, (360°) fully stowed 95 - 103 sec Biodegradable Petro Canada Environ MV 46
Turntable rotate, (360°) boom raised 210 - 250 sec Fire resistant UCON Hydrolube HP-5046
or extended
Note: Genie specifications require additional
Platform rotate, 160° 8 - 12 sec
equipment and special installation instructions for
Platform level (10° range of motion) 3 - 5 sec the approved optional fluids. Consult Genie Product
ANSI, CSA Support before use.
Platform level (10° range of motion) 20 - 22 sec
CE, AS Optional fluids may not have the
For operational specifications, refer to the same hydraulic lifespan and
Operator's Manual. may result in component
damage.

Note: Extended machine operation can cause the

hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

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October 2016 Service and Repair Manual

Specifications

Do not top off with incompatible Chevron Rando HD Premium Oil

hydraulic fluids. Hydraulic fluids
may be incompatible due to the MV Fluid Properties
differences in base additive ISO Grade 32
chemistry. When incompatible
fluids are mixed, insoluble Viscosity index 200
materials may form and deposit Kinematic Viscosity
in the hydraulic system, cSt @ 200°F / 100°C 7.5
plugging hydraulic lines, filters, cSt @ 104°F / 40°C 33.5
control valves and may result in Brookfield Viscosity
component damage. cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 3310
Note: Do not operate the machine when the Flash point 375°F / 190°C
ambient air temperature is consistently above
Pour point -58°F / -50°C
120°F / 49°C.
Maximum continuous operating 171°F / 77°C
temperature
Hydraulic Fluid Temperature Note: A hydraulic oil heating system is
Range recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

Ambient air temperature

1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

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Specifications

Chevron 5606A Hydraulic Oil Shell Tellus S4 VX Fluid

Fluid Properties Properties
ISO Grade 15 ISO Grade 32
Viscosity index 300 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 5.5 cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C 33.8
cSt @ -40°F / -40°C 510 Brookfield Viscosity
Flash point 180°F / 82°C cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
Pour point -81°F / -63°C
cSt @ -40°F / -40°C 2624
Maximum continuous operating 124°F / 51°C
Flash point >100
temperature
Pour point -76°F / -60°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures Maximum continuous operating 103°F / 75°C
are consistently below 0°F / -17°C unless an oil temperature
heating system is used.

Continued use of Chevron

UCON Hydrolube HP-5046 Fluid
5606A hydraulic fluid, or Properties
equivalent, when ambient
temperatures are consistently ISO Grade 46
above 32°F / 0°C may result in Viscosity index 192
component damage Kinematic Viscosity
cSt @ 149°F / 65°C 22
Petro-Canada Environ MV 46 cSt @ 104°F / 40°C 46
cSt @ 0°F / -18°C 1300
Fluid Properties
Flash point None
ISO Grade 46 Pour point -81°F / -63°C
Viscosity index 154 Maximum continuous operating 189°F / 87°C
Kinematic Viscosity temperature
cSt @ 200°F / 100°C 8.0
cSt @ 104°F / 40°C 44.4
Flash point 482°F / 250°C
Pour point -49°F / -45°C
Maximum continuous operating 180°F / 82°C
temperature

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Specifications

Hydraulic Component Specifications Function manifold

Drive Pump System relief valve pressure, 3200 psi

maximum 221 bar
Type: bi-directional variable displacement piston pump
Primary boom extend relief pressure 2400 psi
Displacement per revolution 0 to 2.8 cu in (measured at PTEST port) 165 bar
0 to 46 cc
Platform Manifold and Oscillate Valve
Flow rate @ 2300 rpm 30.3 gpm
114.7 L/min Platform level flow regulator 0.6 gpm
2.3 L/min
Drive pressure, maximum 3750 psi
Platform rotate flow regulator 0.3 gpm
259 bar
1.1 L/min
Charge Pump Oscillate relief pressure 950 psi
Type gerotor 65.5 bar
Displacement per revolution 0.85 cu in Traction Manifold
13.9 cc
Hot oil relief pressure 280 psi
Flow rate @ 2300 rpm 9 gpm 19.3 bar
34 L/min Brakes
Charge pressure @ 2300 rpm 310 psi
Brake release pressure, 240 psi
Neutral position 21.4 bar
Wheel drive hubs 16.5 bar
Function pump Drive Motors
Type: variable displacement piston pump Displacement per revolution 0.9 cu in
Displacement per revolution 0 to 2.3 cu in high speed: 14.7 cc
0 to 38 cc Displacement per revolution 2.7 cu in
Flow rate @ 2300 rpm 0 to 23 gpm low speed 45 cc
0 to 87 L/min Hydraulic Filters
Pressure, maximum 2900 psi
High pressure filter: Beta 3 ≥200
200 bar
High pressure filter bypass pressure 102 psi
Pressure compensator 2900 psi
7 bar
200 bar
Medium pressure filter Beta 3 ≥200
Standby pressure 250 psi
17.3 bar Medium pressure filter bypass 51 psi
pressure 3.5 bar
Auxiliary Pump
Hydraulic tank return filter 10 micron with
Type: fixed displacement gear pump 25 psi / 1.7 bar
Displacement per revolution 0.15 cu in bypass
2.47 cc Drive motor case drain return filter Beta 10 ≥2

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Specifications

Manifold Component
Specifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
SAE No. 6 14 ft-lbs / 19 Nm
SAE No. 8 38 ft-lbs / 51 Nm
SAE No. 10 41 ft-lbs / 55 Nm
SAE No. 12 56 ft-lbs / 76 Nm

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Specifications

Continental TME27 Engine Oil Pressure switch

Installation torque 8 - 18 ft-lbs
Displacement 164 cu. in 11 - 24 Nm
2.68 liters
Pressure switch point 7 psi
Number of cylinders 4 0.55 bar
Bore and Stroke 3.58 x 4.06 inches Fuel pump
91 x 103.2 mm
Fuel pressure 39-40 psi
Horsepower, continuous 59 hp / 43.9 kW 2.7 bar
@ 2500 rpm
Fuel flow rate 0.42 gpm
Firing order 1-3-4-2 1.59 L/min
Standby idle-computer 1000 rpm Fuel requirement
controlled Frequency
For fuel requirements, refer to the engine Operator
Low function idle-computer 1500 rpm Manual for your engine.
controlled Frequency
Starter motor
53.33 rpm
Current draw, normal load 150-345A
High function idle-computer 2500 rpm
controlled Frequency Cranking speed 200 - 250 rpm
83.33 Hz Battery – Engine starting and control system
Compression ratio 8.2:1 Type 12V DC, Group 31
Compression pressure pressure (psi or bar) of the Quantity 2
lowest cylinder must be at least 75% of the highest
cylinder Battery capacity, maximum 1000A
Governor electronic Reserve capacity @ 25A rate 200 Minutes

Valve clearance, warm Engine coolant

Intake 0.014 in Capacity 10.7 quarts

0.36 mm (engine only) 10.1 liters

Exhaust 0.018 in Coolant temperature switch

0.45 mm Installation torque 8 - 18 ft-lbs
Lubrication system 11 - 24 Nm

Oil pressure, hot 40 to 60 psi Temperature switch point 230°F

2.8 to 4.1 bar 110°C
Oil capacity (including filter) 7 quarts Alternator output 65A @ 13.8V DC
6.6 liters Fan belt deflection 1/2 inch
Oil viscosity requirements 12 mm
-22°F to 86°F / -30°C to 30°C 5W-20
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Deutz TD2011L04i Engine Oil temperature switch

Installation torque 8 - 18 ft-lbs
Displacement 220.9 cu. in 11 - 24 Nm
3.62 liters
Temperature switch point 275°F
Number of cylinders 4 135°C
Bore and Stroke 3.78 x 4.92 inches Oil Pressure switch
96 x 125 mm
Installation torque 8 - 18 ft-lbs
Horsepower net intermittent @ 74 hp 11 - 24 Nm
2400 rpm 55 kW
Pressure switch point 22 psi
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle 1300 rpm Injection pump pressure, maximum 15,000 psi
Low idle w/ belt driven generator 1500 rpm 1034 bar

High idle 2350 rpm Injector opening pressure 3046 psi

210 bar
Compression ratio 17.5:1
Fuel requirement
Compression pressure pressure (psi or bar) of the
For fuel requirements, refer to the engine Operator
lowest cylinder must be at least 75% of the highest
Manual for your engine.
cylinder
Starter motor
Governor centrifugal
mechanical Current draw, normal load 140 - 200A
Valve Clearance, cold Cranking speed 250 - 350 rpm
Intake 0.012 in Battery – Engine starting and control system
0.3 mm Type 12V DC, Group 31
Exhaust 0.020 in Quantity 2
0.5 mm
Battery capacity, maximum 1000A
Lubrication system
Reserve capacity @ 25A rate 200 Minutes
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar Alternator output 80A @ 14V DC
Oil capacity (including filter) 12.8 quarts Fan belt deflection 3/8 to 1/2 inch
12.1 liters 9 to 12 mm
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C 5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Deutz TD 2.9 Engine Oil temperature switch

Installation torque 8 - 18 ft-lbs
Displacement 177 cu. in 11 - 24 Nm
2.9 liters
Temperature switch point 275°F
Number of cylinders 4 135°C
Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch
92 x 110 mm
Installation torque 8 - 18 ft-lbs
Horsepower net intermittent @ 74.2 hp 11 - 24 Nm
2600 rpm 55 kW
Pressure switch point 22 psi
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle 900 rpm Injection pump pressure, maximum 15,000 psi
Low idle w/ belt driven generator 1500 rpm 1034 bar

High idle 2500 rpm Injector opening pressure 3046 psi

210 bar
Compression ratio 17.4:1
Fuel requirement
Compression pressure pressure (psi or bar) of the
For fuel requirements, refer to the engine Operator
lowest cylinder must be at least 75% of the highest
Manual for your engine.
cylinder
Starter motor
Governor electronic
Current draw, normal load 140 - 200A
Valve Clearance, cold
Cranking speed 250 - 350 rpm
Intake 0.012 in
0.3 mm Battery – Engine starting and control system
Exhaust 0.020 in Type 12V DC, Group 31
0.5 mm Quantity 2
Lubrication system Battery capacity, maximum 1000A
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Reserve capacity @ 25A rate 200 Minutes
2.8 to 4.1 bar
Alternator output 95A @ 14V DC
Oil capacity (including filter) 12.8 quarts
12.1 liters Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C 5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Perkins 804D-33 Injection system

Injection pump make Zexel
Displacement 201 cu. in
3.3 liters Injection pump pressure 1707 to 1849 psi
117.7 to 127.5 bar
Number of cylinders 4
Injector opening pressure ~2000 psi
Bore and Stroke 3.70 x 4.72 inches ~138 bar
94 x 120 mm
Fuel requirement
Horsepower 63 @ 2600 rpm
47 KW @ 2600 rpm For fuel requirements, refer to the engine Operator
Manual for your engine.
Firing order 1-3-4-2
Engine coolant
Compression ratio 22:1
Capacity 12.5 quarts
Compression pressure 300 to 500 psi 11.8 liters
20.7 to 34.5 bar
Batteries
Pressure (psi or bar) of lowest cylinder must be
within 50 psi / 3.45 bar of highest cylinder Type 12V DC

Low idle 1650 rpm Group 31

Frequency 335.5 Hz Quantity 2
High idle 2300 rpm Cold cranking ampere 1000A
Frequency 467.7 Hz
Reserve capacity @ 25A rate 200 minutes
Governor mechanical all speed Alternator output 90A @ 12V DC
Valve Clearance, cold
Fan belt deflection 3/8 to 1/2 inch
Intake 0.0098 in 9 to 12 mm
0.25 mm
Exhaust 0.0098 in
0.25 mm
Lubrication system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar
Oil capacity (including filter) 10.6 quarts
10 liters
Oil viscosity requirements
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Perkins 404F-22T Oil Pressure switch

Installation torque 8 - 18 ft-lbs
Displacement 134 cu. in 11 - 24 Nm
2.2 liters
Pressure switch point 14.2 psi
Number of cylinders 4 1 bar
Bore and Stroke 3.31 x 3.94 inches Fuel injection system
84 x 100 mm
Injection pump make Zexel
Horsepower net intermittent @ 55 hp / 41.1 kW
2800 rpm Injection pressure 2133 psi
Horsepower continuous 147 bar
52 hp / 38.8 kW
@ 2800 rpm Fuel requirement
Induction system turbocharged For fuel requirements, refer to the engine Operator
Firing order 1-3-4-2 Manual for your engine.
Starter motor
Standy idle 1000 rpm
Current draw, normal load 140A - 200A
Low function idle 1500 rpm
Cranking speed 200 - 250 rpm
High function idle 2500 rpm
Battery – Engine starting and control system
Compression ratio 23.3:1
Type 12V DC, Group 31
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest Quantity 2
cylinder Battery capacity, maximum 1000A
Governor electronicl Reserve capacity @ 25A rate 200 Minutes
Valve Clearance, cold Engine coolant
Intake 0.008 in Capacity 13.3 quarts
0.2 mm (engine only) 12.6 liters
Exhaust 0.018 in Coolant temperature switch
0.45 mm
Installation torque 8 - 18 ft-lbs
Lubrication system 11 - 24 Nm
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Temperature switch point 221°F
2.8 to 4.1 bar 105°C
Oil capacity (including filter) 9.4 - 11.2 quarts Alternator output 85A @ 12V DC
8.9 - 10.6 liters
Fan belt deflection 3/8 to 1/2 inch
Oil viscosity requirements 9 to 12 mm
-22°F to 86°F / -30°C to 30°C 5W-20 CJ4
-4°F to 104°F / -20°C to 40°C 10W-40 CJ4
Above 5°F / -15°C 15W-40 CJ4
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

Part No. 1269074 S-80 • S-85 • S-80X 11

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Specifications

Machine Torque Specifications

Platform rotator
1-8 center bolt, GR 5, lubricated 480 ft-lbs
(before SN 15-12988) 651 Nm
3/8-16 bolts, GR 8 35 ft-lbs*
(before SN 15-12988) 47 Nm*
*(use blue thread locking compound)
1-8 center bolt, GR 5, dull gray 615 ft-lbs
(from SN 15-12988) 834 Nm
3/8-16 bolts, GR 8 35 ft-lbs*
(from SN 15-12988) dull gray 47 Nm*
*(use blue thread locking compound)
Turntable rotate assembly
Rotate bearing mounting bolts, 180 ft-lbs
lubricated 244 Nm
Rotate drive hub mounting bolts, 80 ft-lbs
lubricated 108 Nm
Backlash plate mounting bolts, 280 ft-lbs
lubricated 379 Nm
Drive motors and hubs
Drive hub mounting bolts,lubricated 180 ft-lbs
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
Engine vibration isolators
Compressed height 0.50 in
12.7 mm

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Specifications

Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be -4 14 ft-lbs / 19 Nm
torqued to specification when they are removed -6 23 ft-lbs / 31.2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 54.2 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169.5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204.7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249.5 Nm
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
Adjustable Fitting Non-adjustable fitting
-24 180 ft-lbs / 245 Nm
1 jam nut

JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats
(tube fitting - installed into Steel)
-4 7/16-20 2 SAE Dash Size Torque
-6 9/16-18 1¼
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-8 3/4-16 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
-10 7/8-14 1 37° (Non-adj) 22 ft-lbs / 30 Nm

-12 1 1/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm

37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-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

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Specifications

Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
1 Replace the O-ring. The O-ring must be
approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the hex
fitting. Refer to Illustration 1.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut finger
tight. Illustration 1
5 Tighten the nut or fitting to the appropriate 1 hex nut
torque. Refer to the appropriate torque chart in 2 reference mark
this section. 3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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Specifications

3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the proper
tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.

Illustration 2
1 body hex fitting
2 reference mark
3 second mark

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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Service and Repair Manual October 2016

Repair Procedures
Section 3 Repair Pr oc edures

Machine Configuration:
 Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of this position at both the ground and platform
machine. controls
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
 Repair any machine damage or malfunction from the machine
before operating the machine.
• Boom in the stowed position
• Turntable secured with the turntable rotation
Before Repairs Start: lock
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

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Repair Procedures

About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point where
repairs can be completed. Then to re-assemble,
perform the disassembly steps in reverse order.

Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous

situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous

situation which, if not avoided,
may result in property damage.

Indicates that a specific result is expected after

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

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Service and Repair Manual October 2016

Platform Controls

Platform Controls 1-1

The platform control box contains one printed
ALC-500 Circuit Board
circuit board. The ALC-500 circuit board inside the Note: When the ALC-500 circuit board is replaced,
platform control box controls all proportional the joystick controllers will need to be calibrated.
machine functions from the platform. The joystick Refer to Repair Procedure, How to Calibrate a
controllers at the platform controls utilize Hall Effect Joystick.
technology and require no adjustment. The How to R emove the ALC-500 Circuit Boar d

operating parameters of the joysticks are stored in

memory at the ECM circuit board at the platform
controls. If a joystick error occurs or if a joystick is How to Remove the ALC-500
replaced, it will need to be calibrated before that Circuit Board
particular machine function will operate. Refer to
Repair Procedure, How to Calibrate a Joystick. 1 Push in the red Emergency Stop button to the
off position at both the ground and platform
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.
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.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
1 ALC-500 circuit board
grounded wrist strap.
2 drive/steer joystick controller
3 secondary boom up/down joystick 5 Carefully disconnect the wire connectors from
controller
the circuit board.
4 primary boom up/down and turntable rotate
left/right joystick controller 6 Remove the ALC-500 circuit board mounting
fasteners.
7 Carefully remove the ALC-500 circuit board
from the platform control box.

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Platform Controls

1-2 7 Return the joystick to the neutral position,

pause for a moment, then move the joystick full
Joysticks stroke in the opposite direction. Hold for
5 seconds and return the joystick to the neutral
How to Calibrate a Joystick position.

The joysticks on this machine utilize digital Hall Result: The alarm should sound indicating
Effect technology for proportional control. If a successful joystick calibration.
joystick is disconnected or replaced, it must be 8 Repeat this procedure for each joystick
calibrated before that particular machine function controlled machine function including the
will operate. thumb rocker steer switch.
Note: The joystick must be calibrated before the Note: No machine function should operate while
threshold, max-out or ramp rate can be set. performing the joystick calibration procedure.

Note: Perform this procedure with the engine off.

1 Open the platform control box.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Turn the key switch to platform control. Do not
start the engine.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from
the joystick for approximately 10 seconds or
until the alarm sounds. Connect the wire
harness connector to the joystick.
6 Move the joystick full stroke in either direction
and hold for 5 seconds.

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Platform Controls
How to Adj ust the Joystic k Max- out Setting

How to Adjust the Joystick 8 Start the engine from the platform controls and
press down the foot switch.
Max-out Setting
9 Start a timer and activate the machine function
The max-out setting of a joystick controls the
that needs to be adjusted. Record the time it
maximum speed of a joystick-controlled machine
takes for that function to complete a full cycle
function. Whenever a hydraulic cylinder, drive
(ie; boom up).
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum 10 Compare the machine function time with the
performance. The max-out settings on the joystick function times listed in Refer to Specifications,
can be changed to compensate for hydraulic pump Performance Specifications. Determine
wear to maintain peak performance from the whether the function time needs to increase or
machine. decrease.
Note: Perform this procedure with the boom in the 11 While the joystick is activated, adjust the
stowed position. max-out setting to achieve the proper function
cycle time. Momentarily move the drive enable
1 Pull out the red Emergency Stop button to the toggle switch in the right direction to increase
on position at both the ground and platform the function speed or momentarily move the
controls. drive enable toggle switch in the left direction
2 Turn the key switch to platform control. Do not to decrease the function speed.
start the engine. Note: Each time the drive enable toggle switch is
3 Push in the platform controls red Emergency momentarily moved, the function speed will change
Stop button to the off position. in 2% increments from a default of 100%, with a
minimum of 60% and a maximum of 120%.
4 Do not press down the foot switch.
12 Repeat steps 9 through 11 for each joystick
5 Move and hold the drive enable toggle switch controlled machine function.
in the right position and pull out the red
Emergency Stop button to the on position. 13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
6 When the alarm sounds, release the drive settings to be saved.
enable toggle switch.
Result: The alarm should sound indicating that
7 Momentarily activate the drive enable toggle the settings have been saved in memory.
switch in the right direction 4 times.
Note: Do not operate any machine function during
Result: There should be a pause and the alarm the 10 second waiting time.
should sound 4 times indicating that the
machine is in max-out calibration mode. Function speeds (factory settings)
Result: The alarm does not sound. Repeat Boom up 89 to 93 seconds
steps 3 through 7. Boom down 90 to 94 seconds
Boom extend 73 to 79 seconds
Boom retract 79 to 84 seconds
Turntable rotate, 360°boom fully 95 to 103 seconds
stowed
Drive speeds (factory settings)
Stowed- high speed 7.9 to 8.5 seconds
Non-stowed 40 to 45 seconds

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Platform Controls
How to Adj ust the Joystic k Ramp R ate Setting

How to Adjust the Joystick Ramp 8 Start the engine from the platform controls and
press down the foot switch.
Rate Setting
9 Start a timer and simultaneously move the
The ramp rate setting of a joystick controls the time
joystick in either direction full stroke. Note how
at which it takes for the joystick to reach maximum
long it takes the function to reach maximum
output, when moved out of the neutral position. The
speed. This is the ramp rate.
ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain 10 Compare the function ramp rate time with the
peak performance from the machine. table below and determine whether the ramp
rate time needs to increase or decrease.
Note: Perform this procedure with the boom in the
stowed position. 11 Release the foot switch.

1 Pull out the red Emergency Stop button to the 12 While the joystick is activated, set the ramp
on position at both the ground and platform rate. Momentarily move the drive enable
controls. toggle switch in the right direction to increase
the time or momentarily move the drive enable
2 Turn the key switch to platform control. Do not toggle switch in the left direction to decrease
start the engine. the time.
3 Push in the platform controls red Emergency Note: Each time the drive enable toggle switch is
Stop button to the off position. momentarily moved, the time will change in 10%
4 Do not press down the foot switch. increments.

5 Move and hold the drive enable toggle switch 13 Repeat steps 9 through 11 for each joystick
in the right position and pull out the red controlled machine function.
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 6 times.
Result: There should be a pause and the alarm
should sound 6 times indicating that the
machine is in ramp rate calibration mode.

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Platform Controls
How to Adj ust the Joystic k Thr es hol d Setting

14 Return the joystick to the neutral position and How to Adjust the Joystick
wait for approximately 10 seconds to allow the
settings to be saved.
Threshold Setting
The threshold setting of a joystick is the minimum
Result: The alarm should sound indicating that
output at which a function proportional valve can
the settings have been saved in memory.
open and allow the function to operate.
Note: Do not operate any machine function during
the 10 second waiting time. Note: Perform this procedure with the boom in the
stowed position.
15 Cycle the red Emergency Stop button off, then
back on. 1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
Ramp rate (factory settings) controls.
Boom up/down 2 Turn the key switch to platform control. Do not
accelerate 3 seconds start the engine.
decelerate 1 second 3 Push in the platform controls red Emergency
Boom extend/retract Stop button to the off position.
accelerate 2.5 seconds 4 Do not press down the foot switch.
decelerate 1 second
5 Move and hold the drive enable toggle switch
Turntable rotate in the right position and pull out the red
accelerate 3 seconds Emergency Stop button to the on position.
decelerate 2 second 6 When the alarm sounds, release the drive
Drive enable toggle switch.
accelerate 4 seconds 7 Momentarily activate the drive enable toggle
decelerate to neutral 0.5 second switch in the right direction 8 times.
decelerate, change of direction 0.75 second Result: There should be a pause and the alarm
decelerate, coasting 1 second should sound 8 times indicating that the
decelerate, braking 1 second machine is in threshold calibration mode.
decelerate, shift from low to high speed 1 seconds Result: The alarm does not sound. Repeat
decelerate, shift from high to low speed 4 seconds steps 3 through 7.
8 Start the engine from the platform controls and
press down the foot switch.

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Platform Controls
How to C alibr ate the Boom Angle Sensor

9 Select a boom function joystick to set the How to Calibrate the Boom Angle
threshold.
Sensor
10 Slowly move the joystick off center in either
The boom angle sensor controls the maximum
direction just until the function begins to move.
angle that the boom can attain.
11 Slowly move the joystick back towards the
neutral position. Just before the function stops Note: Perform this procedure with the boom in the
moving, move the drive enable toggle switch to stowed position.
either side to set the threshold. 1 Pull out the red Emergency Stop button to the
Result: The alarm should sound indicating a on position at the ground controls.
successful calibration. 2 Turn the key switch to platform controls.
Note: For each joystick axis, the threshold must be 3 Move and hold the drive enable toggle switch
set for both directions. to the right and pull out the red Emergency
12 Repeat steps 9 through 11 for each direction Stop button to the on position.
of boom joystick controlled machine function 4 When the alarm sounds, release the drive
(boom up/down, boom extend/retract and enable toggle switch.
turntable rotate left/right).
5 Momentarily activate the drive enable toggle
13 Return the joystick to the neutral position and switch to the right 12 times.
wait for approximately 10 seconds to allow the
settings to be saved. Result: There should be a pause and the alarm
should sound 12 times indicating that the
Result: The alarm should sound indicating that machine is in Angle Sensor calibration mode.
the settings have been saved in memory.
6 Start the engine from the platform controls and
Note: Do not operate any machine function during press down the foot switch.
the 10 second waiting time.
7 Momentarily activate the drive enable toggle
14 Cycle the red Emergency Stop button off, then switch to the right 1 time to set the stowed
back on. position.
Note: The alarm will not sound indicating the
setting.

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Platform Controls

8 Raise the primary boom to the fully elevated

position.
Note: Manually reduce the boom speed as it
reaches the fully elevated position.
9 Momentarily activate the drive enable toggle
switch to the right 1 time to set the elevated
position.
Result: The alarm will sound indicating that the
angle sensor has been calibrated.
10 Release the joystick and the foot switch and
wait for 10 seconds.
Result: The alarm will sound indicating that the
settings have been saved and is leaving
calibration mode.
11 Cycle the red Emergency Stop button off, then
back on. Start the machine and return to the
stowed position.

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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 machine if not properly
power to platform outlet box bracket. Lay the supported.
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.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

6 Remove the platform control box mounting

fasteners. Lower the control box and set it
aside.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

Note: If your machine is equipped with an airline to

platform option, the airline must be disconnected
from the platform before removal.

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Platform Components

2-2 4 Remove the pin retaining fastener from the

slave cylinder rod-end pivot pin. Use a soft
Platform Leveling Cylinder metal drift to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the two Crushing hazard. The jib boom
primary supports for the platform. The slave could fall when the slave cylinder
cylinder keeps the platform level through the entire rod-end pivot pin is removed if
range of boom motion. It operates in a closed-circuit not properly supported.
hydraulic loop with the master cylinder. The slave
cylinder is equipped with counterbalance valves to 5 Remove the external snap rings from the
prevent movement in the event of a hydraulic line barrel-end pivot pin.
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 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 hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
How to R emove the Pl atfor m Leveling Slave C yli nder
squirt or spray.
1 Extend the primary boom until the slave
cylinder barrel-end pivot pin is accessible.
How to Bleed the Sl ave C ylinder

2 Raise the primary boom slightly and place

blocks under the platform for support. How to Bleed the Slave Cylinder
3 Lower the primary boom until the platform is Note: Do not start the engine. Use auxiliary power
resting on the blocks just enough to support for this procedure.
the platform.
1 Raise the primary boom to a horizontal
Note: Do not rest the entire weight of the boom on position.
the blocks.
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.

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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
How to R emove the Pl atfor m Rotator

connections very slowly to allow

the oil pressure to dissipate
How to Remove the Platform gradually. Do not allow oil to
squirt or spray.
Rotator
Component damage hazard. 3 S-85: Support the jib boom leveling arms and
Mark the platform mounting the platform mounting weldment with an
weldment and the rotator flange appropriate lifting device. Do not apply any
before removing the platform lifting pressure.
mounting weldment. The 4 Remove the mounting bolts from the platform
platform mounting weldment mounting weldment. Remove the center bolt
must be replaced in the exact and slide the platform mounting weldment off
same position on the rotator of the platform rotator.
flange as it was before removal.
If a new rotator is installed or the Crushing hazard. The platform
rotator is disassembled, proper mounting weldment may
alignment can be achieved by become unbalanced and fall if it
rotating the rotator all the way to is not properly supported.
the left and then installing the
platform mounting weldment all 5 Support the platform rotator with an
the way in the left position. appropriate lifting device. Do not apply any
lifting pressure.
Note: When removing a hose assembly or fitting, S-80:
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 6 Support the rod end of the platform leveling
torqued to specification during installation. Refer to slave cylinder. Protect the cylinder rod from
Specifications, Hydraulic Hose and Fitting Torque damage.
Specifications.
7 Remove the pivot pin retaining fasteners from
1 Remove the platform. Refer to Repair both the slave cylinder rod-end pivot pin and
Procedure, How to Remove the Platform. the rotator pivot pin.

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Platform Components
How to Bleed the Pl atfor m R otator

8 Use a soft metal drift to remove both pivot pins. How to Bleed the Platform Rotator
Remove the platform rotator from the machine.
Note: This procedure will require two people. Do not
Crushing hazard. The platform start the engine. Use auxiliary power for this
rotator may become unbalanced procedure.
and fall if not properly supported.
1 Move the function enable toggle switch to
Note: When installing the platform rotator fasteners, either side and activate the platform rotate
torque the fasteners to specifications. toggle switch to the right then the left through
two platform rotation cycles, then hold the
S-85: switch to the right position until the platform is
fully rotated to the right.
9 Remove the pin retaining fasteners from the jib
boom and jib boom leveling arms to platform 2 Place a suitable container underneath the
rotator pivot pins. Do not remove the pins. platform rotator.
10 Support the jib boom leveling arms. 3 Open the top bleed screw on the rotator, but do
not remove it.
11 Use a soft metal drift to drive both pins out,
then remove the platform rotator from the Bodily injury hazard. Spraying
machine. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Bodily injury hazard. The jib connections very slowly to allow
boom leveling arms may fall if the oil pressure to dissipate
not properly supported. gradually. Do not allow oil to
squirt or spray.
12 Lower the jib boom leveling arms.
Crushing hazard. The platform 4 Move the function enable button to either side
rotator could fall when removed and hold the platform rotate toggle switch to
from the machine if not properly the left position until the platform is fully rotated
supported. to the left. Continue holding the toggle switch
until air stops coming out of the bleed screw.
Note: When installing the platform rotator fasteners, Close the bleed screw.
torque the fasteners to specifications.
Crushing hazard. Keep clear of
the platform during rotation.

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Platform Components

5 Open the bottom bleed screw on the rotator, 2-4

but do not remove it.
Platform Overload System
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic How to Calibrate the Platform
connections very slowly to allow Overload System (if equipped)
the oil pressure to dissipate
gradually. Do not allow oil to Calibration of the platform overload system is
squirt or spray. essential to safe machine operation. Continued use
of an improperly calibrated platform overload
6 Move the function enable toggle switch to system could result in the system failing to sense an
either side and hold the platform rotate toggle overloaded platform. The stability of the machine is
switch to the right position until the platform is compromised and it could tip over.
fully rotated to the right. Continue holding the Note: Perform this procedure with the machine on a
toggle switch until air stops coming out of the firm, level surface.
bleed screw. Close the bleed screw.
1 Turn the key switch to platform control. Start
Crushing hazard. Keep clear of the engine and level the platform.
the platform during rotation.
2 Determine the maximum platform capacity.
7 Clean up any hydraulic oil that may have Refer to the machine serial plate.
spilled.
3 Remove all weight, tools and accessories from
8 Rotate the platform fully in both directions and the platform.
inspect the bleed screws for leaks.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform
capacity at the center of the platform floor.

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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 bounces approximately 2.5 to 5 cm / 1 to
2 inches. Allow the platform to settle. 2 inches. Allow the platform to settle.
Result: The overload indicator lights are off Result: The overload indicator lights are off
and the alarm does not sound. Proceed to step and the alarm does not sound. Proceed to step
6. 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
Note: There may be a 2 second delay before the
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
Note: There may be a 2 second delay before the
at both the ground and platform controls, and
platform overload indicator light and alarm
the alarm is sounding. Proceed to step 9.
responds.
Result: The overload indicator light is off at
6 Move the platform up and down by hand, so it both the ground and platform controls, and the
bounces approximately 2.5 to 5 cm / 1 to alarm does not sound. Remove the additional
2 inches. Allow the platform to settle. 10 lb / 4.5 kg test weight. Repeat this
Result: The overload indicator lights are off at procedure beginning with step 6.
the platform and ground controls, and the Note: There may be a 2 second delay before the
alarm does not sound. Slowly loosen the load platform overload indicator light and alarm
spring adjustment nut in a counterclockwise responds.
direction in 10° increments until the overload
indicator light flashes at both the platform and
ground controls, and the alarm sounds.
Proceed to step 7.
Result: The overload indicator lights are
flashing at the platform and ground controls,
and the alarm is sounding. Repeat this
procedure beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.

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Platform Components

9 Test all machine functions from the platform

controls.
Result: All platform control functions should
not operate.
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.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
13 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.

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Jib Boom Components

3-1 5 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on
Jib Boom the 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
the oil pressure to dissipate
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or hose squirt or spray.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 6 Attach a lifting strap from an overhead crane to
Specifications, Hydraulic Hose and Fitting Torque the jib boom assembly.
Specifications.
7 Place blocks under the platform leveling
1 Remove the platform. Refer to Repair cylinder for support. Protect the cylinder rod
Procedure, How to Remove the Platform. from damage.

Note: Models equipped with platform overload 8 Remove the pin retaining fastener from the
system: If the platform overload components are slave cylinder rod-end pivot pin. Use a soft
disassembled and/or removed from the platform metal drift to remove the pin.
support, the platform overload system will need to
Crushing hazard. The jib boom
be calibrated. Refer to Repair Procedure, How to
could fall when the slave cylinder
Calibrate the Platform Overload System.
rod-end pivot pin is removed if
2 Models equipped with platform overload not properly attached to the
system: Tag and disconnect the electrical overhead crane.
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
may become unbalanced and fall
Component damage hazard. when it is removed from the
Cables and hoses can be machine if it is not properly
damaged if they are kinked or supported by the overhead
pinched. crane.

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Jib Boom Components

3-2 4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
Jib Boom Lift Cylinder lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
How to Remove the Jib Boom Lift opposite leveling arm. Do not remove the pin.
Cylinder 5 Support the jib boom lift cylinder with a lifting
device.
Note: Perform this procedure with the boom in the
stowed position. 6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
Note: When removing a hose assembly or fitting, soft metal drift to remove the barrel-end pin
the O-ring (if equipped) on the fitting and/or hose and let the cylinder hang down.
end must be replaced. All connections must be
torqued to specification during installation. Refer to Crushing hazard. The platform
Specifications, Hydraulic Hose and Fitting Torque and jib boom could become
Specifications. unbalanced and fall when the jib
boom barrel-end pivot pin is
1 Raise the jib boom slightly and place blocks removed if not properly
under the platform mounting weldment. Then supported.
lower the jib boom until the platform is resting
on the blocks just enough to support the 7 Attach a lifting strap from an overhead crane to
platform. the lug on the rod end of the jib boom lift
cylinder.
Note: Do not rest the entire weight of the boom on
the blocks. 8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
2 Tag, disconnect and plug the jib boom lift the machine.
cylinder hydraulic hoses. Cap the fittings on
the cylinder. Crushing hazard. The jib boom
lift cylinder may become
Bodily injury hazard. Spraying unbalanced and fall when it is
hydraulic oil can penetrate and removed from the machine if it is
burn skin. Loosen hydraulic not properly supported by the
connections very slowly to allow overhead crane.
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

3 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Do not
remove the pin.

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Service and Repair Manual October 2016

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 R emove the Cable Trac k, S-80

gradually. Do not allow oil to

squirt or spray.
How to Remove the Cable Track
7 Tag, disconnect and plug the hydraulic hoses
Note: When removing a hose assembly or fitting, from the platform leveling slave cylinder at the
the O-ring (if equipped) on the fitting and/or hose platform manifold and cap the fittings.
end must be replaced. All connections must be
torqued to specification during installation. Refer to Bodily injury hazard. Spraying
Specifications, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
connections very slowly to allow
1 Open the platform control box. the oil pressure to dissipate
gradually. Do not allow oil to
2 Tag and disconnect the foot switch wiring from
squirt or spray.
the terminal strip inside the platform control
box.
8 Remove the timing link/timing link cam pin and
3 Loosen the squeeze connector and remove gently rest the timing link against the
the foot switch cable from the control box. counterweight.
4 Disconnect the wire connectors from the 9 S-85:Remove the hose and cable cover from
bottom of the platform control box. the 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.
11 Tag, disconnect and plug the wiring from the
5 Remove the mounting fasteners from the jib boom/platform rotate select manifold.
power to platform outlet box bracket. Lay the
outlet box and bracket assembly off to the side.

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Boom Components

12 Tag, disconnect and plug the hydraulic hoses 18 Place blocks between the upper and lower
from the jib boom lift cylinder. Cap the fittings cable tracks and secure the upper and lower
on the cylinder. tracks together.
Bodily injury hazard. Spraying Crushing hazard. If the upper
hydraulic oil can penetrate and and lower cable tracks are not
burn skin. Loosen hydraulic properly secured together, the
connections very slowly to allow cable track could become
the oil pressure to dissipate unbalanced and fall when
gradually. Do not allow oil to removed from the machine.
squirt or spray.
19 Attach a lifting strap from an overhead crane to
All models: the cable track.
13 From the ground controls, raise the boom to a 20 Remove the mounting fasteners that attach the
horizontal position. lower cable track to the boom.
14 Remove the fasteners from the drive speed 21 Remove the cable track from the machine and
limit switch bracket (LS1RS) mounted on the place it on a structure capable of supporting it.
side of the boom at the platform end of the
boom. Do not remove the limit switch from the Crushing hazard. The cable
bracket. track could become
unbalanced and fall if not
15 Remove the cotter pin from the upper cable properly attached to the
track at the platform end of the boom. overhead crane.
Note: Always replace the cotter pin with a new one.
Component damage hazard.
16 Remove the cable track guide fasteners from Cables and hoses can be
the cable track guides at the platform end of damaged if they are kinked or
the boom. Remove the cable track guides from pinched.
the boom.
17 Remove the cable clamp from the pivot end of Component damage hazard. The
the boom. cable track can be damaged if it
is twisted.

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Boom Components
How to R epair the C abl e Tr ac k

4-2
How to Repair the Cable Track Boom
How to Shi m the Boom

Component damage hazard.

The boom cable track can be
damaged if it is twisted.
How to Shim the Boom
1 Measure each wear pad.
Note: A cable track repair kit is available through
Genie Service Parts, part no. 77896. The kit Boom wear pad specifications
includes a 4-link section of cable track. Boom number one Minimum
1 Visually inspect the cable track and determine Bottom wear pads 0.50 inch
which 4 link section needs to be replaced. (extension end of boom) 12.7 mm
Top and side wear pads 0.625 inch
2 Carefully remove the snap rings from each end (extension end of boom) 15.9 mm
of the damaged section of cable track.
Boom number two
3 Remove the retaining fasteners from the upper
Top, bottom and side wear pads 0.50 inch
black rollers from the 4-link section of cable (extension end of boom) 12.7 mm
track to be replaced. Remove the rollers.
Bottom wear pads 0.50 inch
4 Lift up the hoses and cables and carefully (pivot end of boom) 12.7 mm
remove the damaged 4-link section of cable Top and side wear pads 0.625 inch
track. (pivot end of boom) 15.9 mm
Component damage hazard. Boom number three
Hoses and cables can be Top, bottom and side wear pads 0.50 inch
damaged if they are kinked or (pivot end of boom) 12.7 mm
pinched. Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
5 Remove the upper rollers from the
minimum specification, perform the following
replacement section of cable track.
procedure.
6 Lift up the hoses and cables and carefully
insert the new 4 link section of cable track. 2 Extend the boom until the wear pads are
accessible.
Component damage hazard.
3 Loosen the wear pad mounting fasteners.
Hoses and cables can be
damaged if they are kinked or 4 Install the new shims under the wear pad to
pinched. obtain zero clearance and zero drag.
5 Tighten the mounting fasteners.
7 Connect the ends of the replacement cable
track section to the existing cable track using 6 Extend and retract the boom through an entire
the snap rings. cycle. Check for tight spots that could cause
binding or scraping.
8 Install the rollers onto the new section of cable
track. Note: Always maintain squareness between the
outer and inner boom tubes.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.

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Boom Components
How to R emove the Boom

How to Remove the Boom 4 Place a block of wood measuring 4 x 4 x

60 inches / 10 x 10 x 152 cm under the long
Tip-over hazard. This procedure link arm, across the turntable covers.
requires the removal of the 5 Slowly lower the boom until the long link arm
turntable counterweight. Failure contacts the wood block. Do not rest the entire
to remove the counterweight weight of the boom on the block. Turn the
before removing the boom machine off.
assembly will result in the
machine tipping over. Do not Component damage hazard. The
remove the boom without first turntable covers can become
removing the counterweight. damaged if the weight of the
boom is allowed to rest on the
Tip-over hazard. When installing block.
the boom onto the machine, the
boom assembly must be first 6 Place wood blocks between the short link arm
installed prior to the installation of and the turntable weldment for support.
the counterweight. If the 7 Insert a 1.125 x 12 inches / 32 x 300 mm
counterweight is installed before eye-bolt through each hole located on the top
the boom assembly, the machine surface of the counterweight. Secure the
will tip over resulting in death or eye-bolts in position with flat washers and
serious injury. nuts.

Tip-over hazard. The turntable 8 Securely attach lifting straps or chains with a
counterweight is essential for minimum rating of 5 tons / 5000 kg to the lifting
machine stability. Failure to install points on the top of the turntable
the counterweight after installing counterweight. Attach the lifting straps or
the boom assembly will chains to a 5 ton / 5000 kg overhead crane.
compromise machine stability Note: A spreader bar and other hardware may be
resulting in the machine tipping needed to safely remove the counterweight.
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. Refer to Repair

Procedure, How to Remove the Jib Boom.
2 Remove the cable track. Refer to Repair
Procedure, How to Remove the Cable Track.
3 Raise the boom until the short and long link
arm to boom pivot pins are above the turntable
covers.

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9 Slowly operate the overhead crane to apply 14 Using auxiliary power, activate the boom down
tension to the lifting straps. Do not attempt to function so the cylinder will retract. Retract the
lift the machine with the overhead crane. cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
10 Locate and remove the counterweight
boom. Turn the machine off.
retaining fastener at the center of the
counterweight. Carefully lift the counterweight Crushing hazard. The boom lift
upwards and remove the counterweight from cylinder could fall if not properly
the machine. Set the counterweight on the supported and secured to the
ground. Do not leave the counterweight lifting device.
suspended above the ground.
15 Using the overhead crane, carefully lower the
Crushing hazard. The turntable
boom lift cylinder and allow it to rest on the
counterweight will fall if not boom rest pad. Protect the cylinder rod from
properly supported by the damage.
overhead crane resulting in
death or serious injury. Keep 16 Remove the boom end cover retaining
personnel away from the area fasteners and remove the cover.
when removing the
17 Tag, disconnect and plug the boom extension
counterweight.
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
11 Attach lifting straps from a 5 ton / 5000 kg
overhead crane to each end of the boom. Bodily injury hazard. Spraying
Support the boom. Do not apply any lifting hydraulic oil can penetrate and
pressure. burn skin. Loosen hydraulic
12 Support and secure the rod end of the boom lift connections very slowly to allow
cylinder to a second overhead crane or similar the oil pressure to dissipate
lifting device. gradually. Do not allow oil to
squirt or spray.
13 Remove the lift cylinder rod-end pivot pin
retaining fasteners. Use a soft metal drift to 18 Tag and disconnect the electrical connector for
remove the pin. the cable break limit switch.
Crushing hazard. The boom 19 Tag and disconnect all boom wire harness
could fall if not properly electrical connectors located at the pivot end of
supported when the lift cylinder the boom.
rod-end pivot pin is removed.

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20 Support the platform leveling master cylinder. 4-3

Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
Boom Lift Cylinder
and twist to remove. Carefully lower the master The boom lift cylinder raises and lowers the boom.
cylinder down. The boom lift cylinder is equipped with
21 Tag, disconnect and plug the hydraulic hoses counterbalance valves to prevent movement in the
from the bulkhead fittings at the pivot end of event of a hydraulic line failure.
the boom. Cap the bulkhead fittings.
Bodily injury hazard. Spraying How to Remove the Boom Lift
hydraulic oil can penetrate and Cylinder
burn skin. Loosen hydraulic
connections very slowly to allow Bodily injury hazard. This
the oil pressure to dissipate procedure requires specific repair
gradually. Do not allow oil to skills, lifting equipment and a
squirt or spray. suitable workshop. Attempting
this procedure without these skills
22 Remove the external snap rings from both and tools could result in death or
boom pivot pins at the short and long link arms. serious injury and significant
Do not remove the pins. component damage. Dealer
23 Using the overhead crane, adjust the boom as service is strongly recommended.
necessary to relieve pressure from the pivot
Note: When removing a hose assembly or fitting,
pins.
the O-ring (if equipped) on the fitting and/or hose
24 Use a soft metal drift to remove each boom end must be replaced. All connections must be
pivot pin. Carefully remove the boom assembly torqued to specification during installation. Refer to
from the machine and place it on a structure Specifications, Hydraulic Hose and Fitting Torque
capable of supporting it. Specifications.

Crushing hazard. The boom 1 Raise the boom to a horizontal position.

could fall if not properly supported
2 Attach a 5 ton / 5000 kg overhead crane to the
by the overhead crane when
boom at the platform end for support. Do not lift
each boom pivot pin is removed.
the boom.
Crushing hazard. The long and
short link arms may fall if not
properly supported when the
boom pivot pins are removed.

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Boom Components

3 Support and secure both ends of the boom lift 8 Use a slide hammer to remove the barrel-end
cylinder to a second overhead crane or similar pivot pins.
lifting device.
Crushing hazard. The lift cylinder
4 Remove the pin retaining fastener from the could become unbalanced and
boom lift cylinder rod-end pivot pin. Use a soft fall if not properly supported and
metal drift to remove the pin. secured to the lifting device.
Crushing hazard. The boom will 9 Move the boom lift cylinder towards the
fall if not properly supported
counterweight end of the machine. Rotate the
when the primary boom rod-end
boom lift cylinder until the barrel-end pivot pin
pivot pin is removed.
bores will clear the boom linkage.
5 Using auxiliary power, activate the boom down 10 Carefully remove the boom lift cylinder from
function so the cylinder will retract. Retract the the machine.
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the Crushing hazard. The lift cylinder
boom. Turn the machine off. could become unbalanced and
fall if not properly supported and
6 Tag, disconnect and plug the boom lift cylinder secured to the lifting device.
hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

7 Remove the pin retaining fasteners from the

boom lift cylinder barrel-end pivot pins. Do not
remove the pins.

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4-4 4 Fully loosen the lock nuts on the extend

cables. Do not remove the nuts.
Boom Extension Cylinder
The boom extension cylinder is located inside the
boom assembly and incorporates cables and
pulleys that are responsible for extending the
number 3 boom tube. The primary boom extension
cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
failure.

How to Remove the Boom

Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.

Note: When removing a hose assembly or fitting,

the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 1 cable guard
torqued to specification during installation. Refer to 2 retaining block
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 5 Loosen the retract cable nut at the platform
end of the boom. Pull the cable rod from the
Note: Perform this procedure with the boom fully
support and let it hang down.
retracted.
6 Remove the cable guard fasteners and
1 Raise the boom to a horizontal position. remove the cable guard.
2 Remove the boom end cover retaining 7 Locate the retaining plates that secure the
fasteners and remove the cover. retract cables to the inside of the number
3 Remove the access covers from both sides of 3 boom tube.
the boom at the pivot end. 8 Remove the cable retaining plates and pull the
retract cables off of the pulleys. Lay the cables
flat and out of the way.

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Boom Components

9 Remove the fasteners from the retaining 13 Lift up the extend cable mounting plate and
blocks from the extension cylinder saddle. push the extend cables towards the platform to
Remove the blocks. create slack in the cables. Rest the cable and
bracket assembly on top of the extend
Note: Access the fasteners through the access hole
cylinder.
in the outer boom tube at the pivot end.
14 Locate the lower extend cable bracket on the
10 Disconnect the wire connector to the extend bottom of the number 3 boom tube.
cable break limit switch.
15 Remove the lower extend cable bracket
11 Remove the retaining fasteners that secure the mounting fasteners and pull back on the
extend cable mounting plates to the inside of bracket to release it from the number 3 boom
the number 1 boom tube. 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.
18 Remove the external snap rings from the
extension cylinder pin at the pivot end of the
boom.
19 Use a soft metal drift to remove the pin.
20 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
1 extend cable lock nuts
squirt or spray.
2 extend cable mounting plate
3 extend cable mounting plate fastener 21 Attach a lifting strap from a 5 ton / 5000 kg
4 extend cable bracket overhead crane to the lug at the rod end of the
boom extension cylinder.
12 Pull back on the extend cable mounting plate
until it clears the blocks welded to the inside of
the number 1 boom tube.

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22 Lift the boom extension cylinder with the crane 4-5

until it clears the cylinder saddle inside the
number 2 boom tube.
Boom Extend/Retract Cables
How to Adj ust the Extend/R etrac t C abl es

23 Carefully support and slide the extension

cylinder out of the boom. How to Adjust the Boom
Crushing hazard. The extension
Extend/Retract Cables
cylinder could fall when removed The boom extend/retract cables are responsible for
from the extension boom if not the extension and retraction of the number 3 boom
properly supported. tube. Proper adjustment of the boom extend/retract
cables and related components on a regular basis
Component damage hazard. Be is essential to good machine performance and safe
careful not to damage the cable machine operation. The boom extend and retract
break limit switch. functions should operate smoothly and be free of
hesitation, jerking and unusual noise.
Component damage hazard. Be Note: Perform this procedure with the boom in a
careful not to damage the horizontal position.
counterbalance valves on the
primary boom extension cylinder 1 Start the engine from the ground controls.
when removing the cylinder from
the primary boom. 2 Raise the boom to a horizontal position
3 Fully retract the boom.
Note: During removal of the extension cylinder, the
overhead crane strap will need to be carefully 4 Stop the engine.
adjusted for proper balancing. 5 Remove the boom end cover retaining
fasteners and remove the cover.
6 Inspect the threaded ends of the boom extend
cables. The threads must be clean and in good
condition with no damaged threads.
7 Locate the retract cable adjustment nut on the
bottom of the number 1 boom tube at the
platform end of the boom. Loosen the nut, but
do not remove the nut.

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Boom Components

8 Locate the extend cable adjustment nuts on 11 Locate the retract cable adjustment nut on the
the counterweight end of boom tube #1. Refer bottom of the number 1 boom tube at the
to Illustration 1. Loosen the nylock nuts and platform end of the boom.
jam nuts on the cable tension equalizer 12 Using a dial type torque wrench, torque the
bracket. Do not remove the nuts. retract cable adjustment nut to 32-36 ft lbs /
9 Adjust the extend cable adjustment nut to 43-49 Nm using gentle and steady torque.
obtain 6 3/8 inches/16.2 cm to 6 13 Retract and extend the boom approximately
1/2 inches/16.5 cm between the platform end 3 feet / 1 m two times and stop during the
of boom tube #2 and boom tube #3. Refer to extension cycle. This will create slack in the
illustration 2. There should be approximately retract cables.
1/2 inch of exposed threads on the adjustment
bolts. Refer to Illustration 1. Note: Be sure to not fully extend the boom. Stop
when there is approximately 3 feet / 1 m of travel
Note: If the cables have been replaced, be sure the left.
adjustment nuts have been replaced. Do not re-use
the existing nuts. 14 Repeat steps 12 and 13 two to three times.

10 Extend the boom until there is approximately 15 Fully extend the boom then retract the boom
3 feet / 1 m of travel left. Do not fully extend the approximately 12 inches / 30 cm.
boom. 16 At the pivot end of the boom, visually inspect
the boom extend cables for even cable droop
or sag.
Note: If the boom extend cables are uneven, tighten
the boom extend cable adjustment nut at the pivot
end of the boom for the appropriate cable.

llustration 2
1 6.375 inches / 16.2 cm

Illustration 1
1 cable break limit switch
2 extend cable adjustment nut
3 extend cable pivot plate

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Boom Components
How to R eplac e the Boom Extend/R etr act Cables

17 Visually inspect the cable break limit switch How to Replace the Boom
arm to be sure the wheel of the limit switch arm
is centered in the notch of the pivot plate.
Extend/Retract Cables
Note: The cable pulleys must also be replaced
Note: If the boom extend cables are adjusted
when replacing the cables.
evenly, the wheel of the limit switch arm should be
centered in the notch of the pivot plate. 1 Remove the boom extension cylinder. Refer to
Repair Procedure, How to Remove the Boom
18 Install the boom end cover at the pivot end of
Extension Cylinder.
the boom.
Boom extend cables:
19 Fully retract and lower the boom to the stowed
position. 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
from the extension cylinder assembly. Discard
the old cables and pulleys.
6 Route the new boom extend cables through
the boom extend pulley bracket.
7 Install the new boom extend cable pulley, pivot
pin and snap rings.
Note: Be sure the boom extend cables are routed
through the grooves of the pulley and the upper
wear pad on the extension cylinder.

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Boom Components

8 Install the boom extend cable clevis pins and 17 Repeat steps 14 through 19 for the other boom
rue rings to the pivot plate near the cable break retract cable.
limit switch.
18 At the platform end of the boom, install the
9 Install the boom extend cables to the lower retract cables, clevis pins and rue rings to the
extend cable bracket that mounts to the adjustment plate.
number 3 boom tube.
19 Remove and discard the old boom retract
Boom retract cables: pulleys from 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 20 Install the new boom retract pulleys to the pivot
boom. end of the boom extension cylinder.
11 Attach the cable pulling tool or a rope to one of 21 Install the boom extension cylinder assembly
the boom retract cables at the pivot end of the into the boom.
boom. Note: Before lowering the extension cylinder into
Note: A cable pulling tool is available through Genie the saddles of the number 1 boom tube, wrap the
Service Parts Department (Genie part no. 94510) boom retract cables around the pulleys.

12 At the platform end of the boom, pull on the 22 Adjust the boom extend/retract cables. Refer
boom retract cable that has the rope attached to Repair Procedure, How to Adjust the Boom
to it. Extend/Retract Cables.
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.

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Boom Components

4-6 5 Place a rod through the barrel-end pivot pin

and twist to remove the pin.
Platform Leveling Master Cylinder
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,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 6 Attach a lifting strap from an overhead crane to
torqued to specification during installation. Refer to the lug on the rod end of the master cylinder.
Specifications, Hydraulic Hose and Fitting Torque 7 Remove the pin retaining fastener from the
Specifications. rod-end pivot pin.
1 Raise the boom until the master cylinder 8 Place a rod through the rod-end pivot pin and
rod-end pivot pin is accessible. twist to remove the pin.
2 Remove the turntable end cover to access the 9 Remove the master cylinder from the machine.
master cylinder.
Crushing hazard. The master
3 Tag, disconnect and plug the master cylinder cylinder could become
hydraulic hoses. Cap the fittings on the unbalanced and fall if not
cylinder. properly attached to the
overhead crane.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

4 Remove the pin retaining fastener from the

master cylinder barrel-end pivot pin.

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Boom Components

4-7 7 Referring to the illustration, hold the angle

sensor/bracket assembly at an angle away
Primary Boom Angle Sensor from the mounting plate and match up the hex
The primary boom angle sensor works in shaft to the sensor. Rotate the assembly
conjunction with the boom extend limit switches, towards the mounting plate and install the
maintaining the working envelope. The primary angle sensor assembly to the mounting plate
boom angle sensor is located underneath the swing using the fasteners removed in step 5. Do not
chassis between the timing link arms. completely tighten at this time.
Note: This will index the sensor to obtain the
required voltage to allow calibration.
How to Replace the Primary
Boom Angle Sensor
1 From the ground controls lower the primary
boom to the stowed position and then rotate
the swing chassis so that it is perpendicular to
the drive chassis.
2 Push in the red Emergency Stop button at the
ground controls and turn the key switch to the
off position.
3 Locate the primary boom angle sensor under
the swing chassis, between the timing link.
Remove the cover to gain access to the
sensor.
4 Locate and disconnect the angle sensor
harness connector.
5 Remove the angle sensor mounting bracket 1 hex key
retaining fasteners and set aside to be reused. 2 boom angle sensor
Remove the angle sensor and bracket 3 angle sensor mounting bracket.
assembly. 4 mounting plate
6 Remove the angle sensor from the mounting 8 Securely connect the angle sensor harness to
bracket and install the new angle sensor using the main harness.
the same fasteners.

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9 Turn the key switch to platform controls. Pull

out the red Emergency Stop buttons at the
ground and platform controls to the on
position.
10 Using a volt meter set to DC volts, back probe
the angle sensor harness connector. Insert the
negative lead into terminal 2, the positive lead
into terminal 3.

1 terminal 2
2 terminal 3
11 The volt meter should read 2.16V dc to 2.2V
dc.
If the voltage reading is correct, tighten the
mounting bracket fasteners and re-install the
cover removed in step 3.
If the voltage is not between 2.16V dc and 2.2V
dc, remove the mounting bracket assembly,
remove the sensor from the hex key and rotate
the assembly to index the sensor and obtain
the correct voltage. If the voltage was less then
2.16V dc, rotate the assembly approximately
60° from the mounting plate. If the voltage was
more than 2.2V dc rotate the assembly
approximately 30° from the mounting plate.
Insert the sensor onto the hex key and attach
the mounting bracket. Confirm the voltage is
between 2.16V dc to 2.2V dc.
12 Tighten the fasteners securing the sensor
mounting bracket and re-install the cover.
13 Calibrate the boom angle sensor. Refer to
Repair Procedure, How to Calibrate the Boom
Angle Sensor.

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Engines

5-1 5-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure in the appropriate The flex plate acts as a coupler between the engine
Service or Maintenance Manual for your machine, and the pump. It is bolted to the engine flywheel
Check and Adjust the Engine RPM. 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)
How to R emove the Flex Pl ate

How to Remove the Flex Plate

Note: Perform this procedure with the engine off
and cool to the touch.
1 Open the engine side turntable cover.
2 Tag and disconnect the battery cables from the
battery(s).
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

3 Tag and disconnect the wiring plug at the

electronic displacement controller (EDC),
located on the drive pump.

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Engines

Deutz TD2011L04i models: 3 Carefully pull the pump and bell housing
assembly away from the engine and secure it
1 Tag and disconnect the wiring from the bell from moving.
housing.
2 Remove the U-bolt from the exhaust flex pipe Component damage hazard.
Hoses can be damaged if they
at the muffler.
are kinked or pinched.
Burn hazard. Beware of hot
engine components. Contact 4 Remove the flex plate mounting fasteners, and
with hot engine components remove the flex plate from the engine flywheel.
may result in severe burns. Perkins 804D models:
3 Remove the muffler bracket retaining 1 Tag and disconnect the wiring from the bell
fasteners from bell housing. Remove the housing.
muffler and bracket assembly from the engine.
2 Remove the exhaust pipe clamp at the muffler.
4 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell Burn hazard. Beware of hot
housing engine fasteners. engine components. Contact
with hot engine components
5 Carefully pull the pump and bell housing may result in severe burns.
assembly away from the engine and secure it
from moving. 3 Remove the muffler mounting bracket
fasteners. Remove the muffler and bracket
Component damage hazard.
assembly from the engine.
Hoses can be damaged if they
are kinked or pinched. 4 Remove the hose clamps from the air cleaner
elbow and the engine intake manifold.
6 Remove the flex plate mounting fasteners, and
remove the flex plate from the engine flywheel. 5 Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
Deutz TD 2.9 models: assembly from the engine.
1 Tag and disconnect the wiring from the bell 6 Support the drive pump with an appropriate
housing. lifting device. Remove all of the remaining bell
housing to engine fasteners.
2 Support the drive pump with an appropriate
lifting device. Remove all of the bell housing 7 Carefully pull the pump and bell housing
engine fasteners. assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.

8 Remove the flex plate mounting fasteners, and

remove the flex plate from the engine flywheel.

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Engines

Perkins 404F-22T models: Continental model:

1 Tag and disconnect the wiring from the bell 1 Tag and disconnect the wire harness from the
housing. oxygen sensor.
2 Remove the fasteners supporting the muffler 2 Remove the exhaust pipe heat shield
assembly from the bell housing. fasteners from the top of the muffler.
Burn hazard. Beware of hot Burn hazard. Beware of hot
engine components. Contact engine components. Contact
with hot engine components with hot engine components
may result in severe burns. may result in severe burns.

3 Support the drive pump with an appropriate 3 Remove the muffler retainer bracket fasteners.
lifting device. Remove all of the bell housing to
4 Remove the muffler fasteners securing the
engine fasteners.
muffler to the exhaust manifold. Remove the
4 Carefully pull the pump and bell housing muffler from the bracket.
assembly away from the engine and secure it
5 Remove the relay housing from the muffler
from moving.
mount. Do not disconnect the relays.
Component damage hazard. 6 Disconnect and remove the ECM from the
Hoses can be damaged if they muffler mount.
are kinked or pinched.
7 Close the shutoff valve on the Liquid
5 Remove the flex plate mounting fasteners, and Petroleum Gas (LPG) tank by turning it
remove the flex plate from the engine flywheel. clockwise (if equipped).
8 Unbolt the EPR valve from the muffler mount.
Leave the hoses attached to the EPR valve.
9 Remove the muffler mount.
10 Support the drive pump with an appropriate
lifting device. Remove all of pump plate
mounting fasteners.
11 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they
are kinked or pinched.

12 Remove the flex plate mounting fasteners.

Remove the flex plate from the engine
flywheel.

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Engines
How to Ins tall the Fl ex Plate

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 models: Torque the flex plate Apply Loctite® removable thread sealant to the
mounting bolts in sequence to 20.8 ft-lbs / 28 pump retaining fasteners. Torque the pump
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. Then not force the drive pump during
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 bolts in sequence to 28 ft-lbs / 38 Nm. 5 Install the pump coupler onto the pump shaft
Then torque the flex plate mounting bolts in with the set screw toward the pump. Leave the
sequence to 40 ft-lbs / 54 Nm. appropriate gap between coupler and pump
end plate for your engine.
6 Install the pump and pump mounting plate
assembly onto the engine. Apply Loctite®
removable thread sealant to the mounting
screws.

Deutz, Perkins and Continental Flex Plate

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Engines
How to i nstall the Pump and Bell H ousing Ass embl y

How to Install the Pump and Bell Deutz Pump Mounting Plate

Housing Assembly
1 Install the pump and bell housing assembly.
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.
Perkins 804D models: Torque the bell
housing mounting bolts in sequence to
28 ft-lbs / 38 Nm and then to 49 ft-lbs / 66 Nm.
Perkins 404F models:Torque the bell
housing mounting bolts labeled "B" in Perkins 804D Pump Mounting Plate
sequence to 28 ft-lbs / 38 Nm and the
mounting bolts labeled "A" to 49 ft-lbs / 66 Nm.
Then torque the bell housing mounting bolts
labeled "B" in sequence to 40 ft-lbs / 54 Nm
and the mounting bolts labeled "A" to 70 ft-lbs /
95 Nm.
Continental model:Torque the pump
mounting plate fasteners in sequence to
23 ft-lbs / 31.2 Nm.
Component damage hazard.
When installing the pump, do not
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.

Component damage hazard. Do Perkins 404F-22T Pump Mounting Plate

not force the drive pump during
installation or the flex plate teeth
may become damaged.

Continental Pump Mounting Plate

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Ground Controls

6-1 3 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
Control Relays terminal combinations.
Relays used for single function switching are single Test Desired result
pole double throw (SPDT) relays.
terminal 87 to 87a and 30 no continuity
(infinite Ω)
How to Test a Single Pole Double terminal 87 to 30 continuity
(zero Ω)
Throw Relay
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

Electrocution/burn hazard. Contact with electrically

charged circuits could result in death or serious
injury. Remove all rings, watches and other jewelry. • terminal no. 87a - N.C.

1 Tag and disconnect all the wiring from the • terminal no. 85 - coil negative (-)
relay to be tested. • terminal no. 30 - common
2 Connect the leads from an ohmmeter or • terminal no. 86 - coil positive (+)
continuity tester to each terminal combination
and check for continuity. Terminals 85 and • terminal no. 87 - N.O.
86 represent the coil and should not be tested
in any other combination. Control Relay Schematic
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)

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Hydraulic Pumps

7-1 2 Tag, disconnect and plug the function pump

hydraulic hoses. Cap the fittings on the pump.
Function Pump
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the Function burn skin. Loosen hydraulic
Pump connections very slowly to allow
the oil pressure to dissipate
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or hose squirt or spray.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 3 Support the pump with a suitable lifting device.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 4 Remove the pump mounting bolts. Carefully
remove the pump.
1 Locate the two hydraulic tank valves at the
hydraulic tank. Close the valves. Component damage hazard. Be
sure to open the two hydraulic
Component damage hazard. tank valves and prime the pump
The engine must not be started after installing the pump.
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.

open closed

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Hydraulic Pumps

7-2 2 Locate the two hydraulic tank valves at the

hydraulic tank. Close the valves.
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should be performed at an authorized
Sauer-Danfoss service center. Contact Genie
open closed
Product Support to locate your local authorized
service center. Component damage hazard.
The engine must not be started
with the hydraulic tank shut-off
How to Remove the Drive Pump valves in the closed position or
Component damage hazard. The component damage will occur. If
work area and surfaces where the tank valves are closed,
this procedure will be performed remove the key from the key
must be clean and free of debris switch and tag the machine to
that could get into the hydraulic inform personnel of the
system and cause severe condition.
component damage. Dealer
service is recommended. 3 Tag, disconnect and plug the hydraulic hoses
from the drive and function pumps. Cap the
Note: When removing a hose assembly or fitting, fittings on the pumps.
the O-ring (if equipped) on the fitting and/or hose
Bodily injury hazard. Spraying
end must be replaced. All connections must be hydraulic oil can penetrate and
torqued to specification during installation. Refer to
burn skin. Loosen hydraulic
Specifications, Hydraulic Hose and Fitting Torque
connections very slowly to allow
Specifications.
the oil pressure to dissipate
1 Disconnect the wiring plug at the electronic gradually. Do not allow oil to
displacement controller (EDC), located on the squirt or spray.
drive pump.
4 Support the pumps with a suitable lifting device
and remove the two drive pump mounting
fasteners.

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Hydraulic Pumps
How to Prime the Pump

5 Carefully pull the drive pump out until the pump How to Prime the Pump
coupler separates from the flex plate.
Component damage hazard. Be
6 Remove the drive pump from the machine. sure that the hydraulic tank
Component damage hazard. shutoff valves (if equipped) are in
The pump(s) may become the open position before priming
unbalanced and fall if not the pump. The engine must not
properly supported. be started with the hydraulic tank
shutoff valves in the closed
position or component damage
Component damage hazard.
will occur.
The engine must not be started
with the hydraulic tank shut-off 1 Connect a 0 to 600 psi / 0 to 40 bar pressure
valves in the closed position or gauge to the diagnostic nipple on the drive
component damage will occur. If pump.
the tank valves are closed,
remove the key from the key 2 Continental models: If equipped, close the
switch and tag the machine to valve on the LPG tank, then disconnect the
inform personnel of the hose from the tank. Move the fuel select toggle
condition. switch to the LPG position.
Deutz and Perkins models: Disconnect the
engine wiring harness from the fuel solenoid at
the injector pump.
3 Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
pressure reaches 300 psi / 20.7 bar.
4 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.
5 Start the engine from the ground controls and
check for hydraulic leaks.

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Manifolds

8-1
Function Manifold Components
The function manifold assembly is located on the tank side tray, behind the ground control box.

Index Schematic
Description Function Torque
No. Item
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 30-35 ft-lbs / 41-47 Nm
pump
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 30-35 ft-lbs / 41-47 Nm
rotate
20 Flow regulator valve SM Steering flow control 20-25 ft-lbs / 27-34 Nm

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How to Adj ust the Boom Down R elief Val ve

8-2 Valve Adjustments - Function How to Adjust the Boom Down

Manifold Relief Valve
How to Adj ust the System Reli ef Val ve

Note: Perform this procedure with the boom in the

stowed position.
How to Adjust the System Relief Note: Refer to Function Manifold Component list to
Valve locate the boom down relief valve.
Note: Perform this procedure with the boom in the 1 Connect a 0 to 5000 psi / 0 to 350 bar
stowed position. pressure gauge to the diagnostic nipple
Note: Refer to Function Manifold Component list to located next to the auxiliary pump.
locate the system relief valve. 2 Start the engine from the ground controls.
Note: Auxiliary power will be used to perform this 3 Hold the function enable/rpm select toggle
procedure. Do not start the engine. switch to the high idle position and activate and
hold the boom down toggle switch with the
1 Connect a 0 to 5000 psi / 0 to 350 bar boom fully lowered. Observe the pressure
pressure gauge to the diagnostic nipple (ptest) reading on the pressure gauge. Refer to
located next to the auxiliary pump. Specifications, Hydraulic Specifications.
2 Simultaneously activate and hold the auxiliary 4 Turn the engine off. Use a wrench to hold the
power toggle switch and the primary boom relief valve and remove the cap on the function
retract toggle switch with the primary boom manifold.
fully retracted. Observe the pressure reading
on the pressure gauge. Refer to 5 Adjust the internal hex socket. Turn it
Specifications, Hydraulic Specifications. clockwise to increase pressure or
counterclockwise to decrease pressure. Install
3 Locate the system relief valve on the function the relief valve cap.
manifold. Use a wrench to hold the relief valve
and remove the cap using an allen wrench. Tip-over hazard. Do not adjust
the relief valve higher than
4 Adjust the internal hex socket. Turn it specified.
clockwise to increase the pressure or counter
clockwise to reduce the pressure. Install the 6 Repeat steps 2 through 5 and recheck relief
relief valve cap. valve pressure.
Tip-over hazard. Do not adjust 7 Remove the pressure gauge.
the relief valve higher than
specified.

5 Repeat step 2 to confirm relief valve pressure.

6 Remove the pressure gauge.

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How to Adj ust the Boom Extend R elief Val ve

How to Adjust the Boom Extend

Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
Note: Refer to Function Manifold Component list to
locate the boom extend relief valve.
1 Connect a 0 to 3000 psi / 0 to 200 bar
pressure 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
Specifications, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap on the function
manifold.
5 Adjust the internal hex socket. 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 valve higher than
specified.

6 Repeat steps 2 through 5 and recheck relief

valve pressure.
7 Remove the pressure gauge.

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8-3
Brake/Two-Speed Manifold Components
The brake/two speed manifold is mounted inside the drive chassis.

Index Schematic
Description Function Torque
No. Item
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

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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
Description Function Torque
No. Item
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

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8-5
Platform Rotate Manifold Components
The platform rotate manifold is mounted on the platform rotator.

Index Schematic
Description Function Torque
No. Item
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

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8-6
Platform Manifold Components, S-80
The jib boom/platform rotate manifold is mounted on the platform end of the boom.

Index Schematic
Description Function Torque
No. Item
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

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8-7
Platform Manifold Components, S-85
The jib boom/platform rotate manifold is mounted on the platform end of the boom.

Index Schematic
Description Function Torque
No. Item
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

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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
Description Function Torque
No. Item
1 Relief Valve, 280 psi / 19.3 bar DA Charge pressure circuit 30-35 ft-lbs / 41-47 Nm
2 Flow Divider / Combiner Valve DB Controls flow to drive motors in 90-100 ft-lbs / 120-133 Nm
forward and reverse
3 Check Valve DC Drive circuit 30-35 ft-lbs / 41-47 Nm
4 Check Valve DD Drive circuit 30-35 ft-lbs / 41-47 Nm
5 Shuttle Valve, 3 position 3 way DE Controls flow to drive motors in 50-55 ft-lbs / 67-73 Nm
forward and reverse
6 Orifice Plug, 0.070 inch / 1.8 mm DF Equalizes flow across flow
divider/combiner valve BY

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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
Description Function Torque
No. Item
1 Relief valve, 280 psi / 19.3 bar HA Charge pressure circuit 35-40 ft-lbs / 48-54 Nm
2 Flow divider/combiner valve HB Controls flow to non-steer end 80-90 ft-lbs / 108-122 Nm
drive motors in forward and
reverse
3 Check valve HC Steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm
4 Check valve HD Non-steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm
5 Flow divider/combiner valve HE Controls flow to flow 80-90 ft-lbs / 108-122 Nm
divider/combiner valves 2 and 13
6 Check valve HF Non-steer end drive motor circuit 60-70 ft-lbs / 81-95 Nm
7 Orifice, 0.040 inch / 1 mm HG Equalizes pressure on both sides
of flow divider/combiner valve 5
8 Orifice, 0.040 inch / 1 mm HH Equalizes pressure on both sides
of flow divider/combiner valve 2
9 Orifice, 0.040 inch / 1 mm HI Equalizes pressure on both sides
of flow divider/combiner valve 13
10 Check valve HJ Steer end drive motor circuit 60-70 ft-lbs / 81-95 Nm
11 Check valve HK Steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm
12 Shuttle valve, 3 position 3 way HL Charge pressure circuit that 80-90 ft-lbs / 108-122 Nm
directs hot oil out of low pressure
side of drive pump
13 Flow divider/combiner valve HM Controls flow to steer end drive 80-90 ft-lbs / 108-122 Nm
motors in forward and reverse
14 Check valve HN Non-steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm

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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
Description Function Torque
No. Item
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

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Manifolds

8-11
Valve Adjustments - Traction
Manifold

How to Adjust the Hot Oil Shuttle

Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the traction
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 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.
2 Start the engine from the platform controls and
allow the engine to run at low idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a 0 to 600 psi /
0 to 40 bar pressure gauge to the diagnostic
nipple located on the traction manifold.
4 Start the engine from the platform controls and
drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.
5 Turn the engine off, and remove the hot oil
shuttle relief valve cap (item BJ). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
6 Repeat steps 4 and 5 until a pressure
differential (between the charge pump reading
and the hot oil shuttle relief valve) of 40 psi /
3 bar is obtained.

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Val ve C oil Resistanc e Speci fications

8-12 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromotive force which operates the solenoid increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil that provides this force field. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification
resistance values outside specification can produce
erratic operation. When coil resistance decreases Proportional solenoid valve (schematic 4.8Ω
items K and W)
below specification, amperage increases. As
resistance rises above specification, voltage 2 position 3 way solenoid valve 6.3Ω
increases. (schematic items D, R, X, TT and UU)
2 position 3 way solenoid valve 3.3Ω
While valves may operate when coil resistance is (schematic items G)
outside specification, maintaining coils within
3 position 4 way solenoid valve 6.3Ω
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 6.3Ω
Electrocution/burn hazard. (schematic items AK, AM, VV and WW)
Contact with electrically charged 2 position 3 way solenoid valve 3.3Ω
circuits could result in death or (schematic item G)
serious injury. Remove all rings,
watches and other jewelry.

1 Tag and disconnect the wiring from the coil to

be tested.
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.

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How to Test a Coil Diode

Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

1 Test the coil for resistance. Refer to Repair 1 multimeter

Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative 4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a Note: Dotted lines in illustration indicate a reversed
terminal on the coil. connection as specified in step 6.
Resistor 10Ω 3 Set a multimeter to read DC current.
Genie part number 27287
Note: The multimeter, when set to read DC current,
Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.
measured across the terminals.
4 Connect the negative lead to the other terminal
on the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
DC battery. Note and record the current
reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.

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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.
Component damage hazard. The
Engine fuels are combustible.
fuel tank is plastic and may
Perform this procedure in an
become damaged if allowed to
open, well-ventilated area away
fall.
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within Component damage hazard.
easy reach. When installing the plastic fuel
tank, do not overtighten the
retaining fasteners.
Explosion and fire hazard. When
transferring fuel, connect a Note: Clean the fuel tank and inspect for damage
grounding wire between the before installing it onto the machine.
machine and pump or container.

Explosion and fire hazard. Never

drain or store fuel in an open
container due to the possibility of
fire.

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
Specifications, Machine Specifications.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.

Note: Be sure to only use a hand operated pump

suitable for use with gasoline and diesel fuel.

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Fuel and Hydraulic Tanks

9-2 2 Close the two hydraulic tank valves located at

the hydraulic tank (if equipped).
Hydraulic Tank
Component damage hazard.
The primary functions of the hydraulic tank are to The engine must not be started
cool, clean and de-aerate the hydraulic fluid during with the hydraulic tank shut-off
operation. The tank utilizes internal suction valves in the closed position or
strainers for the pump supply hoses and has an component damage will occur. If
external return filter equipped with a filter condition the tank valves are closed,
indicator. remove the key from the key
switch and tag the machine to
How to Remove the Hydraulic inform personnel of the
condition.
Tank
Component damage hazard. 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 and cause severe
component damage. Dealer
service is recommended.
open closed
Note: When removing a hose assembly or fitting, 3 Remove the drain plug from the hydraulic tank
the O-ring (if equipped) on the fitting and/or hose and completely drain the tank into a container
end must be replaced. All connections must be of suitable capacity. Refer to Specifications,
torqued to specification during installation. Refer to Machine Specifications.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 4 Tag, disconnect and plug the two suction
hoses that are attached to the hydraulic tank.
1 Remove the fuel tank. Refer to Repair
Procedure, How to Remove the Fuel Tank. 5 Tag and disconnect and plug the hose from the
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.

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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 (if
hold down straps from the hydraulic tank.
equipped).
8 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank Component damage hazard. Be
and attach the lifting straps to an overhead sure to open the two hydraulic
crane. tank shutoff valves (if equipped)
and prime the pump after
9 Remove the hydraulic tank from the machine. installing 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 fall if not properly supported
when removed from the
machine.

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.

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Turntable Rotation Components

10-1 4 Attach a suitable lifting device to the lifting

eyes on the drive hub assembly.
Turntable Rotation Drive Hub
Assembly
How to R emove the Tur ntabl e R otation Dri ve H ub As sembl y

How to Remove the Turntable

Rotation Drive Hub Assembly
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Secure the turntable from rotating with the
turntable rotation lock pin.

1 backlash pivot plate

2 adjustment bolt with lock nut
3 backlash pivot plate mounting bolts

5 Remove the backlash pivot plate mounting

unlocked locked bolts. Carefully remove the drive hub assembly
2 Tag, disconnect and plug the hydraulic hoses from the machine.
from the drive motor. Cap the fittings on the Crushing hazard. The turntable
motor. rotate drive hub assembly could
Bodily injury hazard. Spraying become unbalanced and fall
hydraulic oil can penetrate and when removed from the machine
burn skin. Loosen hydraulic if not properly supported by the
connections very slowly to allow lifting device.
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

3 Loosen the backlash pivot plate and

adjustment bolts.

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Turntable Rotation Components

How to R emove the Tur ntabl e R otation H ydr aulic M otor

When installing the drive hub assembly: How to Remove the Turntable
6 Install the drive hub. Apply removable thread Rotation Hydraulic Motor
locking compound to fastener threads.Torque
Note: When removing a hose assembly or fitting,
the backlash pivot plate mounting fasteners to
the O-ring (if equipped) on the fitting and/or hose
specification. Refer to Specifications, Machine
end must be replaced. All connections must be
Torque Specifications.
torqued to specification during installation. Refer to
7 Install the brake and then the motor onto the Specifications, Hydraulic Hose and Fitting Torque
drive hub. Apply removable thread locking Specifications.
compound to fastener threads.Torque the
motor/brake mounting fasteners to 1 Secure the turntable from rotating with the
specification. Refer to Specifications, Machine turntable rotation lock pin.
Torque Specifications. 2 Tag, disconnect and plug the hydraulic hoses
8 Adjust turntable rotation gear backlash. Refer from the drive motor. Cap the fittings on the
to Repair Procedure, How to Adjust the motor.
Turntable Rotation Gear Backlash. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

3 Remove the hydraulic tube that connects from

the counterbalance manifold to the brake. Cap
the fittings on the brake and manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

4 Remove the motor/brake mounting fasteners.

Carefully remove the motor from the brake.

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Turntable Rotation Components

How to Adj ust the Tur ntabl e R otati on Gear Bac klash

5 Clean up any oil that may have spilled. How to Adjust the Turntable
Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
adjustable plate that controls the gap between the
rotation motor pinion gear and the turntable bearing
ring gear.
Note: Perform this procedure with the boom
between the non-steer end tires and with the
machine on a firm and level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
Note: The turntable rotation lock pin is located next
to the boom rest pad.
2 Loosen the backlash pivot plate mounting
fasteners.

1 motor
2 drive hub mounting bolts
3 drive hub with brake

1 backlash pivot plate

2 adjustment bolt with lock nut
3 backlash pivot plate mounting bolts

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Turntable Rotation Components

3 Push the backlash pivot plate towards the

turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6 Turn the adjustment bolt one half turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
7 Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Then torque the mounting fasteners on the
backlash pivot plate. Refer to Specifications,
Machine Torque Specifications.
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.

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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
8 Remove the drive motor mounting fasteners.
Drive Hub Assembly
9 Slide the drive motor shaft out of the drive hub
Note: When removing a hose assembly or fitting, and remove the drive motor from the machine.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 10 Remove the pin retaining fasteners from the
torqued to specification during installation. Refer to upper and lower yoke pivot pins.
Specifications, Hydraulic Hose and Fitting Torque 11 Support and secure the yoke and drive hub
Specifications. 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.
2 Tag, disconnect and plug the hydraulic hoses Crushing hazard. The yoke and
from the drive motor. Cap the fittings on the drive hub assembly could
drive motor. become unbalanced and fall
when the yoke pivot pins are
Bodily injury hazard. Spraying
removed if not properly
hydraulic oil can penetrate and
supported and secured to the
burn skin. Loosen hydraulic
lifting jack.
connections very slowly to allow
the oil pressure to dissipate
13 Place the yoke and drive hub assembly on a
gradually. Do not allow oil to
flat surface with the drive hub facing down.
squirt or spray.
14 Remove the drive hub mounting fasteners that
3 Loosen the wheel lug nuts. Do not remove attach the drive hub to the yoke. Remove the
them. yoke from the drive hub. Refer to
Specifications, Machine Torque
4 Block the non-steer wheels, and center a lifting
Specifications.
jack of ample capacity under the steer axle.
Note: Replace the thrust washer when installing the
5 Raise the machine approximately 6 inches /
yoke and drive hub assembly onto the axle.
15 cm and place blocks under the chassis for
support.

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Steer Axle Components

11-2 11-3
Drive Motors Drive Hubs

How to Remove a Drive Motor How to Remove a Drive Hub

Component damage hazard. Note: When removing a hose assembly or fitting,
Repairs to the motor should only the O-ring (if equipped) on the fitting and/or hose
be performed by an authorized end must be replaced. All connections must be
dealer. torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Component damage hazard. The Specifications.
work area and surfaces where 1 Remove the drive motor. Refer to Repair
this procedure will be performed Procedure, How to Remove a Drive Motor.
must be clean and free of debris
that could get into the hydraulic 2 Loosen the wheel lug nuts. Do not remove
system and cause severe them.
component damage. Dealer
3 Center a lifting jack of ample capacity under
service is recommended.
the non-steer axle.
Note: When removing a hose assembly or fitting, 4 Raise the machine approximately 6 inches /
the O-ring (if equipped) on the fitting and/or hose 15 cm and place blocks under the chassis for
end must be replaced. All connections must be support.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 5 Remove the wheel lug nuts, then the tire and
Specifications. wheel assembly.
6 Place a second lifting jack under the drive hub
1 Extend the axles.
for support and secure the drive hub to the
2 Remove the drive motor access covers from lifting jack.
both sides of the inner axle. 7 Remove the drive hub mounting fasteners that
3 Tag, disconnect and plug the hydraulic hoses attach the drive hub to the axle. Remove the
from the drive motor. Cap the fittings on the drive hub.
drive motor.
Crushing hazard. The drive hub
Bodily injury hazard. Spraying could become unbalanced and
hydraulic oil can penetrate and fall if not properly supported by an
burn skin. Loosen hydraulic overhead crane or lifting device
connections very slowly to allow when removed from the machine.
the oil pressure to dissipate
gradually. Do not allow oil to Note: Do not re-use the drive hub mounting
squirt or spray. fasteners. Genie specifications require the use of
new fasteners.
4 Remove the drive motor mounting fasteners.
5 Slide the drive motor shaft out of the drive hub,
and remove the drive motor from the machine.

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Steer Axle Components

11-4
Steer Cylinders

How to Remove a Steer Cylinder

There are two identical steer cylinders that work in
parallel. They are part of the same hydraulic circuit,
but move in opposite directions. The tie rod cylinder
maintains equal movement of the tires.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

2 Remove the hose bracket mounting fastener

on the steer cylinder barrel-end pivot pin.
3 Remove the pin retaining fasteners from the
steer cylinder pivot pins. Remove the pivot pin
from each end of the steer cylinder.
4 Remove the steering cylinder from the
machine.

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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. Refer to Repair Procedure, How to procedure. Refer to Repair Procedure, How to
Remove a Drive Motor. Remove a Drive Hub.

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Oscillating Axle Components

13-1 4 Remove the pin retaining fasteners from the

rod-end pivot pin. Use a soft metal drift to
Oscillating Axle Cylinders remove the pin.
The oscillating axle cylinders extend and retract 5 Attach a lifting strap from an overhead crane to
between the drive chassis and the axle to maintain the barrel end of the oscillating cylinder.
a level chassis while driving over uneven terrain.
6 Remove the pin retaining fasteners from the
The cylinders are equipped with counterbalance
barrel-end pivot pin. Use a soft metal drift to
valves to prevent movement in the event of a
remove the pin.
hydraulic hose failure.
7 Remove the cylinder from the machine.
How to Remove an Oscillating Crushing hazard. The oscillate
Axle Cylinder cylinder may become
unbalanced and fall when
Note: Perform this procedure on a firm, level removed from the machine if not
surface with the boom in the stowed position. properly attached to the
overhead crane.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Rotate the turntable until the boom is between
the steer tires.
2 Remove the fasteners from the drive chassis
cover at the steer end. Remove the cover.
3 Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

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Oscillating Axle Components

13-2 4 Start the engine from the ground control.

Oscillate Directional Valve 5 With the engine running, manually activate the
How to Adj ust the Oscill ate R elief Val ve
valve and observe the pressure reading on the
pressure gauge. Refer to Specifications,
Hydraulic Component Specifications.
How to Adjust the Oscillate Relief
6 Turn the engine off.
Valve
7 Locate the relief valve on the function manifold
1 Connect a 0 to 2000 psi / 0 to 150 bar (item SC).
pressure gauge to the diagnostic nipple
located on the function manifold. 8 Loosen the jam nut on the relief valve.
2 Remove the drive chassis cover from the 9 Turn the valve clockwise to increase the
non-steer end of the machine. pressure or counterclockwise to decrease the
pressure.
3 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive Tip-over hazard. Do not adjust
chassis. the relief valve higher than
specified.

10 Tighten the jam nut.

11 Repeat steps 4 through 10 to confirm the
oscillate relief valve pressure.
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.

1 oscillate valve
2 clevis yoke
3 drive chassis

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Oscillating Axle Components

How to Set U p the Direc tional Val ve Li nkage

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 11 Measure the gap between the drive chassis
surface the machine is on is completely level. and the non-steer axle on both sides (from the
Tip-over hazard. Failure to inside of the drive chassis).
perform this procedure on a Result: The measurements should be equal.
firm, level surface will
compromise the stability of the Note: The gap on both sides should be between
machine and could result in the 0.150 inch / 0.381 cm and 0.170 inch / 0.432 cm.
machine tipping over. 12 Add or remove shims between the oscillation
stop bar and the drive chassis to achieve the
3 Check the tire pressure in all four tires and add proper gap.
air if needed to meet specification.
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.

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Fault Codes
Section 4 Faul t Codes

Before Troubleshooting:
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
 Troubleshooting and repair procedures shall be conditions.
completed by a person trained and qualified on
the repair of this machine  Be aware of the following hazards and follow
generally accepted safe workshop practices.
 Immediately tag and remove from service a
damaged or malfunctioning machine. Electrocution/burn hazard.
Contact with electrically charged
 Repair any machine damage or malfunction
circuits could result in death or
before operating the machine.
serious injury. Remove all rings,
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)

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Control System Fault Codes

How to R etrieve Contr ol System F ault 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
Fault Codes per second. It will then pause for 1.5 seconds
and flash the second digit once per
At least one fault code is present when the alarm at 0.5 second.
the platform controls produces two short beeps
Note: When the red LED is flashing the code, the
every 30 seconds for 10 minutes.
yellow LED will be on solid.
Perform this procedure with the engine off, the key
4 Determine the error type: The yellow LED
switch turned to platform controls and the red
indicates the error type and will flash two
Emergency Stop button pulled out to the on position
separate codes. The first code will indicate the
at both the ground and platform controls.
first digit of the two digit code, flashing once
1 Open the platform control box lid. per second. It will then pause for 1.5 seconds
and flash the second digit once per
Electrocution/burn hazard. 0.5 second.
Contact with electrically charged
circuits could result in death or Note: When the yellow LED is flashing the code, the
serious injury. Remove all rings, red LED will be on solid.
watches and other jewelry. 5 Use the fault code table on the following pages
to aid in troubleshooting the machine by
2 Locate the red and yellow fault LEDs on the pinpointing the area or component affected.
ALC-500 circuit board inside the platform
control box. Do not touch the circuit board.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

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Control System Fault Codes

Control System F ault C odes

Error Source Error Type Condition Solution

ID Name ID Name

21 Primary Up / 11 Value at 5V Function is inoperative.Alarm sounds Cycle power off, then on

Down Joystick indicating a fault. after problem has been
corrected.
12 Value too high
15 Value too low
16 Value at 0V
17 Not calibrated Calibrate joystick.
22 Primary Up / 21 Fault Valve is operating outside of limits. Cycle power off, then on
Down Directional after problem has been
Valves corrected.
Alarm sounds indicating a fault.
23 Primary Up / 12 Value too high Valve is operating outside of limits. Cycle power off, then on
Down Flow Valve after problem has been
15 Value too low Alarm sounds indicating a fault.
corrected.
17 Not calibrated Normal function except threshold for Calibrate valve threshold.
one or both directions is zero.
24 Angle sensor 11 Value at 5V Reduced speed function. Cycle power off, then on
after problem has been
12 Value too high Alarm sounds indicating a fault.
corrected.
15 Value too low
16 Value at 0V
17 Not calibrated Calibrate angle sensor.
31 Invalid setup Initiate 1 -second beep of Alarm Buzzer Calibrate angle sensor.
and required retract into safe envelope
26 Angle sensor 19 Out of range Reduced speed, required retract into Power up controller with
cross check safe envelope problem corrected
31 Secondary Up / 11 Value at 5V Function is inoperative. Alarm sounds Cycle power off, then on
Down. Joystick indicating a fault. after problem has been
corrected.
12 Value too high
15 Value too low
16 Value at 0V
17 Not calibrated Calibrate joystick.

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Control System Fault Codes

Error Source Error Type Condition Solution

ID Name ID Name

32 Secondary Up / 21 Fault Valve is operating outside of limits. Cycle power off, then on
Down. Directional Alarm sounds indicating a fault. after problem has been
Valves corrected.
33 Secondary Up / 12 Value too high Valve is operating outside of limits. Cycle power off, then on
Down Flow Valve after problem has been
corrected.
15 Value too low Alarm sounds indicating a fault.
17 Not calibrated Normal function except threshold for Calibrate valve threshold.
one or both directions is zero.
34 Ext. Ret. Limit 31 Invalid setup Initiate 1-second beep of Alarm Buzzer Fully retract, then lower
Switch boom
1000lb. Mode: Required retract into Check and service ext/ret
FULLY RETRACTED state before and fully stowed switches
lowering
500lb. Mode: Operates normally
41 Turntable Rotate 11 Value at 5V Limited speed and direction frozen at Cycle power off, then on
Joystick zero and neutral. after problem has been
corrected.
12 Value too high Alarm sounds indicating a fault.
15 Value too low
16 Value at 0V
17 Not calibrated Calibrate joystick.
42 Turntable Rotate 21 Fault Limited direction. Frozen at zero and Cycle power off, then on
Directional Valves neutral. Alarm sounds indicating a after problem has been
fault. corrected.
43 Turntable Rotate 12 Value too high Limited speed and direction. Cycle power off, then on
Flow Valve after problem has been
corrected.
15 Value too low Frozen at zero and neutral.
Alarm sounds indicating a fault.
17 Not calibrated Normal function except threshold for Calibrate valve threshold.
one or both directions is zero.
44 Drive Enable 21 Fault Drive enable override direction is Cycle power off, then on
Override Switch frozen at neutral. after problem has been
corrected.

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Control System Fault Codes

Error Source Error Type Condition Solution

ID Name ID Name

45 Platform Level 21 Fault Platform level frozen at neutral Power up controller with
Switch problem corrected
46 Primary 21 Fault Platform Ext/Ret frozen at neutral Power up controller with
Extend/Retract problem corrected
Switch
51 Drive Joystick 11 Value at 5V Limited speed and direction. Cycle power off, then on after
Frozen at zero and neutral. Alarm problem has been corrected.
sounds indicating a fault.
12 Value too high
15 Value too low
16 Value at 0V
17 Not calibrated Calibrate joystick.
53 Drive Flow Valve 12 Value too high Limited speed and direction. Cycle power off, then on after
(EDC) Frozen at zero and neutral. ALarm problem has been corrected.
sounds indicating a fault.
15 Value too low
17 Not calibrated Normal function except threshold Calibrate valve threshold.
for one or both directions is zero.

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Control System Fault Codes

Error Source Error Type Condition Solution

ID Name ID Name

54 Drive Brake Valve 21 Fault Drive frozen at zero and neutral. Cycle power off, then on after
problem has been corrected.
Alarm sounds indicating a fault.
55 High Drive Motor 21 Fault Motor speed in the low state. Cycle power off, then on after
Speed Valve Alarm sounds indicating a fault. problem has been corrected.
56 Platform Level 21 Fault Direction frozen at zero and Power up controller with
Value neutral, AB problem corrected
57 Foot switch/ECU 12 Value too high Direction frozen at zero and Power up controller with
Power neutral, AB problem corrected
Crosscheck
15 Value too low
61 Steer Joystick 11 Value at 5V Limited speed and direction. Cycle power off, then on after
Frozen at zero and neutral. Alarm problem has been corrected.
sounds indicating a fault.
12 Value too high
15 Value too low
16 Value at 0V
17 Not calibrated Calibrate joystick.
62 Steer Directional 21 Fault Limited speed and direction. Cycle power off, then on after
Valve Frozen at zero and neutral. Alarm problem has been corrected.
sounds indicating a fault.

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Fault Code Display - Deutz and Perkins Models

How to R etrieve Ac ti ve Engine F ault Codes D eutz D 2.9 L4 and Per ki ns 404F- 22 Models

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

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Fault Code Display - Deutz and Perkins Models

Faul t Code Dis play - Flashi ng and Solid LED's - D eutz D 2.9 L4 and Per ki ns 404F- 22 Models

Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models

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

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Fault Code Display - Deutz and Perkins Models

Soft Key F unc tions and Ic ons - Deutz D 2.9 L4 and Per ki ns 404F-22 M odels

Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22
Models

1 Next menu • Exit / Back one screen • Decrease brightness (-)

2 Brightness / Contrast • Scroll up • Increase • Increase brightness (+)
3 Regeneration forced • Scroll down • Decrease • Decrease contrast (-)
4 Regeneration inhibited • Select / Next • Main menu • Increase contarst (+)
Note: Regeneration, initiate, inhibit and soot
only apply to the Perkins 404F-22 models.

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Fault Code Display - Deutz and Perkins Models

Main M enu Str ucture - Deutz D 2.9 L4 Models

Main Menu Structure - Deutz D 2.9 L4 Models

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Fault Code Display - Deutz and Perkins Models

Main M enu Str ucture - Per kins 404F-22 M odels

Main Menu Structure - Perkins 404F-22 Models

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Deutz D 2.9 L4 Engine Fault Codes

SPN FMI KWP Description

SPN = Suspect Parameter Number
51 11 1231 Actuator error EGR-Valve; Power
FMI = Failure Mode Identifier
stage over temp due to high
KWP = Keyword Protocol current
SPN FMI KWP Description 51 12 1018 Actuator EGR-Valve; powerstage
51 3 1019 EGR-Valve, short circuit to over temperature
battery 51 12 1021 Mechanical actuator defect
51 3 1024 Position sensor error of actuator EGR-Valve
EGR-Valve; signal range check 51 12 1225 Actuator EGR-Valve; over
high temperature
51 3 1226 EGR-Valve; short circuit to 94 1 474 Low fuel pressure; warning
battery (A02) threshold exceeded
51 3 1227 EGR-Valve; short circuit to 94 1 475 Low fuel pressure; shut off
battery (A67) threshold exceeded
51 4 1020 EGR-Valve; short circuit to 94 3 472 Sensor error low fuel pressure;
ground signal range check high
51 4 1025 Position sensor error actuator 94 4 473 Sensor error low fuel pressure;
EGR-Valve; signal range check signal range check low
low
97 3 464 Sensor error water in fuel; signal
51 4 1228 EGR-Valve; short circuit to range check high
ground (A02)
97 4 465 Sensor error water in fuel; signal
51 4 1229 EGR-Valve; short circuit to range check low
ground (A67)
97 12 1157 Water in fuel level prefilter;
1 4 1232 Actuator error EGR-Valve; maximum value exceeded
Voltage below threshold
100 0 734 High oil pressure; warning
51 5 1015 Actuator error EGR-Valve; signal threshold exceeded
range check low
100 0 735 High oil pressure; shut off
51 5 1017 Actuator EGR-Valve; open load threshold exceeded
51 5 1023 Actuator error EGR-Valve; signal 100 1 736 Low oil pressure; warning
range check low threshold exceeded
51 5 1223 Actuator EGR-Valve; open load 100 1 737 Low oil pressure; shut off
51 6 1014 Actuator error EGR-Valve; signal threshold exceeded
range check high 100 3 732 Sensor error oil pressure; signal
51 6 1022 Actuator error EGR-Valve; signal range check high
range check high 100 4 733 Sensor error oil pressure sensor;
51 6 1224 Actuator EGR-Valve; over signal range check low
current 102 2 88 Charged air pressure above
51 6 1230 Actuator error EGR-Valve; warning threshold
Overload by short-circuit 102 2 89 Charged air pressure above shut
51 7 1016 Actuator position for EGR-Valve off threshold
not plausible 102 4 777 Sensor error charged air press.;
signal range check low

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 168 0 1180 Physical range check high for
KWP = Keyword Protocol battery voltage
SPN FMI KWP Description 168 1 1181 Physical range check low for
105 0 996 High charged air cooler battery voltage
temperature; warning threshold 168 2 47 High battery voltage; warning
exceeded threshold exceeded
105 0 997 High charged air cooler 168 2 48 Low battery voltage; warning
temperature; shut off threshold threshold exceeded
exceeded
168 3 45 Sensor error battery voltage;
105 3 994 Sensor error charged air signal range check high
temperature; signal range check
168 4 46 Sensor error battery voltage;
high
signal range check low
105 4 995 Sensor error charged air
171 3 417 Sensor error environment
temperature; signal range check
temperature; signal range check
low
high
108 3 412 Sensor error ambient air press.;
171 4 418 Sensor error environment
signal range check high
temperature; signal range check
108 4 413 Sensor error ambient air press.; low
signal range check low
172 0 1182 Physical range check high for
110 0 98 High coolant temperature; intake air temperature
warning threshold exceeded
172 1 1183 Physical range check low for
110 0 99 High coolant temperature; shut intake air temperature
off threshold exceeded
172 2 9 Sensor ambient air temperature;
110 3 96 Sensor error coolant temp.; plausibility error
signal range check high
172 2 983 Intake air sensor; plausibility
110 4 97 Sensor error coolant temp.; error
signal range check low
172 3 981 Sensor error intake air; signal
111 1 101 Coolant level too low range check high
132 11 1 Air flow sensor load correction 172 4 982 Sensor error intake air sensor;
factor exceeding the maximum signal range check low
drift limit; plausibility error
174 0 481 High low fuel temperature;
132 11 2 Air flow sensor load correction warning threshold exceeded
factor exceeding drift limit;
174 0 482 High Low fuel temperature; shut
plausibility error
off threshold exceeded
132 11 3 Air flow sensor low idle correction
175 0 740 Physical range check high for oil
factor exceeding the maximum
temperature
drift limit
175 0 745 High oil temperature; warning
132 11 4 Air flow sensor load correction
threshold exceeded
factor exceeding the maximum
drift limit 175 0 746 High oil temperature; shut off
threshold exceeded
157 3 877 Sesnor error rail pressure; signal
range check high 175 1 741 Physical range check low for oil
temperature
157 4 878 Sensor error rail pressure; signal
range check low

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 412 3 1007 Sensor error EGR cooler
KWP = Keyword Protocol downstream temperature; signal
SPN FMI KWP Description range check high

175 2 738 Sensor oil temperature; 412 4 1008 Sensor error EGR cooler
plausibility error downstream temperature; signal
range check low
175 2 739 Sensor oil temperature;
plausibility error oil temperature 520 9 306 Timeout Error of
too high CAN-Receive-Frame TSC1TR;
Setpoint
175 3 743 Sensor error oil temperature;
signal range check high 597 2 49 Break lever mainswitch and
break lever redundancy switch
175 4 744 Sensor error oil temperature; status not plausible
signal range check low
624 3 971 SVS lamp; short circuit to batt.
190 0 389 Engine speed above warning
threshold (FOC-Level 1) 624 4 972 SVS lamp; short circuit to grd.

190 2 421 Offset angle between crank- and 624 5 969 SVS lamp; open load
camshaft sensor is too large 624 12 970 SVS lamp; powerstage over
190 8 419 Sensor camshaft speed; temperature
disturbed signal 630 12 376 Access error EEPROM memory
190 8 422 Sensor crankshaft speed; (delete)
disturbed signal 630 12 377 Access error EEPROM memory
190 11 390 Engine speed above warning (read)
threshold (FOC-Level 2) 630 12 378 Access error EEPROM memory
190 12 420 Sensor camshaft speed; no (write)
signal 639 14 84 CAN-Bus 0 "BusOff-Status"
190 12 423 Sensor crankshaft speed; no 651 3 580 Injector 1 (in firing order); short
signal circuit
190 14 391 Engine speed above warning 651 4 586 High side to low side short circuit
threshold (Overrun Mode) in the injector 1 (in firing order)
190 14 1222 Camshaft- and Crankshaft speed 651 5 568 Injector 1 (in firing order);
sensor signal not available on interruption of electric connection
CAN
652 3 581 Injector 2 (in firing order); short
411 0 791 Physical range check high for circuit
differential pressure Venturiunit
652 4 587 High side to low side short circuit
(EGR)
in the injector 2 (in firing order)
411 1 792 Physical range check low for
652 5 569 Injector 2 (in firing order);
differential pressure Venturiunit
interruption of electric connection
(EGR)
653 3 582 Injector 3 (in firing order); short
411 3 795 Sensor error differential pressure
circuit
Venturiunit (EGR); signal range
check high 653 4 588 High side to low side short circuit
in the injector 3 (in firing order)
411 4 381 Physical range check low for
EGR differential pressure 653 5 570 Injector 3 (in firing order);
interruption of electric connection
411 4 796 Sensor error differential pressure
Venturiunit (EGR); signal range
check low

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 1109 2 121 Engine shut off demand ignored
KWP = Keyword Protocol
1136 0 1398 Physikal range check high for
SPN FMI KWP Description ECU temperature
654 3 583 Injector 4 (in firing order); short 1136 1 1399 Physikal range check low for
circuit ECU temperature
654 4 589 High side to low side short circuit 1136 3 1400 Sensor error ECU temperature;
in the injector 4 (in firing order) signal range check high
654 5 571 Injector 4 (in firing order); 1136 4 1401 Sensor error ECU temperature;
interruption of electric connection signal range check low
676 11 543 Cold start aid relay error. 1176 3 849 Sensor error pressure sensor
676 11 544 Cold start aid relay open load upstream turbine; signal range
check high
677 3 956 Starter relay high side; short
circuit to battery 1176 4 850 Sensor error pressure sensor
downstream turbine; signal range
677 3 960 Starter relay low side; short check high
circuit to battery
1180 0 1193 Physical range check high for
677 4 957 Starter relay high side; short exhaust gas temperature
circuit to ground upstream turbine
677 4 961 Starter relay low side; short 1180 0 1460 Turbocharger Wastegate CAN
circuit to ground feedback; warning threshold
677 5 958 Starter relay; no load error exceeded
677 12 959 Starter relay; powerstage over 1180 0 1462 Exhaust gas temperature
temperature upstream turbine; warning
threshold exceeded
703 3 426 Engine running lamp; short circuit
to battery 1180 1 1194 Physical range check low for
exhaust gas temperature
703 4 427 Engine running lamp; short circuit upstream turbine
to ground
1180 1 1461 Turbocharger Wastegate CAN
703 5 424 Engine running lamp; open load feedback; shut off threshold
703 12 425 Engine running lamp; exceeded
powerstage over temperature 1180 1 1463 Exhaust gas temperature
729 5 545 Cold start aid relay open load upstream turbine; shut off
threshold exceeded
729 12 547 Cold start aid relay; over
temperature error 1180 3 1067 Sensor error exhaust gas
temperature upstream turbine;
898 9 305 Timeout Error of
signal range check high
CAN-Receive-Frame TSC1TE;
Setpoint 1180 11 1066 Sensor exhaust gas temperature
upstream turbine; plausibility
1079 13 946 Sensor supply voltage monitor
error
1 error (ECU)
1188 2 1414 Wastegate; status message from
1080 13 947 Sensor supply voltage monitor
ECU missing
2 error (ECU)

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature exhaust
KWP = Keyword Protocol gas mass flow; plausibility error
SPN FMI KWP Description 2659 12 1526 Exhaust gas recirculation; AGS
1188 7 1415 Wastegate actuator; blocked sensor has "burn off" not
performed
1188 11 1411 Wastegate actuator; internal
error 2797 4 1337 Injector diagnostics; timeout error
of short circuit to ground
1188 11 1412 Wastegate actuator; EOL measurement cyl. Bank 0
calibration not performed
correctly 2798 4 1338 Injector diagnostics; timeout error
of short circuit to ground
1188 11 1416 Wastegate actuator; over measurement cyl. Bank 1
temperature (> 145øC)
2798 4 1339 Injector diagnostics; short circuit
1188 11 1417 Wastegate actuator; over to ground monitoring Test in Cyl.
temperature (> 135øC) Bank 0
1188 11 1418 Wastegate actuator; operating 2798 4 1340 Injector diagnostics; short circuit
voltage error to ground monitoring Test in Cyl.
1188 13 1413 Wastegate actuator calibration Bank 1
deviation too large, recalibration 3224 2 127 DLC Error of
required CAN-Receive-Frame AT1IG1
1231 14 85 CAN-Bus 1 "BusOff-Status" NOX Sensor (SCR-system
upstream cat; DPF-system
1235 14 86 CAN-Bus 2 "BusOff-Status" downstream cat); length of frame
1237 2 747 Override switch; plausibility error incorrect
1322 12 610 Too many recognized misfires in 3224 9 128 Timeout Error of
more than one cylinder CAN-Receive-Frame AT1IG1;
NOX sensor upstream
1323 12 604 Too many recognized misfires in
cylinder 1 (in firing order) 3248 4 1047 Sensor error particle filter
downstream temperature; signal
1324 12 605 Too many recognized misfires in
range check low
cylinder 2 (in firing order)
3699 2 1616 DPF differential pressure sensor
1325 12 606 Too many recognized misfires in
and a further sensor or actuator
cylinder 3 (in firing order)
CRT system defective
1326 12 607 Too many recognized misfires in
3699 2 1617 Temperature sensor us. and ds.
cylinder 4 (in firing order)
DOC simultaneously defect
2659 0 1524 Physical range check high for
3699 14 1615 Maximum stand-still-duration
EGR exhaust gas mass flow
reached; oil exchange required
2659 1 1525 Physical range check low for
4765 0 1039 Physical range check high for
EGR exhaust gas mass flow
exhaust gas temperature
2659 2 1523 Exhaust gas recirculation AGS upstream (DOC)
sensor; plausibility error
4765 1 1042 Physical range check low for
exhaust gas temperature
upstream (DOC)

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523212 9 171 Timeout Error of
KWP = Keyword Protocol CAN-Receive-Frame
SPN FMI KWP Description ComEngPrt; Engine Protection

4766 0 1029 Physical range check high for 523216 9 198 Timeout Error of
exhaust gas temperature CAN-Receive-Frame
downstream (DOC) PrHtEnCmd; pre-heat command,
engine command
4766 1 1032 Physical range check low for
exhaust gas temperature 523240 9 179 Timeout CAN-message
downstream (DOC) FunModCtl; Function Mode
Control
4768 2 1036 Sensor exhaust gas temperature
upstream (DOC); plausibility 523350 4 565 Injector cylinder-bank 1; short
error circuit

4768 3 1044 Sensor error exhaust gas 523352 4 566 Injector cylinder-bank 2; short
temperature upstream (DOC); circuit
signal range check high 523354 12 567 Injector powerstage output defect
4768 4 1045 Sensor error exhaust gas 523470 2 826 Pressure Relief Valve (PRV)
temperature upstream (DOC) forced to open; performed by
signal range check low pressure increase
4769 2 1026 Sensor exhaust gas temperature 523470 2 827 Pressure Relief Valve (PRV)
downstream (DOC); plausibility forced to open; performed by
error pressure shock
4769 3 1034 Sensor error exhaust gas 523470 7 876 Maximum rail pressure in limp
temperature downstream (DOC); home mode exceeded (PRV)
signal range check high
523470 11 831 The PRV can not be opened at
4769 4 1035 Sensor error exhaust gas this operating point with a
temperature downstream (DOC); pressure shock
signal range check low
523470 11 832 Rail pressure out of tolerance
523006 3 34 Controller mode switch; short range
circuit to battery
523470 12 828 Open Pressure Relief Valve
523006 4 35 Controller mode switch; short (PRV); shut off condition
circuit to ground
523470 12 829 Open Pressure Relief Valve
523008 1 648 Manipulation control was (PRV); warning condition
triggered
523470 14 830 Pressure Relief Valve (PRV) is
523008 2 649 Timeout error in Manipulation open
control
523550 12 980 T50 start switch active for too
523009 9 825 Pressure Relief Valve (PRV) long
reached maximun allowed
523601 13 948 Sensor supply voltage monitor
opening count
3 error (ECU)
523009 10 833 Pressure relief valve (PRV)
523603 9 126 Timeout Error of
reached maximun allowed open
CAN-Receive-Frame AMB;
time
Ambient Temperature Sensor

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
523612 12 637 Internal ECU monitoring
KWP = Keyword Protocol
detection reported error
SPN FMI KWP Description
523612 12 1170 Internal software error ECU
523605 9 300 Timeout Error of 523612 14 973 Softwarereset CPU SWReset_0
CAN-Receive-Frame TSC1AE;
Traction Control 523612 14 974 Softwarereset CPU SWReset_1
523606 9 301 Timeout Error of 523612 14 975 Softwarereset CPU SWReset_2
CAN-Receive-Frame TSC1AR; 523613 0 856 Maximum positive deviation of
Retarder rail pressure exceeded
523612 12 387 Internal software error ECU; (RailMeUn0)
injection cut off 523613 0 857 Maximum positive deviation of
523612 12 612 Internal ECU monitoring rail pressure in metering unit
detection reported error exceeded (RailMeUn1)
523612 12 613 Internal ECU monitoring 523613 0 858 Railsystem leakage detected
detection reported error (RailMeUn10)
523612 12 614 Internal ECU monitoring 523613 0 859 Maximum negative deviation of
detection reported error rail pressure in metering unit
exceeded (RailMeUn2)
523612 12 615 Internal ECU monitoring
detection reported error 523613 0 860 Negative deviation of rail
pressure second stage
523612 12 616 Internal ECU monitoring (RailMeUn22)
detection reported error
523613 0 862 Maximum rail pressure exceeded
523612 12 617 Internal ECU monitoring (RailMeUn4)
detection reported error
523613 1 861 Minimum rail pressure exceeded
523612 12 618 Internal ECU monitoring (RailMeUn3)
detection reported error
523613 2 864 Setpoint of metering unit in
523612 12 619 Internal ECU monitoring overrun mode not plausible
detection reported error
523615 3 594 Metering unit (Fuel-System);
523612 12 620 Internal ECU monitoring short circuit to battery highside
detection reported error
523615 3 596 Metering unit (Fuel-System);
523612 12 621 Internal ECU monitoring short circuit to battery low side
detection reported error
523615 4 595 Metering unit (Fuel-System);
523612 12 623 Internal ECU monitoring short circuit to ground high side
detection reported error
523615 4 597 Metering Unit (Fuel-System);
523612 12 624 Internal ECU monitoring short circuit to ground low side
detection reported error
523615 5 592 Metering unit (Fuel-System);
523612 12 625 Internal ECU monitoring open load
detection reported error
523615 12 593 Metering unit (Fuel-System);
523612 12 627 Internal ECU monitoring powerstage over temperature
detection reported error
523619 2 488 Physical range check high for
523612 12 628 Internal ECU monitoring
exhaust gas temperature
detection reported error upstrem (SCR-CAT)
523698 11 122 Shut off request from supervisory
monitoring function

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523788 12 299 Timeout Error of
KWP = Keyword Protocol CAN-Transmit-Frame TrbCH;
SPN FMI KWP Description Status Wastegate

523717 12 125 Timeout Error of 523793 9 202 Timeout Error of

CAN-Transmit-Frame AmbCon; CAN-Receive-Frame UAA10;
Weather environments AGS sensor service message

523718 3 1488 SCR mainrelay; short circuit to 523794 9 203 Timeout Error of
battery (only CV56B) CAN-Receive-Frame UAA11;
AGS sensor data
523718 4 1489 SCR mainrelay; short circuit to
ground (only CV56B) 523895 13 559 Check of missing injector
adjustment value programming
523718 5 1486 SCR mainrelay; open load (only (IMA) injector 1 (in firing order)
CV56B)
523896 13 560 check of missing injector
523718 12 1487 SCR mainrelay; powerstage over adjustment value programming
temperature (only CV56B) (IMA) injector 2 (in firing order)
523766 9 281 Timeout Error of 523897 13 561 check of missing injector
CAN-Receive-Frame Active adjustment value programming
TSC1AE (IMA) injector 3 (in firing order)
523767 9 282 Timeout Error of 523898 13 562 check of missing injector
CAN-Receive-Frame Passive adjustment value programming
TSC1AE (IMA) injector 4 (in firing order)
523768 9 283 Timeout Error of 523910 6 1261 Air Pump; over current
CAN-Receive-Frame Active
TSC1AR 523913 3 74 Sensor error glow plug control
diagnostic line voltage; signal
523769 9 284 Timeout Error of range check high
CAN-Receive-Frame Passive
TSC1AR 523913 4 75 Sensor error glow plug control
diagnostic line voltage; signal
523770 9 285 Timeout Error of range check low
CAN-Receive-Frame Passive
TSC1DE 523914 3 78 Glow plug control; short circuit to
battery
523776 9 291 Timeout Error of
CAN-Receive-Frame TSC1TE - 523914 4 79 Glow plug control; short circuit to
active ground

523777 9 292 Passive Timeout Error of 523914 5 76 Glow plug control; open load
CAN-Receive-Frame TSC1TE; 523914 5 1216 Glow plug control release line;
Setpoint short circuit error
523778 9 293 Active Timeout Errorof 523914 11 1217 Glow plug control; internal error
CAN-Receive-Frame TSC1TR
523914 12 77 Glow plug control; powerstage
523779 9 294 Passive Timeout Error of over temperature
CAN-Receive-Frame TSC1TR
523919 2 1378 Sensor air pump airpressure;
plausibility error
523920 2 1379 Sensor exhaust gas back
pressure burner; plausibility error

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
523946 1 1164 Zero fuel calibration injector 1 (in
KWP = Keyword Protocol
firing order); minimum value
SPN FMI KWP Description exceeded
523922 7 1262 Burner Shut Off Valve; blocked 523947 0 1159 Zerofuel calibration injector 2 (in
closed firing order); maximum value
exceeded
523922 7 1264 Burner Shut Off Valve; blocked
closed 523947 1 1165 Zerofuel calibration injector 2 (in
firing order); minimum value
523929 0 109 Fuel Balance Control integrator
exceeded
injector 1 (in firing order);
maximum value exceeded 523948 0 1160 Zerofuel calibration injector 3 (in
523929 1 115 Fuel Balance Control integrator firing order); maximum value
exceeded
injector 1 (in firing order);
minimum value exceeded 523948 1 1166 Zerofuel calibration injector 3 (in
523930 0 110 Fuel Balance Control integrator firing order); minimum value
exceeded
injector 2 (in firing order);
maximum value exceeded 523949 0 1161 Zerofuel calibration injector 4 (in
523930 1 116 Fuel Balance Control integrator firing order); maximum value
exceeded
injector 2 (in firing order);
minimum value exceeded 523949 1 1167 Zerofuel calibration injector 4 (in
523931 0 111 Fuel Balance Control integrator firing order); minimum value
exceeded
injector 3 (in firing order);
maximum value exceeded 523960 0 1011 Physical range check high for
EGR cooler downstream temp.
523931 1 117 Fuel Balance Control integrator
injector 3 (in firing order); 523960 0 1458 High exhaust gas temperature
minimum value exceeded EGR cooler downstream;
warning threshold exceeded
523932 0 112 Fuel Balance Control integrator
injector 4 (in firing order); 523960 1 1012 Physical range check low for
maximum value exceeded EGR cooler downstream temp.
523932 1 118 Fuel Balance Control integrator 523960 1 1459 High exhaust gas temperature
injector 4 (in firing order); EGR cooler downstream; shut off
minimum value exceeded threshold exceeded
523935 12 168 Timeout Error of 523980 14 1187 Bad quality of reduction agent
CAN-Transmit-Frame detected
EEC3VOL1; Engine send 523981 11 918 Urea-tank without heating
messages function (heating phase)
523936 12 169 Timeout Error of 523982 0 360 Powerstage diagnosis disabled;
CAN-Transmit-Frame high battery voltage
EEC3VOL2; Engine send
messages 523982 1 361 Powerstage diagnosis disabled;
low battery voltage
523946 0 1158 Zero fuel calibration injector 1 (in
firing order); maximum value
exceeded

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
524032 2 1442 EGR actuator; status message
KWP = Keyword Protocol
EGRCust is missing
SPN FMI KWP Description
524033 7 1443 EGR actuator; due to overload in
523988 3 1245 Charging lamp; short circuit to Save Mode
battery 524034 3 1438 Disc separator; short circuit to
523988 4 1246 Charging lamp; short circuit to battery
ground 524034 4 1439 Disc separator; short circuit to
523988 5 1243 Charging lamp; open load ground
523988 12 1244 Charging lamp; over temp. 524034 5 1436 Disc Separator; open load
523998 4 1327 Injector cylinder bank 2 slave; 524034 12 1437 Disc Separator; powerstage over
short circuit temperature
523999 12 1328 Injector powerstage output Slave 524035 12 1341 Injector diagnostics; time out
defect error in the SPI communication
524014 1 1254 Air pressure glow plug flush line; 524057 2 1505 Electric fuel pump; fuel pressure
below limit build up error
524016 2 1259 Amount of air is not plausible to 524097 9 1663 Timeout error of
pump speed CAN-Transmit-Frame
DPFBrnAirPmpCtl
524016 2 1260 Calculated amount of air is not
plausible to HFM reading 524098 9 1664 Timeout error of
524016 11 1258 HFM sensor; electrical fault CAN-Transmit-Frame
ComDPFBrnPT
524021 11 1263 Burner fuel line pipe leak behind
524099 9 1665 Timeout error of
Shut Off Valve
CAN-Transmit-Frame
524024 11 1302 Deviation of the exhaust gas ComDPFC1
temp. setpoint to actual value
524100 9 1666 Timeout error of
downstream (DOC) too high
CAN-Transmit-Frame
524028 2 1431 CAN message PROEGRActr; ComDPFHisDat
plausibility error
524101 9 1667 Timeout error of
524029 2 1432 Timeout Error of CAN-Transmit-Frame
CAN-Receive-Frame ComDPFTstMon
ComEGRActr - exhaust gas
recirculation positioner
524030 7 1440 EGR actuator; internal error
524031 13 1441 EGR actuator; calibration error

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Deutz D 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
524114 9 1659 Timeout error of
KWP = Keyword Protocol
CAN-Transmit-Frame A1DOC
SPN FMI KWP Description
524115 9 1660 Timeout error of
524102 9 1674 Timeout error of CAN-Transmit-Frame AT1S
CAN-Receive-Frame 524116 9 1661 Timeout error of
ComRxDPFBrnAirPmpCtl CAN-Transmit-Frame SCR2
524103 9 1675 Timeout error of 524117 9 1662 Timeout error of
CAN-Receive-Frame CAN-Transmit-Frame SCR3
ComRxDPFBrnAirPmp
524118 9 1672 Timeout error of
524104 9 1676 Timeout error of
CAN-Receive-Frame
CAN-Receive-Frame ComRxCM1
ComRxDPFCtl
524119 9 1673 Timeout error of
524105 9 1668 Timeout error of
CAN-Receive-Frame
CAN-Transmit-Frame ComRxCustSCR3
ComEGRMsFlw
524120 9 1682 Timeout error of
524106 9 1677 Timeout error of CAN-Receive-Frame
CAN-Receive-Frame ComRxSCRHtDiag
ComRxEGRMsFlw1
524121 9 1683 Timeout error of
524107 9 1678 Timeout error of CAN-Receive-Frame
CAN-Receive-Frame ComRxTrbChActr
ComRxEGRMsFlw2
524122 9 1684 Timeout error of
524108 9 1669 Timeout error of
CAN-Receive-Frame
CAN-Transmit-Frame ComRxUQSens
ComEGRTVActr
524123 9 1685 Timeout error of
524109 9 1679 Timeout error of
CAN-Receive-Frame
CAN-Receive-Frame ComSCRHtCtl
ComRxEGRTVActr
524124 9 1686 Timeout error of
524110 9 1670 Timeout error of
CAN-Receive-Frame
CAN-Transmit-Frame ComTxAT1IMG
ComETVActr
524125 9 1687 Timeout error of
524111 9 1680 Timeout error of CAN-Receive-Frame
CAN-Receive-Frame ComTxTrbChActr
ComRxETVActr
524112 9 1671 Timeout ComITVActr
524113 9 1681 Timeout error of
CAN-Receive-Frame
ComRxITVActr

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Perkins 404F-22 Engine Fault Codes

SPN FMI Description

SPN = Suspect Parameter Number
723 3 Engine Speed Sensor #2: Voltage
FMI = Failure Mode Identifier
Above Normal
SPN FMI Description
723 4 Engine Speed Sensor #2: Voltage
29 3 Accelerator Pedal Position 2: Voltage Below Normal
Above Normal 723 8 Engine Speed Sensor#2: Abnormal
29 4 Accelerator Pedal Position 2: Voltage Frequency, Pulse Width or Period"
Below Normal 723 10 Engine Speed Sensor #2: Abnormal
91 3 Accelerator Pedal Position 1: Voltage Rate of Change
Above Normal 733 3 Engine Rack Position Sensor: Voltage
91 4 Accelerator Pedal Position 1: Voltage Above Normal
Below Normal 733 4 Engine Rack Position Sensor: Voltage
100 1 Engine Oil Pressure :Low- most Below Normal
severe (3) 1485 7 ECU Main Relay : Not Responding
108 3 Barometric Pressure : Voltage Above Property
Normal 2840 11 ECU Instance: Other Failure Mode
108 4 Barometric Pressure : Voltage Below 2840 12 ECU Instance: Failure
Normal
2840 13 ECU Instance: Out of Calibration
110 3 Engine Coolant Temperature : Voltage
Above Normal 2970 3 Accelerator Pedal 2 Low Idle Switch:
Voltage Above Normal
110 4 Engine Coolant Temperature : Voltage
Below Normal 2970 4 Accelerator Pedal 2 Low Idle Switch:
Voltage Below Normal
110 15 Engine Coolant Temperature : High
-least severe (1) 3241 1 Exhaust Gas Temperature 1: Low-
most severe (3)
168 0 Battery Potential/ Power Input 1 :
High- most severe (3) 3241 3 Exhaust Gas Temperature 1: Voltage
Above Normal
168 3 Battery Potential/ Power Input 1:
Voltage Above Normal 241 4 Exhaust Gas Temperature 1: Voltage
Below Normal
168 4 Battery Potential/ Power Input 1:
Voltage Below Normal 3241 15 Exhaust Gas Temperature 1: High-
least severe (1)
172 3 Engine Air Inlet Temperature: Voltage
Above Normal 3241 16 Exhaust Gas Temperature 1: High-
moderate severity (2)
172 4 Engine Air Inlet Temperature: Voltage
Below Normal 3242 1 Particulate Trap Intake Gas Temp:
Low- most severe(3)"
190 0 Engine Speed : High- most severe (3)
3242 3 Particulate Trap Intake Gas Temp:
190 8 Engine Speed : Abnormal Frequency, Voltage Above Normal"
Pulse Width or Period
3242 4 Particulate Trap Intake Gas Temp:
558 3 Accelerator Pedal1 Low Idle Switch: Voltage Below Normal"
Voltage Above Normal
3242 15 Particulate Trap Intake Gas Temp:
558 4 Accelerator Pedal1 Low Idle Switch: High - least severe(1)"
Voltage Below Normal
3242 16 Particulate Trap Intake Gas Temp:
638 6 Engine Fuel Rack Actuator: Current High-moderate severity (2)
Above Normal
639 14 J1939 Network#1: Special Instruction

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Perkins 404F-22 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI Description

FMI = Failure Mode Identifier
4201 4 Engine Speed Sensor #1: Voltage
SPN FMI Description Below Normal
3251 3 Particulate Trap Differential Pressure: 4201 8 Engine Speed Sensor #1: Abnormal
Voltage Above Normal Frequency, Pulse \Nidth, or Period
3251 4 Particulate Trap Differential Pressure: 4201 10 Engine Speed Sensor #1: Abnormal
Voltage Below Normal Rate of Change
3473 7 Aftertreatmert #1 Failed to Ignite: Not 4765 1 Aftertreatmert #1 Diesel Oxidation
Responding Properly Catalyst Intake Gas Temperature:
3473 11 Aftertreatmert #1 Failed to Ignite : Low-most severe (3)
Other Failure Mode 4765 3 Aftertreatmert #1 Diesel Oxidation
3484 0 Aftertreatmert #1 Ignition : High-most Catalyst Intake Gas Temperature:
severe (3) Voltage Above Normal

3484 3 Aftertreatmert #1 Ignition : Voltage 4765 4 Aftertreatmert #1 Diesel Oxidation

Above Normal Catalyst Intake Gas Temperature:
Voltage Below Normal
3484 4 Aftertreatmert #1 Ignition : Voltage
Below Normal 4765 15 Aftertreatmert #1Diesel Oxidation
Catalyst Intake Gas Temperature:
3556 6 Aftertreatmert 1 Hydrocarbon Doser 1: High-least severe (1)
Current Above Normal
4765 16 Aftertreatmert #1 Diesel Oxidation
3610 3 Diesel Particulate Filter Outlet Catalyst Intake Gas Temperature:
Pressure or 1: Voltage Above Normal" High-moderate severity (2)
3610 4 DieselParticulate Filter Outlet 5487 3 Aftertreatmert 1 Burner Unit
Pressure Sensor 1: Voltage Below Combustion Chamber Temperature:
Normal Voltage Above Normal
3713 7 DPF Active Regeneration Inhibited 5487 4 Aftertreatmert 1 Burner Unit
Due to System Timeout: Not Combustion Chamber Temperature:
Responding Properly Voltage Below Normal
3713 31 DPF Active Regeneration Inhibited 6581 6 Aftertreatmert 1 Hydrocarbon Doser
Due to System Timeout 2 : Current Above Normal
3719 0 Particulate Trap #1 Soot Load
Percent: High- most severe (3)
3719 16 Particulate Trap #1 Soot Load
Percent: High-moderate severity (2)
4016 6 High Current Auxiliary Power Relay 1:
Current Above Normal
4201 3 Engine Speed Sensor #1: Voltage
Above Normal

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Continental TME27 Engine Fault Codes

How to R etrieve Conti nental Engine F ault C odes

Note: Once a fault code has been retrieved and the

How to Retrieve Continental repair has been completed, the ECM memory must
Engine Fault Codes be reset to clear the fault code from the ECM. Refer
to How to Clear Engine Fault Codes from the ECM.
The ECM constantly monitors the engine by the use
of sensors on the engine. The ECM also uses
How to Cl ear Engine Fault Codes fr om the ECM

signals from the sensors to initiate sequential fuel

injection and make constant and instantaneous How to Clear Engine Fault Codes
changes to ignition timing, fuel delivery and throttle from the ECM
position to maintain the engine's running condition
at its highest efficiency while at the same time Note: Perform this procedure with the engine off
keeping exhaust emissions to a minimum. When a and the key switch in the off position.
sensor fails or returns signals that are outside of set
parameters, the ECM will store a fault code in 1 Open the engine side turntable cover and
memory that relates to the appropriate sensor and locate the battery.
will turn on the Check Engine Light. 2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
Note: Perform this procedure with the key switch in
the off position. Electrocution/burn hazard.
Contact with electrically charged
1 Open the ground controls side cover and
circuits could result in death or
locate the run/test toggle switch on the side of
serious injury. Remove all rings,
the ground control box.
watches and other jewelry.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform 3 Connect the negative battery cable to the
controls. battery.
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
4 Move and hold the run/test toggle switch to the
test position.
Result: The check engine light should turn on.
The check engine light should begin to blink.
5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 1654 three
times. After the fault codes, the check engine light
will blink a code 1654 three times again indicating
the end of the stored codes.
Note: If any fault codes are present, the ECM will
blink a three or four digit code three times for each
code stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, blink the third digit, then pause and possibly
a fourth digit. For example: the check engine light
blinks 5 consecutive times, blinks 3 times and then
1 time. That would indicate code 531.

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Continental TME27 Engine Fault Codes

Continental TME27 Engine F ault Codes

System Code Fault Name 1 2 3 4 5 6 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/ CHT 118 ECT Voltage High Y ECT voltage > 4.95 vdc
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 External 643 5VE1 High Voltage Y 5VE1 > 5.4 vdc
642 5VE1 Low Voltage Y 5VE1 < 4.6 vdc
TPS 123 TPS1 High Voltage Y TPS1 voltage > 4.8 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 voltages Y Uses same parameters as individual
out of range TPS1/2 voltage fault detection above
1 = Shutdown 2 = AL disable 3 = AL disable key-cycle 4 = Power derate 1 5 = Power derate 2 6 = Low rev limit

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Continental TME27 Engine Fault Codes

System Code Fault Name 1 2 3 4 5 6 Fault Conditions

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 Pressure 524 Oil Pressure Low Y Oil pressure pulled-up input with a
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
Learn 0-9999 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 and MAP between 0-99 psi
1162 AL Low LPG AL_BM < -30% and RPM between
0-9999 and MAP between 0-99 psi
Closed 1155 CL High Gasoline Bank 1 CL_BM > 40% and RPM between
Loop 0-9999 and MAP between 0-99 psi
1156 CL Low Gasoline Bank 1 CL_BM <-40% and RPM between
0-9999 and MAP between 0-99 psi
1151 CL High LPG CL_BM > 35% and RPM between
0-9999 and MAP between 0-99 psi
1152 CL Low LPG CL_BM < -35% and RPM between
0-9999 and MAP between 0-99 psi
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%
1 = Shutdown 2 = AL disable 3 = AL disable key-cycle 4 = Power derate 1 5 = Power derate 2 6 = Low rev limit

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Continental TME27 Engine Fault Codes

System Code Fault Name 1 2 3 4 5 6 Fault Conditions

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 Pressure 524 Oil Pressure Low Y Oil pressure pulled-up input with a
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
Learn 0-9999 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 and MAP between 0-99 psi
1162 AL Low LPG AL_BM < -30% and RPM between
0-9999 and MAP between 0-99 psi
Closed 1155 CL High Gasoline Bank 1 CL_BM > 40% and RPM between
Loop 0-9999 and MAP between 0-99 psi
1156 CL Low Gasoline Bank 1 CL_BM <-40% and RPM between
0-9999 and MAP between 0-99 psi
1151 CL High LPG CL_BM > 35% and RPM between
0-9999 and MAP between 0-99 psi
1152 CL Low LPG CL_BM < -35% and RPM between
0-9999 and MAP between 0-99 psi
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%
1 = Shutdown 2 = AL disable 3 = AL disable key-cycle 4 = Power derate 1 5 = Power derate 2 6 = Low rev limit

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Continental TME27 Engine Fault Codes

System Code Fault Name 1 2 3 4 5 6 Fault Conditions

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 n Y Y Y Injector off-state low-side < 4 vdc and battery
Low-Side Short to Ground voltage > 9 vdc
262 Injector Coil Shorted Y Y Y Injector on-state low-side > 4 vdc and battery
voltage < 16 vdc
Power Relay 686 Relay Control Ground
Control Coil Short
685 Relay Coil Short
687 Relay Coil Short to Pwr
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 fault n Y Y
detection
1178 EPR Internal Comm fault n Y Y
detection
1 = Shutdown 2 = AL disable 3 = AL disable key-cycle 4 = Power derate 1 5 = Power derate 2 6 = Low rev limit

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Continental TME27 Engine Fault Codes

System Code Fault Name 1 2 3 4 5 6 Fault Conditions

Cam Crank 342 Cam Loss Y Y No cam pulse in 4 cycles and RPM > 1000
Sensors
337 Crank Loss Cam pulses without crank activity > 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 at Cranking revs without sync < 4 revs and RPM >
Start 90 rpm
Internal 606 COP Failure Y Y
Process or
Diagnostics 1612 RTI 1 Loss Y Y
1613 RTI 2 Loss Y Y
1614 RTI 3 Loss Y Y
1615 A/D Loss Y Y
1616 Invalid Interrupt Y Y
601 Flash Checksum Invalid Y Y
604 RAM Failure Y Y
J1939 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 Address conflict counter > 5
Failure
1 = Shutdown 2 = AL disable 3 = AL disable key-cycle 4 = Power derate 1 5 = Power derate 2 6 = Low rev limit

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Schematics
Section 5 Schematics

About This Section

There are two groups of schematics in this section.

Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
 Troubleshooting and repair procedures shall be watches 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
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
the oil pressure to dissipate
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and test
equipment are available and ready for use.

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Electrical Symbol Legend

Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge

Diode Hour meter LED Fuse with amperage Foot switch

T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid

T-circuits connect at Circuits crossing - no Quick disconnect Circuit breaker with

Connection - no terminal
terminal connection terminal amperage

Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor

Horn button - normally Emergency stop button -

Resistor with ohm value Battery seperator Gauge sending unit
open normally closed

Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor

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Hydraulic Symbols Legend

Orifice with size Check valve Shut off valve Brake

Pump, bi-directional Motor, 2 speed

Pump, fixed displacement Motor, bi-directional
variable displacement bi-directional

Pump, prime mover (engine Shuttle valve. 2 position,

Cylinder, double acting Differential sensing valve
or motor) 3 way

Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator
valve setting proportional valve

Solenoid operated
Pilot operated 3 position,
Pressure reducing valve Flow divider/combiner valve 2 position, 3 way directional
3 way shuttle valve
valve

Solenoid operated
Counterbalance valve with Pilot operated 2 position, 2 position, 2 way solenoid
3 position 4 way directional
pressure and pilot ratio 2 way directional valve valve
valve

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Relay and Fuse Panel Legend - Deutz TD2011L04i

Deutz TD2011L04i

Label Description
CR1 START RELAY
CR2 IGNITION / FUEL RELAY
CR3 HIGH IDLE RELAY
CR5 HORN RELAY
CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER RELAY
CR39 AUXILIARY PUMP RELAY
F7 FUSE, 30A, OIL COOLER FAN / HORN
F17 FUSE, 30A, ENGINE / AUXILIARY PUMP
F20 FUSE, 20A, ENGINE RPM SOLENOID

F22 FUSE, 60A, GLOW PLUGS

Deutz TD2.9 L4
Label Description
CR2 ENGINE / IGNITION RELAY

CR5 HORN RELAY

CR6 FUEL PUMP RELAY
CR17 HYDRAULIC OIL COOLER RELAY

CR39 VDROP RELAY

F7 FUSE, 20A, B1BAT, P116PWR

F17 FUSE, 20A, B1BAT, P24PWR
F20 FUSE, 20A, B1BAT, P35PWR

Perkins 404F-22T
Label Description
CR4A LOW RPM RELAY

CR4B HIGH RPM RELAY

CR5 HORN RELAY
CR17 HYDRAULIC OIL COOLER
RELAY
CR39 AUXILIARY PUMP RELAY
F7 FUSE, 20A, B1BAT, P116PWR
F17 FUSE, 20A, B1BAT, P24PWR

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Relay and Fuse Panel Legend - Perkins 804D-33

Perkins 804D-33

Label Description
CB20 CIRCUIT BREAKER, 10A, ENGINE
RPM SOLENOID
CR1 START RELAY
CR2 IGNITION / FUEL RELAY

CR3 HIGH IDLE RELAY

CR4 ENGINE RPM SOLENOID RELAY
CR5 HORN RELAY
CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER RELAY
CR39 AUXILIARY PUMP RELAY
F7 FUSE, 30A, OIL COOLER FAN / HORN

F17 FUSE, 30A, ENGINE / AUXILIARY

PUMP
F20 FUSE, 60A, GLOW PLUGS

Continental TME27
LABEL DESCRIPTION
CR1 START RELAY
CR2 IGNITION / FUEL RELAY
CR5 HORN RELAY
CR17 HYDRAULIC OIL COOLER RELAY
CR39A AUXILIARY PUMP RELAY
CR39B AUXILIARY PUMP ENGINE CUTOUT
RELAY
F7 FUSE, 30A, OIL COOLER FAN / HORN
F17 FUSE, 30A, ENGINE / AUXILIARY PUMP

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Connector Pin Legends

C1 DT06-12SA (Gray) 11 C59CNK BL/BK

Pin # Circuit # Color 12 C133PLA BL/WH (CE)
1 C27AUX RD 12 P109LS BL/WH (S-80X)
2 C28TTA RD/BK C4 DT06-12SD (Brown)

3 C29MS RD/WH Pin # Circuit # Color

4 C30EDC+ WH 1 C13DRE BL/RD
5 C31EDC- WH/BK 2 C14PLU OR
6 C32BRK WH/RD 3 C15PLD OR/BK
7 C33STR BK 4 V155PCE OR/RD
8 C34SA BK/WH 5 C17PRL GR
9 C35RPM BK/RD 6 C18PRR GR/BK
10 C36STC BL 7 C43JU GR/WH
11 C37STCC BL/BK 8 C44JD RD/OR
12 C132PLI1 BL/WH (CE) 9 C49DLITE OR/GR
12 C177LS BL/WH (S-80X) 10 SPARE LT BR
C2 DT06-12SB (Black) 11 PLUG
Pin # Circuit # Color 12 PLUG
1 C39LP BL/RD C6 Function Manifold
2 C40LS OR Pin # Circuit # Color
1 C1PBU RD
3 C41RPM OR/BK
2 C2PBD RD/BK
4 C42LS OR/RD
3 C3PBF RD/WH
5 C46HRN GR
4 C4TRL WH
6 P134PWR GR/BK
5 C5TRR WH/BK
7 C45GEN GR/WH 6 C6TRF WH/RD
8 C123PBS GR/RD 7 C7PBE BK
9 P109ANG OR/WH 8 C8PBR BK/WH
10 SNSR GND LT BR 9 C9PERF BK/RD
11 PLUG 10
12 PLUG 11 C59CNK BL/BK
C3 DT06-12SC (Green) 12 P210PWR BK (S-80X)

Pin # Circuit # Color 13 C13DRE BL/RD

14
1 C1PBU RD
15
2 C2PBD RD/BK
16 C109LS GR/WH (S-80X)
3 C3PBF RD/WH
17
4 C4TRL WH
18
5 C5TRR WH/BK
19
6 C6TRF WH/RD
20
7 C7PBE BK 21 C177LS BL/RD (S-80X)
8 C8PBR BK/WH 22 C42LS OR/RD
9 C9PERF BK/RD 23 P134PWR(A) RD
10 C132PLI2 BL (CE) 24 P134PWR(B) RD

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Connector Pin Legends

25 P134PWR(C) RD 12 GND BR
26 J3 ALC500 Power/Valve Input
27 Pin # Circuit # Color
28 C28TTA RD/BK
1 GND BR
29
2 P24FS WH
30 C211LO BL/BK (S-80X)
3 P26ESTP BK
31 C118LSR OR
4 P24FS WH
32
33 C123PBS RD/BK
J1 ALC500 Input
34 SNSR GND BR Pin # Circuit # Color
35 P109ANG GR/WH 1 C165TRS WH/RD
36 C36STC BL 2 C164PES RD/WH
37 C37STCC BL/BK 3 C163PLS WH/BK
38 C212LO GR/BK (S-80X) 4 C160JPL WH/RD
39 C45GEN GR/WH 5 C159STC BL/WH
40 C40LS OR 6 C144DER BL/WH
C7 DTP06-4S, 12V 7 C143DEL BL/BK
Power to Platform
8 C29MS RD/WH
Pin # Circuit # Color
9 P109ANG GR/WH
1 P22PWR BK
10 SNSR GND BR
2 P23PWR WH
11 P162JPW2 OR
3 BATGND BR
12 JSGND2 BR
4 PLUG
13 P162JPW1 OR
C9 FS DT04-4P, Footswitch
14 JSGND1 BR
Pin # Circuit # Color
15 C28TTA RD/BK
1 P26ESTP BK
16 C13DRE(A) BL/RD
2 P24FS WH
J2 ALC500 Output
3 P25FS RD
Pin # Circuit # Color
4 PLUG
1 C40LS OR
J22 Platform Manifold
2 C123PBS RD/BK
Pin # Circuit # Color
3 C13DRE BL/RD
1 GND BR
4 C42LS OR/RD
2 GND BR
5 C41RPM OR/BK
3 C18PRR GR/BK
6 C1PBU RD
4 C17PRL GR
7 C2PBD RD/BK
5 C43JU GR
8 C3PBF RD/WH
6 C44JD GR/BK
9 C4TRL WH
7 C14PLU OR
10 C5TRR WH/BK
8 C15PLD OR/BK
11 C6TRF WH/RD
9 GND BR
12 C7PBE BK
10 GND BR
13 C8PBR BK/WH
11 GND BR
14 C9PERF BK/RD

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Connector Pin Legends

15 C30EDC+ WH 10 C127TSW GN
16 C31EDC- WH/BK 11 C39LP BL/RD
17 C36STC BL 12 C26TSR WH/RD
18 C37STCC BL/BK Gauge Option

19 C32BRK WH/RD
20 C29MS RD/WH
J8 S-80X Model
Pin # Circuit # Color
1 P109LS GR/WH
2 C184PL WH
3 NC
4 NC
5 C169LED2 BL
6 P109LS GR/WH
7 C177LS BL/RD
8 SNSR GND BR
9 NC
10 C169LED1 GR
J144 Engine Plug - Deutz 2011L04i
Pin # Circuit # Color
1 C41RPM OR/BK
2 C107AF WH
3 C26TSR WH/RD
4 C24TS WH
5 C25PSR WH/BK
6 C24PS WH
7 R21IGN WH(14)
8 GND BR
9
10
Engine Plug - Continental TME27
Pin # Circuit # Color
1 R23PWR WH
2 C21RET WH
3 C38RET BL
4 C38FP BL/WH
5 R33STR BK(14)
6 C41RPM OR/BK
7 R21IGN WH
8 C35RPM BK/RD
9 C108ESL BL/WH

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Connector Pin Legends

Deutz 2011L04i Perkins 804 Continental TME27

Pin # Circuit # Color Circuit # Color Circuit # Color
1 P24PWR RD P24PWR RD P23PWR RD
2 C41RPM OR/BK C41RPM OR/BK C41RPM OR/BK
3 C21IGN WH C21IGN WH
4
5 C33STR BK C33STR BK C33STR BK
6 C27AUX RD C27AUX RD C27AUX RD
7 C46HRN GR C46HRN GR C46HRN GR
8 C127TSW GR
9 C35RPM BK/RD
10 C39LP BL/RD
11 R21IGN WH(14) R21IGN WH(14) R21IGN WH(14)
12
13 C108ESL BL/WH
14
15 C24TSPS WH C24TSPS WH P24PWR RD
16
17 R24PWR RD
18 C35RPM BK/RD C35RPM BK/RD
19 V155PCE OR/RD V155PCE OR/RD V155PCE OR/RD
20 C31EDC- WH/BK C31EDC- WH/BK C31EDC- WH/BK
21 C30EDC+ WH C30EDC+ WH C30EDC+ WH
22 C34SA BK/WH C34SA BK/WH
23 C32BRK WH/RD C32BRK WH/RD C32BRK WH/RD
24 C29MS RD/WH C29MS RD/WH C29MS RD/WH

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Continental TME27 Engine Harness

128
 October 2016 Service and Repair Manual

Continental TME27 Engine Harness

Part No. 1269074 S-80 • S-85 • S-80X 129

Service and Repair Manual October 2016

S-80X Ground Control Box Wiring Diagram

Use this wiring diagram with each S-80X Ground Control Box Schematic

130 S-80 • S-85 • S-80X Part No. 1269074

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S-80X Ground Control Box Wiring Diagram

131
Service and Repair Manual October 2016

Deutz TD2.9 L4 Engine Harness

132
 October 2016 Service and Repair Manual

Deutz TD2.9 L4 Engine Harness

Part No. 1269074 S-80 • S-85 • S-80X 133

Service and Repair Manual October 2016

Perkins 404F-22T Engine Harness

134 S-80 • S-85 • S-80X Part No. 1269074

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Perkins 404F-22T Engine Harness

135
Service and Repair Manual October 2016

Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)

136
 October 2016 Service and Repair Manual

Elec trical Schematic, S- 80X - D eutz TD 2.9 L4 Models (AN SI / C SA)

Electrical Schematic, S-80X

Deutz TD2.9 L4 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 137

Service and Repair Manual October 2016

Electrical Schematic, S-80X

Deutz TD2.9 L4 Models (ANSI / CSA)

138 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)

139
Service and Repair Manual October 2016

Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)

140
 October 2016 Service and Repair Manual

Ground C ontrol Box, S-80X - D eutz TD 2.9 L4 Models (AN SI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 141

Service and Repair Manual October 2016

Ground Control Box, S-80X

Deutz TD2.9 L4 Models (ANSI / CSA)
Refer to S-80X Ground Control Box Wiring Diagram for additional wiring.

142 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80X - D eutz TD 2.9 L4 Models (AN SI / C SA)

Platform Control Box, S-80X

Deutz TD2.9 L4 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 143

Service and Repair Manual October 2016

Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)

144
 October 2016 Service and Repair Manual

Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)

145
Service and Repair Manual October 2016

Elec trical Schematic, S- 80X - D eutz TD 2011L04i M odels ( ANSI / C SA)

Electrical Schematic, S-80X

Deutz TD2011L04i Models (ANSI / CSA)

146 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80X

Deutz TD2011L04i Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 147

Service and Repair Manual October 2016

Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)

148
 October 2016 Service and Repair Manual

Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)

149
Service and Repair Manual October 2016

Ground C ontrol Box, S-80X - D eutz TD 2011L04i Models (AN SI / C SA)

Ground Control Box, S-80X

Deutz TD2011L04i Models (ANSI / CSA)
Refer to S-80X Ground Control Box Wiring Diagram for additional wiring.

150 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80X - D eutz TD 2011L04i Models (AN SI / C SA)

Platform Control Box, S-80X

Deutz TD2011L04i Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 151

Service and Repair Manual October 2016

Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)

152
 October 2016 Service and Repair Manual

Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)

153
Service and Repair Manual October 2016

Elec trical Schematic, S- 80X - Per ki ns 404F- 22T Models (AN SI / C SA)

Electrical Schematic, S-80X

Perkins 404F-22T Models (ANSI / CSA)

154 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80X

Perkins 404F-22T Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 155

Service and Repair Manual October 2016

Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)

156
 October 2016 Service and Repair Manual

Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)

157
Service and Repair Manual October 2016

Ground C ontrol Box, S-80X - Per kins 404F-22T M odels (ANSI / CSA)

Ground Control Box, S-80X

Perkins 404F-22T Models (ANSI / CSA)
Refer to S-80X Ground Control Box Wiring Diagram for additional wiring.

158 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80X - Per ki ns 404F- 22T Model s (AN SI / C SA)

Platform Control Box, S-80X

Perkins 404F-22T Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 159

Service and Repair Manual October 2016

Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)

160
 October 2016 Service and Repair Manual

Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)

161
Service and Repair Manual October 2016

Elec trical Schematic, S- 80X - Per ki ns 804D- 33 Models (AN SI / C SA)

Electrical Schematic, S-80X

Perkins 804D-33 Models (ANSI / CSA)

162 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80X

Perkins 804D-33 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 163

Service and Repair Manual October 2016

Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)

164
 October 2016 Service and Repair Manual

Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)

165
Service and Repair Manual October 2016

Ground C ontrol Box, S-80X - Per kins 804D-33 M odels ( ANSI / CSA)

Ground Control Box, S-80X

Perkins 804D-33 Models (ANSI / CSA)
Refer to S-80X Ground Control Box Wiring Diagram for additional wiring.

166 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80X - Per ki ns 804D- 33 M odels (AN SI / CSA)

Platform Control Box, S-80X

Perkins 804D-33 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 167

Service and Repair Manual October 2016

Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)

168
 October 2016 Service and Repair Manual

Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)

169
Service and Repair Manual October 2016

Elec trical Schematic, S- 80X - C ontinental TME27 Models (AN SI / C SA)

Electrical Schematic, S-80X

Continental TME27 Models (ANSI / CSA)

170 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80X

Continental TME27 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 171

Service and Repair Manual October 2016

Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)

172
 October 2016 Service and Repair Manual

Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)

173
Service and Repair Manual October 2016

Ground C ontrol Box, S-80X - C onti nental TM E27 Models (AN SI / CSA)

Ground Control Box, S-80X

Continental TME27 Models (ANSI / CSA)
Refer to S-80X Ground Control Box Wiring Diagram for additional wiring.

174 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80X - C ontinental TME27 Models (AN SI / C SA)

Platform Control Box, S-80X

Continental TME27 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 175

Service and Repair Manual October 2016

Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA)

176
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)

177
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Deutz TD 2.9 L4 Models (AN SI / CSA)

Electrical Schematic, S-80 / S-85

Deutz TD2.9 L4 Models (ANSI / CSA)

178 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Deutz TD2.9 L4 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 179

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)

180
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)

181
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - D eutz TD2.9 L4 M odels ( ANSI / CSA)

Ground Control Box, S-80 / S-85

Deutz TD2.9 L4 Models (ANSI / CSA)

182 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Deutz TD 2.9 L4 M odels (ANSI / CSA)

Platform Control Box, S-80 / S-85

Deutz TD2.9 L4 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 183

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)

184
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Deutz TD2011L04i Models (ANSI / CSA)

185
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Deutz TD 2011L04i Models (AN SI / C SA)

Electrical Schematic, S-80 / S-85

Deutz TD2011L04i Models (ANSI / CSA)

186 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Deutz TD2011L04i Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 187

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Deutz TD2011L04i Models (ANSI / CSA)

188
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Deutz TD2011L04i Models (ANSI / CSA)

189
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - D eutz TD2011L04i M odels ( ANSI / CSA)

Ground Control Box, S-80 / S-85

Deutz TD2011L04i Models (ANSI / CSA)

190 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Deutz TD 2011L04i M odels (AN SI / CSA)

Platform Control Box, S-80 / S-85

Deutz TD2011L04i Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 191

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Deutz TD2011L04i Models (ANSI / CSA)

192
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Perkins 404F-22T Models (ANSI / CSA)

193
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Per kins 404F-22T M odels (ANSI / CSA)

Electrical Schematic, S-80 / S-85

Perkins 404F-22T Models (ANSI / CSA)

194 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Perkins 404F-22T Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 195

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Perkins 404F-22T Models (ANSI / CSA)

196
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Perkins 404F-22T Models (ANSI / CSA)

197
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - Per kins 404F-22T M odels ( ANSI / C SA)

Ground Control Box, S-80 / S-85

Perkins 404F-22T Models (ANSI / CSA)

198 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Per kins 404F-22T M odels ( ANSI / CSA)

Platform Control Box, S-80 / S-85

Perkins 404F-22T Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 199

Service and Repair Manual October 2016

Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)

200
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)

201
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Per kins 804D-33 M odels ( ANSI / CSA)

Electrical Schematic, S-80 / S-85

Perkins 804D-33 Models (ANSI / CSA)

202 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Perkins 804D-33 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 203

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)

204
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)

205
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - Per kins 804D- 33 Models (AN SI / C SA)

Ground Control Box, S-80 / S-85

Perkins 804D-33 Models (ANSI / CSA)

206 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Per kins 804D-33 M odels ( ANSI / C SA)

Platform Control Box, S-80 / S-85

Perkins 804D-33 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 207

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)

208
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)

209
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Conti nental TM E27 M odels (AN SI / CSA)

Electrical Schematic, S-80 / S-85

Continental TME27 Models (ANSI / CSA)

210 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Continental TME27 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 211

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)

212
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)

213
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - C onti nental TM E27 M odels ( ANSI / C SA)

Ground Control Box, S-80 / S-85

Continental TME27 Models (ANSI / CSA)

214 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Conti nental TM E27 M odels (ANSI / CSA)

Platform Control Box, S-80 / S-85

Continental TME27 Models (ANSI / CSA)

Part No. 1269074 S-80 • S-85 • S-80X 215

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)

216
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Deutz TD2.9 L4 Models (CE)

217
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Deutz TD 2.9 L4 Models (CE)

Electrical Schematic, S-80 / S-85

Deutz TD2.9 L4 Models (CE)

218 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Deutz TD2.9 L4 Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 219

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Deutz TD2.9 L4 Models (CE)

220
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Deutz TD2011L04i Models (CE)

221
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - D eutz TD2.9 L4 M odels (C E)

Ground Control Box, S-80 / S-85

Deutz TD2.9 L4 Models (CE)

222 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Deutz TD 2.9 L4 M odels (CE)

Platform Control Box, S-80 / S-85

Deutz TD2.9 L4 Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 223

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Deutz TD2011L04i Models (CE)

224
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Deutz TD2011L04i Models (CE)

225
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Deutz TD 2011L04i Models (CE)

Electrical Schematic, S-80 / S-85

Deutz TD2011L04i Models (CE)

226 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Deutz TD2011L04i Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 227

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Deutz TD2011L04i Models (CE)

228
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Deutz TD2011L04i Models (CE)

229
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - D eutz TD2011L04i M odels (C E)

Ground Control Box, S-80 / S-85

Deutz TD2011L04i Models (CE)

230 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Deutz TD 2011L04i M odels (CE)

Platform Control Box, S-80 / S-85

Deutz TD2011L04i Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 231

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Deutz TD2011L04i Models (CE)

232
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (CE)

233
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Per kins 804D-33 M odels (C E)

Electrical Schematic, S-80 / S-85

Perkins 804D-33 Models (CE)

234 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Perkins 804D-33 Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 235

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (CE)

236
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Perkins 804D-33 Models (CE)

237
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - Per kins 804D- 33 Models (CE)

Ground Control Box, S-80 / S-85

Perkins 804D-33 Models (CE)

238 S-80 • S-85 • S-80X Part No. 1269074

 October 2016 Service and Repair Manual

Platfor m C ontrol Box, S-80 • S- 85 - Per kins 804D-33 M odels (C E)

Platform Control Box, S-80 / S-85

Perkins 804D-33 Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 239

Service and Repair Manual October 2016

Platform Control Box, S-80 / S-85 - Perkins 804D-33 Models (CE)

240
 October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85 - Continental TME27 Models (CE)

241
Service and Repair Manual October 2016

Elec trical Schematic, S- 80 • S- 85 - Conti nental TM E27 M odels (CE)

Electrical Schematic, S-80 / S-85

Continental TME27 Models (CE)

242 S-80 • S-85 • S-80X Part No. 1269074

October 2016 Service and Repair Manual

Electrical Schematic, S-80 / S-85

Continental TME27 Models (CE)

Part No. 1269074 S-80 • S-85 • S-80X 243

Service and Repair Manual October 2016

Electrical Schematic, S-80 / S-85 - Continental TME27 Models (CE)

244
 October 2016 Service and Repair Manual

Ground Control Box, S-80 / S-85 - Continental TME27 Models (CE)

245
Service and Repair Manual October 2016

Ground C ontrol Box, S-80 • S-85 - C onti nental TM E27 M odels (C E)

Ground Control Box, S-80 / S-85

Continental TME27 Models (CE)

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Platfor m C ontrol Box, S-80 • S- 85 - Conti nental TM E27 M odels (CE)

Platform Control Box, S-80 / S-85

Continental TME27 Models (CE)

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Platform Control Box, S-80 / S-85 - Continental TME27 Models (CE)

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Electrical Schematic, S-80 / S-85 - Deutz TD2011L04i Models (AS)

249
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Elec trical Schematic, S- 80 • S- 85 - Deutz TD 2011L04i Models (AS)

Electrical Schematic, S-80 / S-85

Deutz TD2011L04i Models (AS)

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Electrical Schematic, S-80 / S-85

Deutz TD2011L04i Models (AS)

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Electrical Schematic, S-80 / S-85 - Deutz TD2011L04i Models (AS)

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Ground Control Box, S-80 / S-85 - Deutz TD2011L04i Models (AS)

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Ground C ontrol Box, S-80 • S-85 - D eutz TD2011L04i M odels ( AS)

Ground Control Box, S-80 / S-85

Deutz TD2011L04i Models (AS)

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Platfor m C ontrol Box, S-80 • S- 85 - Deutz TD 2011L04i M odels (AS)

Platform Control Box, S-80 / S-85

Deutz TD2011L04i Models (AS)

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Platform Control Box, S-80 / S-85 - Deutz TD2011L04i Models (AS)

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Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (AS)

257
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Elec trical Schematic, S- 80 • S- 85 - Per kins 804D-33 M odels ( AS)

Electrical Schematic, S-80 / S-85

Perkins 804D-33 Models (AS)

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Electrical Schematic, S-80 / S-85

Perkins 804D-33 Models (AS)

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Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (AS)

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Ground Control Box, S-80 / S-85 - Perkins 804D-33 Models (AS)

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Ground C ontrol Box, S-80 • S-85 - Per kins 804D- 33 Models (AS)

Ground Control Box, S-80 / S-85

Perkins 804D-33 Models (AS)

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Platfor m C ontrol Box, S-80 • S- 85 - Per kins 804D-33 M odels ( AS)

Platform Control Box, S-80 / S-85

Perkins 804D-33 Models (AS)

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Platform Control Box, S-80 / S-85 - Perkins 804D-33 Models (AS)

264
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Electrical Schematic, S-80 / S-85 - Continental TME27 Models (AS)

265
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Elec trical Schematic, S- 80 • S- 85 - Conti nental TM E27 M odels (AS)

Electrical Schematic, S-80 / S-85

Continental TME27 Models (AS)

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Electrical Schematic, S-80 / S-85

Continental TME27 Models (AS)

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Electrical Schematic, S-80 / S-85 - Continental TME27 Models (AS)

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Ground Control Box, S-80 / S-85 - Continental TME27 Models (AS)

269
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Ground C ontrol Box, S-80 • S-85 - C onti nental TM E27 M odels ( AS)

Ground Control Box, S-80 / S-85

Continental TME27 Models (AS)

270 S-80 • S-85 • S-80X Part No. 1269074

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Platfor m C ontrol Box, S-80 • S- 85 - Conti nental TM E27 M odels (AS)

Platform Control Box, S-80 / S-85

Continental TME27 Models (AS)

Part No. 1269074 S-80 • S-85 • S-80X 271

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Platform Control Box, S-80 / S-85 - Continental TME27 Models (AS)

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Continental Options Schematic

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Continental Options Sc hematic

Continental Options Schematic

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Deutz and Perki ns Options Sc hematic

Deutz and Perkins Options Schematic

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Deutz and Perkins Options Schematic

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Platform Level Cutout, CTE Option

277
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Platfor m Level Cutout, CTE Opti on

Platform Level Cutout, CTE Option

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12 kW H ydraulic Gener ator Wiring Diagram

12 kW Hydraulic Generator Wiring Diagram

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12 kW Hydraulic Generator Wiring Diagram

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12 kW Hydraulic Generator Electrical Schematic

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12 kW H ydraulic Gener ator El ectric al Schematic

12 kW Hydraulic Generator Electrical Schematic

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Belt Driven Gener ator Opti on

Belt Driven Generator Option

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Belt Driven Generator Option

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Hydraulic Schematic, 2WD Models

285
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Hydraulic Schematic, 2WD M odels

Hydraulic Schematic, 2WD Models

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Hydraulic Schematic, 4WD M odels

Hydraulic Schematic, 4WD Models

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Hydraulic Schematic, 4WD Models

S-80 • S-85 • S-80X Part No. 1269074 Ser vic e and R epair M anual October 2016

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