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S-80/S-85 Service Manual

Contents

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3. 1 305 GREEN BLACK 102 PINK CAVITY C MAP SENSOR OIL PRESSURE SWITCH 104 YELLOW BLACK cavity B 104 YELLOW BLACK 2
4. EE EE ee 1 1 BOOM UP RD C3B 1 RD C6 1 1 RD S P VOLT METER OIL PRESSURE COOLANT TEMPERATURE 1 PRIMARY BOOM DOWN 029 RD BK 2 amp 6 2 2 015 Dave CR8 30 RD BK S P 1 PRIM
5. 5 5 er DT UE o Oa 4 UGS LLI Deutz F4L 913 Models before serial number 3618 GLOW PLUG RELAY FLAMMABLE START IGNITOR AUXILIARY PUMP RELAY AUXILIARY PUMP
6. 5 eo C Y LLI
7. REV Platform Control Wiring Diagram 5 80 Models COMPONENT INDEX 1 P2 STOP BUTTON la 2 9 HORN SWITCH Denn TS1 AUXILIARY TOGGLE SWITCH FB did 259585989595 762 ENGINE START SWITCH Sl gao GE ss ad 7 754 HIGH RPM SWITCH 3 29m 512055295 D12 D12 TS6 GLOW PLUG OPTION P E GND STUD 757 PLATFORM ROTATE TOGGLE SWITCH Lee J1 J2 TS9 PLATFORM LEVEL TOGGLE SWITCH 2 i le or gt
8. h 1 ees 7 DRIVE LIGHT RELAY GR BK C3B 10 GR BK L45 H6 I PLATFORM I OVERLOAD VOLT METER OIL PRESSURE OIL TEMPERATURE 1 I MODULE 10 Fuse BAP I 4 1 1 I I 1 30 G2 G3 PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD CR38 86 RD S P 85 86 GR BK C2B 6 PRIMARY BOOM DOWN RD BK C6 19 RD BK C3B 2 amp C6 2 2 015 RD BK S P 1 I EE PRIMARY BOOM FLOW CONTROL
9. N M L K J D C B A on OO r r a ne ES PLATFORM LEVEL 5 85 Models SLAVE CYLINDERS his 1 02222222222 ge pe eraespeeo 3sbw MEDIUM hi DELI PRESSURE za ___ 1200 psi GERGEN 7 LIFT EE MANIFOLD FILTER iL E e27bar CYLINDER t I y 69 1 ES 1 t Uo 0035 N tee T2 ILLI A N 169 mui vi 0 89
10. 1 Ip EEUE 1 1 RD He 1 1 BUWH C1 12 P134PWR RD 134B BK 22D2 GFVBK C3B 10 DRIVE LIGHT OPTION RELAY U33 GR BK L45 H6 I PLATFORM 5 OVERLOAD RD TS51 1 VOLT METER OIL PRESSURE OIL TEMPERATURE MODULE 7 RD TS52 24 8 GR BK 10 AMP FUSE 12 BRN AG CR23 D C B A 30 PRIMARY BOOM RD C3B 1 RD C6 1 1 RD CR38 86 RD S P G1 G2 G3 85 sel GR BK C2B 6 PRIMARY BOOM DOWN RD BK 6 19 RD BK C3B 2 amp C6 2 2 15
11. 7 i 1 VOLT METER OIL PRESSURE WATER TEMPERATURE 1 7 I 1 1 x gt 1 G1 G2 PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD CR38 86 RD S P L 1 PRIMARY BOOM DOWN RD BK C6 19 RD BK C3B 2 amp C6 2 2 015 gt aos CR8 30 RD BK S P 1 L ON RELAY PRIMARY BOOM FLOW CONTROL C3B 3 C6 3 3 RD WH S P 1 TURNTABLE ROTATE LEFT WH C3B 4 WH C6 4 4 WH S P TURNTABLE ROTATE RIGHT WH BK C3B 5 WH BK C6 5 5 WH BK S P I BL BK 5 16 1 TB24AD TURNTABLE ROTATE WH RD C3
12. I EE LS RSS SSS SSS SSS SSS SS nn m m i l 1 1 i VOLT METER PRESSURE WATER TEMPERATURE 1 al I 1 l F 1 1 D 1 lat G2 Gs PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD CR38486 RD S P DRIVE LIGHT OPTION RELAY PRIMARY BOOM DOWN RDIBK 06 19 RD BK C3B 2806 2 2 pts cnesso RD BI S P PRIMARY BOOM FLOW CONTROL RD WH C3B 3 RD WH 06 3 3 RD WH S P TURNTABLE ROTATE LEFT WH C3B 4 WH 6 4 4 WH S P TURNTABLE ROTATE RIGHT WH BK C3B 5 WHIBK C6 5 5 WH BK S P BL BK 5 16 4 TB24AD TURNTABLE ROTATE WH RD C3B 6 WH RD C6 6 6 057 WH RD S P
13. REVA Platform Control Box Wiring Diagram S 85 COMPONENT INDEX 1 P2 STOP BUTTON 3 2 g P3 HORN SWITCH 44444 8 TS1 AUXILIARY TOGGLE SWITCH jo Bi did 258585989595 TS2 ENGINE START SWITCH i ROG m 5 b h dj M I 500 8 754 HIGH RPM SWITCH SUM 21512055295 786 GLOW PLUG P GND STUD 757 PLATFORM ROTATE TOGGLE SWITCH J1 J2 788 BOOM UP DOWN TOGGLE SWITCH Le o 41 6 les A x 1 759 PLATFORM LEVEL TOGGLE SWITCH 2 N i 9 7814 LOWHIGH DR
14. 7 qu kk 2 22 9 5 8 lt ESE skate AC SEE 5 95559 589 8 J3 mz 2 2 re e BE m 4 012 EE 42 GNDSTUD m 2 e eles nme aa e er _ aaa Wr OR DE y x wj sd Qoooooooooooocrzooo pe scd sd ad VY SAY 4944 50 38508 SE 42 50022 55565 9988 527935484838895150958 5228 89999 BEERS 5 9 909 09 09 lt 5 gt voan gt 00m 2 5 95 255 DIVES 2000 Soret 3550 52 52 9552 15450 9 200 BE dT 5 8292222 225 9921
15. COMPONENT INDEX P2 EMERGENCY STOP BUTTON 1 P3 HORN SWITCH 2 g 751 AUXILIARY TOGGLE SWITCH p T ror I 152 ENGINE START TOGGLE SWITCH 5 E ed Gass EIE EE N g E 5 T D 1 153 FUEL SELECT TOGGLE SWITCH FORD 15 5 2 da 455555555555 013 8 mm 154 HIGH RPM TOGGLE SWITCH S ESS O Q e 5 ALC 500 8 767 PLATFORM TOGGLE SWITCH 210920 1 TS8 BOOM UP DOWN TOGGLE SWITCH 5 m Dr gr argon D12 D12 Le e 759 LEVEL TOGGLE SWITCH GoD gt GND STUD TS14 DRIVE SPEED LOWHIGH TOGGLE SWITCH BE 5 1 7515 DRIVE ENABLE TOGGLE SWITCH oR J
16. SSS SS SSS SSS SS SS 3 F 1 RD l 3 BL WH C1 12 P134PWR RD 134B 1 DRIVE LIGHT OPTION RELAY 1 GR BK L45 6 5 BK C7B 1 6 VOLT METER OIL PRESSURE WATER TEMPERATURE 5 10AMPFUSE BAD 8 GN BK H6 3l 1 An 5 3 cms 1 D C B A G2 30 PRIMARY BOOM UP RD C3B 1 6 1 RD CR38 86 RD S P I G3 85 GR BK C2B 6 PRIMARY BOOM DOWN RD BK 06 19 RD BK C3B 2 amp C6 2 2 215 RD BK S P 1 E 4 EER PRIMARY BOOM FLOW CONTROL RD WH 3 RD WH C6 3 3 RDWH SP 1 87 TURNTABLE ROTATE LEFT WH C3B 4 WH 6 4 4 WH S P RD 4 11 TURNTABLE ROTATE RIGHT WHIBK C3B 5 WHIBK 6 5 5
17. n 0 1 N EE EEN SUA C1 12 P134PWR RD 134B I 1 EET DRIVE LIGHT OPTION RELAY I GR BK L45 5 C7B 1 1 6 VOLT METER OIL PRESSURE WATER TEMPERATURE 7 24 I 8 GN BK H6 T 10 AMP FUSE LEES R23 D C B A 30 G1 G2 G3 PRIMARY BOOM UP RD C3B 1 RD 1 RD CR38 86 RD S P I 85 sel GR BK C2B 6 PRIMARY BOOM DOWN RD BK C6 19 RD BK C3B 2 amp C6 2 2 015 RD BK S P 1 I PRIMARY BOOM FLOW CONTROL C3B 3 RD WH C6 3 3 RD WH S F 87 TURNTABLE ROTATE LEFT WH C3B 4 WH 6 4 4 WH S P gt I RD C4B 11 2 TURNTABLE R
18. COMPONENT INDEX P2 EMERGENCY STOP BUTTON 1 z HORN SWITCH d TS1 AUXILIARY TOGGLE SWITCH EERS A z 3 182 ENGINE START TOGGLE SWITCH 5 5 a m cb EU EAE EJ p V EE 8 FJ ne 9 TS3 FUEL SELECT TOGGLE SWITCH FORD 5t g 9 90 255 8 5 5 5 5 5 5 5 5 013 9 N 754 HIGH RPM TOGGLE SWITCH OAR O ALC 500 TS7 PLATFORM ROTATE TOGGLE SWITCH vvo lt 4 I TS9 PLATFORM LEVEL TOGGLE SWITCH 5 m m ME ee no D12 D12 a 1514 DRIVE SPEED LOWHIGH TOGGLE SWITCH GoD gt 7515 DRIVE ENABLE TOGGLE SWITCH 358 GND STUD RETRACT TOGGLE SWITO OD S J2 l 1516 AXLE EXTEND RETRACT iLE SWITCH 9 J1 DD 1 7547 GENERATOR TOGGLE SWITCH OPTION n 7548 WORK LIGHT RELAY
19. DRIVELIGHT gt LO C2P 6 E DLITE GR BK C2B 6 5 DRIVELITE 2 lt lt A p LO N C4B 11 DRVELTEIRD lt 5 a 4 wo O GND WORKLITE2 BK 0612 7 CI2DRE 2 Z YW 153 pO 2 GND WORKLITE1 BK DRIVE ENABLE LED I SU C23BAT RD 1 BK 9 2 Un zi lt o WORKLIGHT WORKLITE1 WH 9 en lt m 3 WORKLITE2 WH K i 10 purum i RETRACT BL BK C61AXRT BL lt a AXLE 11 C61AX BL BK C3B 11 C6 21 1 RD RE EXTEND pum aD Un Sag 49 n a OR RD 6 22 C42LS2 GR 4 WH mE N lt 1 o E 2 4 C60AX OR RD 4 LS2AO KO ar i lt lt BOOM ANGLE 3 lt BK OPERATIONAL O lex 12 27 C12DR
20. BOOM UP RD 1 RD 6 1 1 RD S P 1 PRIMARY BOOM DOWN 029 RD BK C3B 2 amp C6 2 2 Dis gt RD BK S P PRIMARY BOOM F C RD WH C3B 3 RD WH 6 3 3 RD WH S P TURNTABLE ROTATE RIGHT WH C3B 4 WH 6 4 4 WH S P TURNTABLE ROTATE LEFT WH BK C3B 5 WH BK C6 5 5 WH BK S P TURNTABLE ROTATE WH RD C3B 6 WH RD C6 6 6 WH RD S P BOOM EXTEND BK C3B 7 BK C67 7 DH ano STU BK S P BOOM RETRACT BK WH BK WH C6 8 8 D57 BKWH S P EXTEND RETRACT BK RD C3B 9 BK RD 6 9 9 BK RD S P SBD DESCENT ALARM IF oso BL C3B 10 10 BL S P 11 PLATFORM LEVEL UP C4B 2 6 14 14 OR S P PLATFORM LEVEL DOWN OR BK C4B 3 OR BK C6 15 15 OR BK S P AXLE DUMP VALVE OR RD C6 11 16 OR RD CR8 87A PLATFORM ROTATE LEFT GR C4B 5 GR 6 17 17 GR S P RIGHT GRIBK C4B 6 GR BK 6 18 18 GR BK S P 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P
21. x sees 5 HOUR 8 1 a 5 2 gt C1 9 C35ESPD BK RD ze RPM RELAY o HIGH FS 5 5 E t t HOLD ENGINE REM 5 n RPMSOLENOID 9 1 5 5 PULLIN Ex 3 Eon 8 558 8 u LOW RPM x 3 9 FUNC ENABLE en t HIGH RPM whe ti 933 2 i z 2 18 am 5 5 5 5 lt 4 9 a N C5 18 5 TT WY Y s 8 1 I L GENERATOR L lt N TON 2 7 C45GEN GR WH C512 GRWH 2 GENERATOR 9 5 lt B1 BATTERY 1 E esa lense UON RR EE ER GEE EG a ERI ERR 5 Es 8 Zr 8 C1 8 C34SA BRAWH 4r GLOW PLUG RELAY GLOW PLUG 8 P a GLOW 1 PLUG 4 ale GLOW PLU
22. m C32 1 RD He 1 CONNECTOR BLWHC1 12 P134PWR RD 134B 2202 GR BK C3B 10 DRIVE LIGHT OPTION RELAY GR BK L45 6 i L 5 BK 7 1 6 RD TS51 VOLT METER OIL PRESSURE OIL TEMPERATURE 7 RD TS52 TB24AD 1 8 GR BK H6 gt 10 AMP FUSE 12 BRN CR23 D C B A PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD CR38 86 RD S P 1 85 GR BK C2B 6 1 PRIMARY BOOM DOWN RDIBK C6 19 RD BK C3B 2 amp C6 2 2 15 RD BK S P 4 PRIMARY BOOM FLOW CONTROL RD WH C3B 3 RD WH C6 3 3 RDWH S P 1 87 TURNTABLE ROTATE LEFT WH C3B 4 WH C6 4 4 WH S P RD C4B 11 2 TURNTABLE ROTATE RIGHT WH BK C3B 5 WH BK 6 5 5 WHIBK S P BL BK 5 16 TURNTABLE ROTATE WH RD C3B 6 WH RD C6 6 6 WH RD S P 1 p z BOOM EXTEND BK C3B 7 BK C6 7 7_ gt stud BK S GREK 1 B
23. OIL PRESSURE SENDER OPTIONAL OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH OIL TEMPERATURE SENDER OPTIONAL FUEL SOLENOID RPM SOLENOID STARTER RELAY STARTER MOTOR HYDRAULIC OIL TEMPERATURE SWITCH HYDRAULIC OIL COOLING FAN ALTERNATOR ENGINE STARTING BATTERY oe OFF 296 DRIVELIGHT 2 a C2P 6 lt DLITE GR BK C2B 6 C4B 12 DRIVELITE2RD lt 4 11 DRIVELITE1RD lt 5 lt GND WORKLITE2 i C6 12 lt C12DRE BUWH 2 WH 5 9 9 iss GND WORKLITE1 5 i 5 50 DRIVE ENABLE LED 94 18 LO OFF C6 30 C23BAT RD 1 BK WORKLIGHT Dg WORKLITE1 WH 1 e 3 47 WORKLITE2 WH lt 3 11 C61AX C3B 11 BUBK c6 21 C61AXRT BL RD EXTEND arm OR RD C6 22 C42LS2 GR 4 Z WH LS2AO 2 4 C60AX OR RD 4 5 BOOMANGLE lt lt aude OPERATIONAL ET
24. Peumus n 1 CONNECTOR 1 RD Oi 1 12 P134PWR RD 134B I na 3 x DRIVE LIGHT OPTION RELAY r GR BK L45 H6 I 5 C7B 1 i 1 6 RD TS51 1 VOLT METER OIL PRESSURE OIL TEMPERATURE I 7 RD TSs2 TB24AD 8 GR BK 10 AMP FUSE 12 1 1 CR23 E 0 G1 G2 G3 PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD CR38 86 RD S P I 85 861 GR BK 2 6 PRIMARY BOOM DOWN RD BK 6 19 RD BK C3B 2 amp C6 2 2 015 RD BK S P PRIMARY BOOM FLOW CONTROL RD WH C3B 3 RD WH C6 3 3 RD WH S F RD C4B 11 2 TURNTABLE ROTATE LEFT WH C3B 4 WH 6 4 4 WH S P I RDC4B 11 TURNTABLE ROTATE RIGHT WH BK C3B 5 WH BK C6 5 5 WH BK S P BL BK 5 16 TURNTABLE ROTATE WH RD C3B 6 WH RD 6 6 6 D WH RD S P 1 GR BK C5 14 4 12 BOOM EXTEND BK C3B 7 BK 6 7 7 stud BK S P 852255
25. T N LO 7 ors BEN GROUND 59 C6 18 S3LED 5 AXLE EXTENDED PRESSURE SWITCH SaEEDIBURD p OPEN WHEN AXLE FULLY EXTENDED 79 89 s oz Al AXLE EXTEND RELAY 6 39 C60AX OR RD 34 1 11 EA ELEK AXLE EXTEND RETRACT SELECT RETRACT AXLE EXTEND C6 11 C42AXDP WH C35 1 5 o AXLE DUMP VALVE 85 RETRACT 2 4 C621 62 EXTEND 6 22 C42LS2 GR lt lt oo LS2A0 BOOM ANGLE OPERATIONAL Z DRIVELIMIT SWITCH 4 C40LS OR RD 55 EKS MBK LS2AS BOOM ANGLE SAFETY C40LS2BK 7 1 88 DRIVELIMIT SWITCH Hx C2P 2 C40LS1 OR x lt m 9 9 m oo LS1RO BOOM RETRACT OPERATIONAL Z DRIVE ROTATE SPEED LIMIT SWITCH 5 J2WH Hi RD BK 215 48 JBK 5 9 LS1RS BOOM BS move a 4d 6 DRIVEROTATE SPEED 06 31 RD z LIMIT SW
26. D C B A PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD S P PRIMARY BOOM DOWN HeH 029 RD BK C3B 2 amp C6 2 2 pis RD BK S P 1 RD WH 3 C6 3 3 RD WH S P TURNTABLE ROTATE RIGHT WH C3B 4 WH 6 4 4 WH S P TURNTABLE ROTATE LEFT WH BK C3B 5 WH BK C6 5 5 WH BK S P TURNTABLE ROTATE F C WH RD C3B 6 WH RD C6 6 6 WH RD S P BOOM EXTEND C3B 7 66 7 7 Rees BK S P BOOM RETRACT BK WH C3B 8 BK WH 06 8 8 057 BK WH S P EXTEND RETRACT F C BK RD C3B 9 BK RD C6 9 9 BK RD S P 2 SBD DESCENT ALARM gt 030 BL C3B 10 10 BL S P 11 PLATFORM LEVEL UP 4 2 OR 66 14 14 OR S P PLATFORM LEVEL DOWN C4B 3 C6 15 15 OR BK S P AXLE DUMP VALVE OR RD C6 11 16 OR RD CR8 87A PLATFORM ROTATE LEFT GR 4 5 GR C6 17 17 GRSP PLATFORM ROTATE RIGHT GR BK C4B 6 GR BK C6 18 18 GR BK S P 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P IGNITION POWER WH CR17 86 21 WHSP HORN C7B 1 22 BK CR5 30 BK S P KEY SWITCH PWR
27. Un LO A DRIVELIGHT a 2 6 DLITE GR BK C2B 6 lt 12 pRvELTE2RD lt lt LO C4B 11 O Q DRIVELITE 1 RD lt 5 lt 1 U gt GND WORKLITE2 C6 12 C12DRE BL WH 2 WH Un elo 183 GNDWORKLITEIBK 3 DRIVE ENABLE LED Un d T I C23BAT RD 1 WORKLIGHT 9 WORKLITE1 WH 5890 5 E 9 C Oo 4 5 WORKLITE2 WH e o 1 o s A RETRACT 11 C61AX BLIBK C3B 11 BL BK C6 21 C61AXRT BL 1 RD o mus OR RD C6 22 C42LS2 GR 4 ZZ WH 5 gt 5 5 2 4 C60AX OR RD 2 4 18 LS2AO Z BK BOOM ANGLE u OPERATIONAL LLI lt C3P 12 7 12 C3B 12 2 Z J3 WH 1 RD gt 4 4 8401 52 OR RD 4 ALARM 7 J4 4 WH 5 LS2AS o BOOM ANGLE DRIVE MODE 58 672 06 10 C40LS2 BK 3 Z BK
28. January 2004 Electrical Schematic 5 85 with Dual Battery Option Deutz F4L 913 Models after serial number 3576 Section 7 Schematics m WH 21 9 y HOUR METER 8 8 lt a C1 9 C35ESPD amp RPM RELAY HIGH FS a 5 m m Cw ENGINE SPEED z HOLD 5 gt Wai RPM SOLENOID 9 PULLIN ag 22 5 8 225 2 5 e 9 ut 5 _ ENABLE noB AE aig 9 HIGH I id 5 t e b e Lia 218 a T 29 E x m s 2 k x gt 5 Ei 5 8 lt 9 gt 2 2 C5 18 oz ae NENNEN 26 4 1 O GENERATOR lt N 2 7 C45GEN GR WH 12 _ GR WH GENERATOR 5 3 lt lt lt
29. N 10 7 ers BRN GROUND amp 9 C6 13 S3LED i 5 AXLE EXTENDED PRESSURE SWITCH SEED BERD 2 4 OPEN WHEN AXLE FULLY EXTENDED oz Al AXLE EXTEND RELAY C34 1 11 COTAXBUBK AXLE EXTEND RETRACT SELECT EXTEND C6 11 C42AXDP WH C35 1 5 e ave AXLE DUMP VALVE p 8 4 AXE C2P 4 C6 21 C61AXRTBL EXTEND 06 22 C42LS2 GR LS2A0 BOOM ANGLE OPERATIONAL IM 25 DRIVELIMIT SWITCH 5 5 KS C4P 4 C40LS OR RD a 4 lt gt m LS2AS BOOM ANGLE SAFETY C6 10 C40LS2 E 7 1 DRIVELIMIT SWITCH lt C2P 2 gg C40LSTOR i a C640 04015108 m __ 99 LSIRO BOOM RETRACT OPERATIONAL DRIVEROTATE SPEED LIMIT SWITCH 15 5 e Hi RD BK 215 USBK 5 g LS1RS BOOM RETRACT SAFETY 4 Be DRIVE MODE it ae G DRIVE ROTATE SPEED 06 31 RD SWITCH C29MS RD WH n 5 C620 WH sn LEDBLRD zu 8 8 637 25 1 C25 2 a C1P 11 C37STC BL BK Fig C37STC I STEER RIGHT CDE
30. a 5 i C1 9 C35ESPD BK RD BEBK PRESSURE HIGH FS 7 7 t ENGINE SPEED a 5 C26TSR GR BK WATER TEMPERATURE JLowrpm Oo SENDER OPTION e FUNC ENABLE HIGH RPM 1 e 5 VOLT METER OPTION E q I i Le d ____ GRAN R WH 2 7 C45GEN GR WH 5 12 lt GENERATOR 5 os s sa 1 o e 2 gt 2 1 C39LP BURD j LP SIP z t HOUR METER Gas 2 d u P d e P FUEL Gag SELECT Sem s 1 4 v 9 V C87 WH BL o o ul E C5 18 C35RPMBK RD C82 5 2 C41RPMOR BK 8 8 DK BL l lt 2 8 4 lt GMENGINE HARNESS 1 7 C33STR C5 10 C39LP BURD C8 1 YE ENGINE C5 5 C33STR 8 3 RD BL z e START C5 6 C27AUX 8 5 GR BK 9 5 5 11 C21IGN WH 8 6 RD 6 5 8 8 11 PU BK 5 9 C8 12 BK 2 START 5
31. 7 43 5 80 amp 5 85 Platform Control Wiring Diagram 5 85 Models January2004 T REN 5 leat sil aici S 5 gt ss 5 S lt GIE E E GR WHC2P 7 5 9 lt Zg go 55 5 8 8 8 r Fez 8 B ss x 8 HE gt Z 2 u oo sl
32. k od m a tr 5 WH 21 HOUR METER m 6 1 z gt 1 9 C35ESPD BK RD ze RPM RELAY o HIGH FS 5 5 E t HOLD ENGINE REM 5 Wii RPM SOLENOID 9 5 28 1 a PULL IN mc cr 4 a E 3 N 885 B a LOW RPM _ FUNC ENABLE BORD cat 7 HiGH RPM gt ate ur 9 d z 2 e gt mom o Oo x k x gt 5 5 2 8 lt 9 i T 9 C5 18 s n ON OE OON N A s DOE OE S OE A N te EE ate ae z Ka 2 7 C45GEN GR WH 512 GR WH lt GENERATOR T B1 BATTERY ME bed 5 gt lt o 8 T E C5 22 BK WH ors CASA BEWE 4r GLOW PLUG RELAY GLOW PLUG 8 2 GLOW PLUG 4 ale GLOW PLUG a zz 000 4 7 gt GLOW PLUG FUEL VALVE OIL TEMPERATURE AND M E OIL PRESSURE LED 52 Y z 3 5 1 7 C33STR BEE NE Bo aE OIL TEMPERATURE SWITCH ENGINE 5 START 522649856 k E II P 3 4 65 15 C2ATSTPBURD
33. N LO 7 ere BRN GROUND 06 13 S3LED T 2 gt gt AXLE EXTENDED PRESSURE SWITCH SSEEDIBURD Sl OPEN WHEN AXLE FULLY EXTENDED 82 mM AXLE EXTEND RELAY 11 BUBK AXLE EXT RET SELECT RETRACT AXE YET AXLE DUMP VALVE 5 D lt C60AX OR RD 4 RETRACT 2 4 6 21 CGTAXRT BL AXLE 66 22 C4MS2GR 5 lt lt 9 LS2A0 BOOM ANGLE OPERATIONAL Z DRIVELIMIT SWITCH 5 5 r 4 4 C40LS OR RD ERS lt lt at gt a MBK a __ Q LS2AS BOOM ANGLE SAFETY C6 10 40182 d SA DRIVE LIMIT SWITCH 2 2 C40LS1 9 C6 40 40151 OR E 2 OQ LS1RO BOOM RETRACT OPERATIONAL c t DRIVE ROTATE SPEED LIMIT SWITCH J2WH 8 a gt 15 5 e H1 RD BK JSBK 45 o Pase MODE 4 O LS1RS BOOM RETRACT SAFETY 7 C6 81 2 DRIVE ROTATE SPEED REEDE RD WH gt gt 81 LIMIT SWITCH 5 5 66 20 a D LEDBURD 5 7 8 C6 37 C25 1 C25 2 Im 1 11 C37STC BL BK C37STC BL BK STEER RIGHT CDE2 BL BK 7 s RIGHT 8 06 36 0241 24 2 DRIVE ENABLE Ci C1P 10 C36STCC BL amp C36STCC BL 7 B LEFT 17 E ERe
34. C28TTA RD BK P26ESTP BK REV N ors BRN GROUND 8 C6 13 S3LED BL RD I AXLE NOT EXTENDED PRESSURE SWITCH SSEED BERD 2 T OPEN WHEN AXLE FULLY EXTENDED 82 AXLE EXTEND RELAY C34 1 Bi C34 2 C3P 11 C61AX BL BK SUA ORRD AXLE EXT RET SELECT 4 RETRACT C6 11 C42AXDP WH 35 1 35 2 _ END AXLE DUMP VALVE C60AX OR RD T S6 RETRACT C2P 4 5 lt epe 9 LS2AO BOOM ANGLE OPERATIONAL 4 DA Z amp DRIVE LIMIT SWITCH s S J3WH N C4P 4 C40LS OR RD 5 n o J4BK __ 9 LS2AS BOOM ANGLE SAFETY R C40LS2 BK 9 DRIVE LIMIT SWITCH c 62 2 C40LS1 OR C40LS1 OR __ OQ LSIRO BOOM RETRACT OPERATIONAL dc BW 55 Z DRIVEROTATE SPEED LIMIT SWITCH 8 1 5 H1 RD BK gt o e o gae obe E 4 6 LSIRS BOOM RETRACT SAFETY C631 lt DRIVE ROTATE nsus gt RDWH 2281 LIMIT SWITCH n 5 C6 20 WH amp pp LEDBLIRD sya 5 m 5 1 11 C37STC BL BK E 06 37 C37STC BLIBK Z gt 4 srEERRIGHT 2 BLBK I
35. oe OFF 296 DRIVELIGHT 2 6 lt DLITE GR BK C2B 6 u C4B 12 DRIVELITE2RD lt lt 4 4 11 E I 1 5 lt LO GND WORKLITE2 BK i o e O C6 12 lt C12DRE BUWH 2 WH I GND WORKLITE1 5 I 193 N 50 DIE m 5 DRIVE ENABLE LED Co OFF C6 30 C23BAT RD 1 BK WORKLIGHT Dg WORKLITE1 WH k Q 25 Y e 3 47 WORKLITE2 WH lt WM RETRACT XE GENE BUBK BL BK 66 21 C61AXRT BL 1 RD Un 2 o EXTEND 2240 OR RD C6 22 C42LS2 GR 4 Z WH LS2AO a 5 2 4 C60AX OR RD 4 5 BOOM ANGLE eo lt aude Z OPERATIONAL o lt ET 12 C12DRE BL WH C3B 12 2 BRN T J3 WH 1 RD U 91 4 4 84052 OR RD 4 2 ALARM lt BK 4 WH r I LS2AS q 24 9 BOOM ANGLE DRIVE MODE am Sisa 3 4 LLI C29MS RD NH pue 1 12 BUWH C1B 12 Q HEG EER lt 2 BRN Q gt 9 J1 WH 1 DRE LED BL RD lt DRE BL EK m 9 C6 40 C40LS1 OR 4 WH 5 t LS1RO O 5 BOOM
36. 2 x eec a K WH 21 4 HOUR io o 2 amp a a c1 9 T RPM RELAY HiGH FS 8 o HOLD x T ENGINE SPEED eo RPM SOLENOID T T x U 5 E 5 a a 2 P LOWRPM amp gt 9 FUNC ENABLE 8 HIGH RPM Rar BK RD ale uy 8 i 5 2 2 gt 3 5 a gt 2 29 C5 18 oz ler te EER o GENERATOR i 2 7 GRWH c5 12 GR WH GENERATOR lt OPTION 9r BATTERY 5 AITNE ENT ayasa TE N EE OE N EO DEGIE ENE TEE TR OE N OE EE EN NN OER TEEL HG SEHEN MM METER TEN 1 v 9 8 8 1 8 C34SA 5 22 BK WH 4 GLOW PLUG RELAY GLOW PLUG o E GLOW PLUG 3 GLOW PLUG e o GLOW PLUG FUEL VALVE OIL PRESSURE LED a 58 as 3 Re C33STR able 190 D Sa 22296 2 F ENGINE lOS ub mirus s OIL TEMPERATURE
37. COMPONENT INDEX 1 P2 STOP BUTTON P3 HORN SWITCH TT TT GEE EE EE ee eer el NEN TS1 AUXILIARY TOGGLE SWITCH z m UU TS2 ENGINE START TOGGLE SWITCH did 2555555565565 2 U13 3 TS3 FUEL SELECT TOGGLE SWITCH 229 S 2 LAREO 500 es 154 HIGH RPM TOGGLE SWITCH 3379833523388 4 8 TS7 PLATFORM ROTATE TOGGLE SWITCH gt 012 2 012 rte e TS9 PLATFORM LEVEL TOGGLE SWITCH 3 5 ja 4 TS14 LOW HIGH DRIVE SPEED TOGGLE SWITCH di m 2 TS15 DRIVE ENABLE TOGGLE SWITCH E rar ur Sik Si SET E TS16 AXLE EXTEND RETRACT TOGGLE SWITCH ee 7547 GENERATOR TOGGLE SWITCH OPTION e 848 WORK LIGHT TOGGLE SWITCH OPTION l T sx uk i k w w w TUR DRIVE ENABLEILED OQoooooooooooorooo o cp v 5 5 sd g L40 AXLE EXTENDED LED 22e 35 885 6665 86044 8596505 JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT 8889 5 22d 5 2552555058 n 3 ozo 8999 8 88558 JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT 2 8 9 28 8 2928 2 9 DES D SE BEES 883830 JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE 2 E 8 252535582228 ag 288 Poo 2
38. N M L K J G F E D C B A FEE n ROTATE PLATFORM LEVEL 6 85 Models 0 4 1 SLAVE CYLINDERS si M BRAKE 2 SPEED MEDIUM PRIMARY LIFT PRESSURE zd __ 1200 psi CYLINDER 4 ENTER Cub AN sa t1 eo 1 Fili EM 69 LES X M le 4 SECONDARY PSI gt aM BM IM On MEE ij E BRAKE M 7 GPM REGEN 4 GPM ps 2 jt M m UU ACT aR m3 Al ACCUMULATOR 25079 eae Hoewe TTS T AUXILIARY 17 gpm Qes _ me E mn 1 Pump di min FUNCTION 8 2000 ba 2 EE 1 5 E MANIFOLD JZ M ja 1 i oe F SELECT x T HH m a ER ss I a e PRESS 5 LE ET PLATFORM 3 D m n A pump 1 ROTATE j ma OE A jT TI 7 1 e 69 OO FUNCTION PRESSURE OL ui GR T PUMP
39. C28TTA RD BK REV 7 ero BRN 4 GROUND 06 13 S3LED BL RD lt 9 AXLE NOT EXTENDED PRESSURE SWITCH SSLED BURD OPEN WHEN AXLE FULLY EXTENDED 27 29 AXLE EXTEND RELAY C6 39 C60AXOR RD C34 4 C342 2 GsP n AXLE EXT RET SELECT RETRACT AXLE 2 1 EXTEND C6 11 C42AXDP WH 035 1 35 2 5 D 6 OR RD 4 RETRACT CRRA lt 9 LS2AO BOOM ANGLE OPERATIONAL 28 DRIVELIMIT SWITCH 4 4 C40LS OR RD 8 EK RO 59 LS2AS BOOM ANGLE SAFETY QS DRIVELIMITSWITCH Ex 2 2 C40LS1 Q LS1RO BOOM RETRACT OPERATIONAL DRIVE ROTATE SPEED LIMIT SWITCH J2WH 8 K 15 5 215 5 J5BK 5 L a LS1RS BOOM C6 31 RD DRIVE ROTATE eS ROME gt gt LIMIT SWITCH 5 5 66 20 WH D LEDBURD 16 a 1 11 C37STC BUBK C637 251 C25 2 CDE2 BL BK 6 lt gt STEER RIGHT 2 5 RIGHT ORIVE ENABLE 5 10 C36STCC BL C6 36 BL
40. J3 P24CONT WH 9 2 P2 P23SWBAT WH C7P 2 P2 P22BAT BK C7P 1 TS7 C18JD GR BK 4 6 TS7 C17JU GR 5 TS9 C15PLD OR BK C4P 3 TS9 C14PLU OR C4P 2 L40 S3LED BL RD C4P 1 b o HI C133PLA GN BL C3P 10 a rr TS16 C61AX BL BK C3P t1 TS48 WL1 RD C2P 12 TS48 WL2 RD C2P 11 TS47 C45GEN GR WH C2P 7 DLITE GR BK C2P 6 m P3 C43HRN GR C2P 5 5 TS16 C60AX OR RD C2P 4 el p 6 cast OR caP2 WH RD C3P 6 2185 ae C7PBE 7 ki C12DRE BLWH C3P 12 I C8PBR BK WH C3P 8 94052 OR RD x 1 BK RD C3P 9 IS T o fe e C41RPM C2P 3 e E C30EDC WH 1 4 NE CIPBU RD C3P 1 m C31EDC WH BK C1P 5 5 2 RD BK C3P 2 C37STC C1P 11 um ul C3P 3 4 4 csssrcc 1 10 5 a WH BK 5 C32BRK WH RD 1 6 9 E S CATRL WH 4 28 g C29MS C1P 3 C2P BK 5 29 5 TS4 C35ESPD BK RD C1P 9 TS6 C34SA 1 8 TS2 C33STR C1P 7 1 TS1 C27AUX RD 1 1 RD BK 148 m 2 LJC1 3 OR 1 JC2
41. OFF F DRIVELIGHT st o C2P 6 lt DLITE GR BK C2B 6 C4B 12 DRIVELITE 2 RD lt lt C4B 11 DRIVELITE 1 lt 2c lt 4 GND WORKLITE2 58201 e C6 12 C12DRE BL WH 2 Z elo 183 GND WORKLITE1 54 Ed 5 DRIVE ENABLE LED AF C23BAT RD 1 7 el WORKLIGHT 0 lt WORKLITE1 WH 5 C6 30 2 I u No WORKLITE2 WH Un Cap 11 YS C61AX C3B 11 BUBK 6 21 C61AXRT BL 1 g RD Peat 245 OR RD c6 22 C42LS2 GR 4 WH N lt 8 E gt 2 4 lt lt C60AX OR RD lt lt C2B 4 2 LS2AO i 3 BK BOOM ANGLE OPERATIONAL 12 C12DRE BL WH C3B 12 2 Z BRN lex Bg lt J3 WH 1 RD gt st C4P 4 R40LS2 OR RD C4B 4 ALARM RD BK Y ENS e 152 5 B o 2 BOOM ANGLE DRIVE MODE 57 C6 10 C40LS2 BK 8 4 BK SAFETY C29MS RD WH 1 12 C38ESL BL WH C1B 12 v amp 2 2 27 BRN lt t DRELEDBURD 22 L J1 WH 1 RD 2 DRE BL BK 8 9 C6 40 C40LS1 OR 4 WH gt 1 51 9 us 5 2 898 1 11 C37STC BL BK C1B 11 8 lt gt 2 BRN DS 1 10 7 C36STCC BL C1B 10 ZL lt pie J2 WH 1 RD C2P 2 C40LS1 OR C2B 2 5 BK 4 WH 15185 lo x lt
42. COMPONENT INDEX 1 2 HORN BUTTON TS AUXILIARY TOGGLE SWITCH e v IS ET B m U13 Em 9 82 ENGINE START TOGGLE SWITCH did 4355555558555 a 9 d ma 5 TS4 HIGH RPM TOGGLE SWITCH 594 DAR 5 5 TS7 PLATFORM ROTATE TOGGLE SWITCH Enn 8392285282252 8 J3 Tss JIBBOOM UP DOWN TOGGLE SWITCH 5 2 gt i z m Fe e D 759 PLATFORM LEVEL TOGGLE SWITCH gg 2 42 GND STUD 7614 LOW HIGH DRIVE SPEED TOGGLE SWITCH 2 7515 DRIVE ENABLE TOGGLE SWITCH 9 9 9 9 9 PP 7516 AXLE EXTEND RETRACT TOGGLE SWITCH eo o 7547 GENERATOR TOGGLE SWITCH e e e Y TS48 WORK LIGHT TOGGLE SWITCH OPTION ET EE EE EE ETE u F p L1 DRIVE ENABLE LED 4444 99 124 GLOW PLUG LED 5 95 45 Q 0005598 59 140 AXLE EXTENDED LED 9888 98 5 255899995 2895 222 85 JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT gt 9 SES 32 gt z 855 Zim JC1 BOOM P
43. TS14 GLO 7 12 GR BK 6 C3P 3 65 1 10 WH BK C3P 5 C32BRK WH RD C1P 6 C4TRL WH C3P 4 C29MS RD WH C1P 3 TS4 C35ESPD BK RD C1P 9 TS6 C34SA BK WH C1P 8 TS2 C33STR BK C1P 7 TS1 C27AUX RD C1P 1 RD BK L48 5 I 1 gt 5 12 a lt 1 BLTS16 t t T T T T i i 5 1 LJC1 3 OR LJC2 4RD 01 2 BRN 9 L JC2 5 JC2 3 OR 41 5 YEL Z JC2 2 BRN HJC9 5 WH JC3 3 OR JC3 6 BL JC3 2 BRN 4 1 FTS15 DRE BLWH 1 e 1 515 BL BK T L1 C13LED BL RD 514 29 5 GN BK 10 5 GR WH CABLE TS1 AUXILIARY PUMP N E J2 DIODE WH BRN 19 18 CONTROL CABLE C2P 9 amp 10 AXLE CUTOUT CR26 OR RD C2P 4 AXLE EX RET 140 1 BATGND C7P 3 a BL 10 li Fe 11 BL RD C4P 1 BRN J1 12 OR J1 11 GND STUD RD J1 1 C28TTA RD BK C1P 2 CR13 BRN 040 H1 TILT ALARM D39
44. PLATFORM LEVEL BK RD a 4 room C15PLD OR BK 5 PULL IN o lt QN BL 5 BY zu lt E C17JU GR F u T HER JIB BOOM 028 t DOWN gt C18JD GR BK 1 m HOLD RIGHT e o PLATFORM ROTATE BK 5 7 R33STR PULLIN lt d 2 lt C19JSV GR WH Ses J m 5 x gi 7 a Oo uw me Low RPM ic FUNCTION ENABLE 5 3 lehren BIRD 4 BK RD 8 i m C34SA BK WH 4 GLOW PLUG R33STR BK 5 BATGND BRN L 1 fi C5 5 RD el C25PSR BL BK 5 C26TSR GR BK 5 in 2 4 R21IGN WH E l c6 34 E 4 gt P Ld C6 33 lt R116HYD OR 1 C21IGN WH 4 8 0 ers CASTA a 6 O lt gt N ssvdAg A34 810 5 5 2 C41RPM OR BK A34 210 N P ENGINE 25 Aual va 9 t START 52 B C33STR 8 4 EF NO FO INdNi Luvis H313WOHOVL 49 AQ 1 2 P AUXILIARY POWER 4 9 55 veel 9 4 6 m e 5 E S R C27AUX GR WH gt 4 2281 5 4 P23BAT RD e gt 5 8 n 5 1 lt B
45. 5 ag I 6 5 5 8 C21IGN WH RD 2 Owe Owe 5 116 RD 8 E CB2 c 15AMP P20BAT RD RD a BATGND BRN BATGND BRN APU BATTERY OPTION
46. n1 x 14 1 13 i 1 i A WH vis lt z BLJ1 4 gt i I SE 5 MEE EE N AE EEE NE NETA ul wH 03 2 2 5 RD BK H1 sa 3 3 D Q Mes 1 48 m o 1 1 P2 P26FS C9 1 TS2 P25STR RD 9 3 x J8 P24CONT WH C9 2 a P2 P23SWBAT WH 7 2 9 1 1 2 22 7 1 7 JIB CABLE C19JSV GR WH C4P 7 RD OSSE TS7 C18JD GR BK 4 6 9 J1 16 TS7 C17JU GR 4 5 TS9 C15PLD C4P 3 1 TS9 C14PLU OR C4P 2 1 8 140 531 1 5 HI C133PLA GN BL C3P 10 4 6 Y i TS16 C61AX BL BK C3P11 V 287 ota 2 TS48 WL1 RD C2P 12 pcs eid TS48 WL2 RD C2P 11 BL BK J1 7 omn OG Ose TS47 C45GEN GR WH 2 7 6 DLITE GRIBK 2 6 m P3 C43HRN GR C2P 5 5 Row 1 8 i TS16 C80AX OR RD C2P 4 2 T BRN 1 10 OR 41 9 1 5 oz Zu e C40LS1 2 2 r org 1 C6TRF WHIRD C3P 6 sola
47. 176 190 Nm 8 Relief valve 2100 psi 145 bar BOOM GOWM riti 25 30 ft lbs 34 41 Nm Plug Torque Specifications Description Hex size Torque 3 J I SAE 4 16 13 ft Ibs 18 Valve Resistance SAE No 6 1 4 18 ft Ibs 24 Nm Specification SAE No 8 5 16 50 ft lbs 68 Nm ENT RE OE NE EE EE ee Solenoid valve 2 position 3 way 10V DC 60 10 9 16 55 ft lbs 75 Nm schematic items and 5 44 5 80 8 5 85 77832 Section 5 Repair Procedures January 2004 MANIFOLDS REV 45 Genie S 80 amp Genie S 85 Part No 77832 Section 5 Repair Procedures January 2004 MANIFOLDS 9 3 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the diagnostic nipple PrEsT port on the function manifold 2 Startthe 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 retract toggle switch with the boom fully retracted Observe the pressure reading on the pressure gauge System relief valve specification Pressure 2800 psi 193 bar 4 Turn the engine off Use a wrench to hold the relief valve and remov
48. 8 BK WH 6 8 8 C6 38 BKWH S P 1 WH2SA BRN GND FLOW CONTROL BK RD C3B 9 BK RD C6 9 9 BK RD S P I 1 SBD DESCENT ALARM 10 Lc 11 1 PLATFORM LEVEL UP OR C4B 2 OR 06 14 14 PLATFORM LEVEL DOWN OR BK C4B 8 OR BK C6 15 Dag 15 AXLE DUMP VALVE OR RD C6 11 OR RD CR38 87A 16 OR RD CR8 87A PLATFORM ROTATE LEFT GR C4B 5 GR 06 17 17 PLATFORM ROTATE RIGHT GR BK C4B 6 GR BK C6 18 18 TS51 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 STOP KS1 AUXILIARY 1 3 IGNITION POWER WH 17 86 WH 5 3 amp 5 11 21 p52 srup KEY SWITCH HORN 23 4 22 CR5 30 1 1 KEYSWITCH PWR PWR TO PLAT WH C7B 2 RD C6 30 23 WH ISM 7 WH S P D2 FUSED 12V RD CR28 30 CR39 30 24 RD CR2 30 RD S P CB1 OIL COOLER FAN 24 RD CR17 30 Nc Q AUXILIARY PUMP RD CR39 87 amp C1B1 RD 5 6 27 RDISM 4 BRAKE WT RD 5 23 WH RD 1 6 32 WH RD C6 32 05 1 1 ENGINE START BKCIB 7 BK ISM 3 BK S P START RELAY gt ie 65 5 BK CR28 86 BK ISM 1 GLOW PLUG BK WH C5 22 BK WH C1B 8 34 BK WH S P LABEL DESCRIPTION ENGINE RPM BK RD 1 9 35 BK RD CR3 30 BK RD S P RD 27A 1 STEER RT AXLE EXT BL BK 06 37 BLBK 1 11 37 06 20 REDIEMEHGENGYSTORBUBTON 38 RD BK 2A KS KEY SWITCH LP 39
49. Ground Control Box Wiring Diagram S 85 REVA Deutz F4L 913 Models before serial number 3577 1 1 1 i B A O PRIMARY BOOM UP RD C3B 1 RD
50. FUNCTION ENABLE 5 hs HIGH RPM pte BIRD xb 938 2 28 Bo x aa oz 2 838 3 9 C5 18 rf perc ccce un lg LEE ae 1 e GENERATOR ON C27 GR WH 2 GR WH GENERATOR 3 OPTION E B1 BATTERY lt basa cR EON ee od a GAS DEE WE Re od usss ua asss TS Hell EIS u a DUOC E u ei ee fu on pu a ie SS sss tes amsa x 05 22 BK WH 1 8 C34SA BKWH uiu GLOW PLUG RELAY GLOW PLUG 2 GLOW PLUG 4 sle 4 GLOW PLUG 8 000 G P FUEL VALVE OIL TEMPERATURE AND 5 OIL LED A 3509 9 d SEL gt 22 Bs N ez C33STR BK sl SNR P ENGINE s 2 OIL TEMPERATURE SWITCH 5 x y o START Haloselle 5 15 C24TSTP 5 5 18955 OIL PRESSURE SWITCH 4 ENGINE 8 X n START 8 4 POWER RELAY t 3 me 5 T 1 SIE AUXILIARY HE POWER 5 11 RE C21IGN WH 5 lt WH oz m E lt e 29 FUEL SOLENOID EE eH C27AUX RD 2 5 7 lt 8 5 5 B IGNITION START RELAY MU 9 1 5 H 2 tr j AUXILIARY 5
51. bo Y 5 PLATFORM ROTATE RIGHT JIB BOOM DOWN e PLATFORM LEVEL 6 18 C18JD GR BK 1 5 C4P 3 C15PLD OR BK C4B 3 eo 10 JDALARM BL 3 lt C3B 10 C4P 5 C17JU GR C4B 5 5 BATGND BRN 2 UP m e s e JIBBOOM 027 STEER RIGHT AXLE RETRACT DowN C4P 6 C18JD GR BK C4B 6 C6 37 C37STC BL BK 1 gt g 5g F 2 RIGHT e PLATFORM ROTATE m C STEER LEFT AXLE EXTEND C6 36 BL 1 gt 2 SM S3LED BL RD lt lt AXLE NOT EXTENDED 4 7 lt C19JSV GR WH C4B 7 PRESSURE SWITCH 99 OPEN WHEN AXLES ARE FULLY EXTENDED BATGND 2 MOTOR STROKE 5 24 C29MS RD WH 1 gt JIB VALVES a 2 e m DRIVE BRAKE VALVE gt Fl 5 23 2 WH RD 1 in gt 1 9 C35ESPD BK RD C1B 9 HIGH RPM FS EES 521 C30EDC WH L DRIVE EDC FORWARD f 5 20 C31EDC WH BK 3 E E h DRIVE REVERSE ENGINE SPEED i c La HIGH RPM c6 28 ZZ _ RD BK rg OFF 1 6 23 Z RD LEVEL SENSOR 4 e GENERATOR q ptt I SWITCH LEVEL SENSOR C2P 7 GRWH l GND1 BRN B BK 3 4 1 8 C34SA BK WH 1 8 4 m lt 5 12 45 4 E a a 1 1
52. fire hazard Engine fuels are combustible Remove the CAUTION Component damage hazard fuel tank in an open well The fuel tank is plastic and may ventilated area away from heaters become damaged if allowed to fall sparks flames and lighted Component damage hazard Amays Have NM CAUTION When installing the plastic fuel approved fire extinguisher within tank do not overtighten the easy reach E retaining fasteners 7411 733 in Clean the fuel tank and inspect transferring fuel connect a for damage before installing it onto grounding wire between the the machine machine and pump or container 1 the manual fuel shutoff valve to the closed position if equipped Remove the fuel filler cap from the tank 3 Using an approved hand operated pump drain the fuel tank into a suitable container See capacity specifications ADANGER Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel Part No 77832 Genie S 80 amp Genie S 85 5 61 Section 5 Repair Procedures January 2004 FUEL AND HYDRAULIC TANKS 10 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation The tank utilizes internal suction strainers for the pump su
53. 24 x PRIMARY BOOM a s 4 EXTEND Boc P24FS WH B gt 4 7 RETRACT BKWH E 068 61721 tl 9 8 PRIMARY BOOM RETRACT 2 1 1 27 1 27 2 BK RD C69 C9PERF BK RD GE pe SY 4 BOOM EXTEND RETRACT FLOW CONTROL 2 12 C12DRE BLWH 8 3 i Copa Ly C12DREBLWH _ 5 lt C629 RI6PBRBKWH x 3 88 DRIVE ENABLE SWITCH 9 T C638 C8PBRBKWH m 2 st E 2 2 1 4 EX I 1 C6 30 C23BAT RD 5 lt lt lt lt 4 2 C14PLU OR 4 UP PLATFORM LEVEL DOWN 3 C15PLD 8 20 1 20 2 2 1 2 06 14 14 8 i IA PLATFORM LEVEL UP e PLATFORM LEVEL REDEN ee ORVBRSIENEFE PLATFORM LEVEL DOWN 2 1 21 1 21 2 ad 6 C18JD PRR GR BK t DOWN 1 JIBBOOM 8t C4P 5 C17JU PRL GR g D28 GR BK 18 M H bow 4 lt lt lt J gt PLATFORM ROTATE RIGHT JIB DOWN 18 BOOM C617 t Il PLATFORM ROTATE LEFT JIB BOOM UP 6221 0222 a RIGHT PLATFORM RIGHT PLATFORM 1 5 Te LEFT ROTATE T Te LEFT ROTATE Bei c
54. RH25 5R 196 1 TS1 TS51 Toggle switch 2 position momentary 13480 Microswitch Control Inc ONT 8 2 TS2 6 9 15 52 54 56 and TS59 Toggle switch SPDT position momentary 13037 Microswitch Control Inc ANT 1 7 iua 7 TS48 Toggle switch DPST 2 position maintained 27378 iios Microswitch Control Inc ONT 2 TS4 asia Toggle switch 3 position maintained 13038 Microswitch Control Inc 2NT1 1 ie 1 TS7 16 57 61 62 and 863 Toggle switch DPDT position momentary 16397 Microswitch Control Inc 2NTT 7 6 783 14 47 and 553 Toggle switch 2 position maintained 56457 Microswitch Control Inc INTI S eir eee 1 PartNo 77832 Genie S 80 and Genie S 85 7 3 Section 7 Schematics January 2004 Electrical Symbols Legend BLK 153 Quick disconnect N O H C ere terminal Coil Limit switch Horn button normall n solenoid or relay Otmar ope WHT 21 rg TB21 PLATFORM 44 0162 GROUND N O T circuits connect H1 terminal temperature switch Horn or alarm Key switch normally open T em 09 a J Jj CTS1 N O Flashing beacon Power relay
55. EXTEND 66 11 C42AXDP WH 35 1 A C352 8 C80AX OR RD 4 AXLE DUMP VALVE ER RETRACT C2P 4 C6 21 C61AXATBL 2 C6 22 C42LS2GR x 7 LS2AO BOOM ANGLE OPERATIONAL DA 25 DRIVE LIMIT SWITCH i J3WH 5 4 4 C40LS OR RD IN 5 pe lt lt LS2AS BOOM ANGLE SAFETY C6 10 C40LS2BK 721 98 swiTcH C2P 2 C40LS1 OR 5 C6 40 04015108 m a 99 LSIRO BOOM RETRACT OPERATIONAL DRIVE ROTATE SPEED LIMIT SWITCH HiRDEK 725 8 5 LS1RS BOOM e DRIVE E 4 GT DRIVE ROTATE SPEED 8 6 31 RD 2 LIMIT SWITCH C29MS RDWH lt lt n 6 20 WH a D LED BURD 8 1 11 BUBK C637 0251 s _ CDE2 BL BK i 18 STEER RIGHT 2 2 RIGHT 24 1 24 2 DRIVE ENABLE 1 10 BL C636 BL Il LEFT 4 STEER LEFT BL WH 05 21 C30EDC WH UC 15 cies CS0EDGEWH DRIVE EDC FORWARD RKOUT 6 T 3 S 4 1 5 C31EDC SEED GHEDEWWIER Re He e DRIVE EDC REVERSE su TF w 4 lt BL 5 5 I Pwr lt 2213 4 TRAVELALARM GND 2
56. B1 BATTERY lt lt zu ER EE aa EE EE AE EA EA EE 678 pge 9 A 8 C1 8 C34SA 5 22 GLOW PLUG RELAY e GLOW PLUG E PLUG GLOW PLUG 8 c pu gt M 1 d GLOW PLUG FUEL VALVE OIL OIL PRESSURE LED B E 3 3 PE oz C17 C33STR BK gt A o Ere ENGINE 5 TEMPERATURE SWITCH e e lt S E zs a x START 55652658299 5 F se imo 1 24TSTP BL RD D lt lt 515 C2 TSTP PRESSURE SWITCH FS ENGINE SS SS Pe START 9 T 5 92 I POWER RELAY t 3 5 5 8 AR F Ik AUXILIARY ka POWER 5 5 11 M C21IGN WH 2 RD 288 CY 9 NITINd lt lt 27 FUEL SOLENOID C1 1 7 52 5 7 lt lt lt PURE R33STR lt 8 C5 5 ij CSSSTR EK 4 IGNITION START RELAY Di to i 1 1 B 1 1 b F 5 Se j I e AUXILIARY 5 as POWER Q 25 STARTER MOTOR c o t RD is s DNE C7B 2 t 7 2 P23BAT WH ga e e QN id ale 4 x ___ ____ ge FL 54 3 0182 lt 4 RD In
57. 1 T i m B gist 5 ad Sima St 9 8 5 a B E 1 s START BATTERY 1 P20BAT RD E 1 id RD Zr v LO gt ROCKER STEER OPTION ONLY gt ADD 040 ONLY IF UNIT HAS 14 AND 148 Part No 77832 Genie S 80 amp Genie S 85 7 14 Section 7 Schematics Electrical Schematic 5 80 Models Deutz F4L 913 Models after serial number 3576 January 2004 C28TTA RD BK REVA 7 ers ERN GROUND 06 13 S3LED E 2 gt AXLE NOT EXTENDED PRESSURE SWITCH SSLED BURD SS T OPEN WHEN AXLE FULLY EXTENDED 82 Mi AXLE EXTEND RELAY C6 39 C60AXOR RD C34 C342 11 AXLE EXT RET
58. 7 20 Genie 5 80 amp Genie 5 85 Part No 77832 OIL PRESSURE WATER TEMPERATURE r l 54 62 4 BL BK 5 16 LA GR BK C5 14 1 1 41 551 EMERGENCY STOP gt 9 AUXILIARY O apps Nc I 51 a M 2 RD 23A 5 5 5 4 BK 22A cis 1 RD 27A RD WH 3A RD BK 2A BK 7A BK RD 9A BL RD 39A me TS61 G6 BOOM HOUR METER UE DOWN BRN GND TS53 D FUEL SELECT TS63 BOOM EXTEND EN RETRACT BK 33A dn CHECK ENGINE LED TS52 BL RD C5 13 RD 24AA ENGINE START OIL COOLER TS62 OPTION 20A TURNTABLE OR BK 15A ROTATE RD B2 H1 BK RD 35A 9 554 6 df L1 HIGH LOW Q NI ry 2 ENGINE 15 CONTROLS 15 559 557 RD B1 20A PLATFORM PLATFORM LEVEL ROTATE OR 14A GR 17A GR WH C4B GR BK 18A BRN G6 BRN GND WH 4A WH BK 5A WH RD 6A aL WIRING i HARNESS CR19 R2 TO BASE DAL CONTROL BOX CONNECTIONS
59. 8 BOOM k Ag CUTOUTRELAY C61 C12 1 4 C122 m SETPPU RD lt lt gt PRIMARY BOOM UP te PRIMARY BOOM C13 1 2 DOWN 062 TN git C2PBD RD EK 4 BOOM DOWN Di a E cea 291 _ C292 lt lt 4 PRIMARY BOOM FLOW CONTROL y 1 C1PBU RD 8 5 5 5 7 C3P 2 C2PBD RD BK i C3P 3 8 l EE 5 1 a lt 9 C9PERF BK RD l 1 5 iss 8 PRIMARY BOOM EXTEND ale lt t JA CUTOUT RELAY BRN E hz 7 1 2 8 1 C16 1 C16 2 P24FS WH gt C67 gt 4 EXTEND od 24 BOOM 2 5 gt 4 gy RETRAGT BK WH 2 68 6171 6172 26 8 PRIMARY BOOM RETRACT 3 8 1 gt B BK RD i 069 271 0272 BOOMEXIEND RETRACT M N FLOW CONTROL 12 C12DRE BLWH 8 EK i C612 C12DREBLWH _ 1 BS 0629 lt e RI6PBRBKAWH z l T e 58 DRIVE ENABLE LIMIT SWITCH T C638 C8PBRBKWH o gt 1 1 r 8 a s 59 06 30 C23BAT RD I 4 3 I I i 4 2 C14PLU OR UP I 1
60. 4 15211 05 5 CR19 and 26 Relay SPDT 12V DC 19274 Potter Brumfield VF4 45F11 COS 2 Diode Diode 6 amp 200 PIV 45782 Diodes Inc 6A2 B 22 em Flashing beacon 56704 ECCO Electronic Controls 6400A GEN 2 ES1 acus Foot switch 13482 Linemaster Switch Corp 632 6 1 Gl Gauge Voltage 537061 VDO 332030001 1 2 Gauge Oil Pressure 53758 pom 3500300211 1 Gauge Temperature 53759 VDO retena nin 310030023 1 GO Hour 19506 ENM Corporation T40A4508 1 Alarm tone 45383 Floyd Bell Inc 09 530 1 Horn 12V DC 81578 Hella 95346 EE 1 Alarm Intermittent 18963 Floyd Bell Inc XB 09 630 Q S 1 iun Alarm
61. amp T g 7 C28TTA RD BK 2 CE LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BATGND C7P 3 4 GR WH C4P 7 2 BRNBATEND GND CABLE c3 GRAWHTS7 GND STUD 039 CRISBRN 1 L E Eo fo BK LS CABLE 12 8148 WH TS7 la 18 ls la C7P C9 JIB OPT e N WH TS1 lt 5 gt 25 n 00 mE WH RD C32BRK CODE GND STUD 19 18 CONTROL CABLE 12V DC BATTERY SWITCH to SPLICE C32BRK CR30 5 EE EE EIE EE EE EE ELE EE EE EE la lo 9 2lolklelele soo Do 2 lt lo w ol2 ele 2 gimp E 2 papo m8 5 8 2 gi OR RD R40LS2 Z 0 285909 5998 Sie 13 SPLICE 40152 ve zu es 9250 ez 2 6 0 7 A9 s NISI axe sl 5 RES exret jo JC1 PEZ L 1 m BOOM ro m EXTEND 6 2 RETRACT 7 7 DETAIL 6 CR13 6 6 1 DETAIL WORKLIGHT DRIVELIGHT 5 5 ORO 5 p 2 22 1516
62. 81 7 C12DRE BL WH C3P 12 b 20 8 8 59 amp i 5 24052 OR RD C4P 4 F E SOE 5 S BK RD C3P 9 N gt 9 C41RPM OR EK C2P 3 5 gt a C30EDC WH 4 y lt CIPBURD C3P 1 OOO 1 5 2 a C2PBD RD BK 2 GR 5 i e C37STC C1P 11 DT GR WH JIB CABLE C3PBF RDIWH C3P 3 C4P BR J2 DIODE WH Je prfe C36STCC BL C1P 10 5 WH BK 5 C3P GR 5 R C32BRK WH RD C1P 6 1 GP 9 WH 4 go 125 C29MS C1P 3 C2P BK 8 8 DO E 9 m 9 55 5 5 9 ciP GY 2 BLTSI6 5 Ns TS4 C35ESPD BK RD C1P 9 O s 5 TS6 C34SA BK WH 1 8 2 4 TS2 C33STR 7 ore i L TS1 C27AUX RD m 9 T RD BK 148 2 of G4 1 i 1 5 2 i 5 5 o g x i 2 10 L JC1 3 OR 6 9 Ee LJC2 4 RD
63. TS4 BK P3 odo q o 9 90 RPM lo 152 NG TS48 TS49 89 TS14 GLOW PLUG In DRIVE OPTION START 8 LEVEL SPEED i PUMP P2 N EMERGENCY 5 EE AE A RI 1 1 MODELS SEE DETAIL Part 77832 5 80 8 5 85 7 41 2004 Section 7 Schematics Platform Control Wiring Diagram 5 85 Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Box Wiring Diagram S 85 CE Models REV 1 Deutz F4L 913 Models after serial number 3576 A B G H 9 K L M N
64. 9 FUNCTION ENABLE 5 hs HIGH RPM 984 2 28 Bo x aa oz 2 3 838 lt 3 N 9 5 18 rf perc ccce un lg LEE ae 1 e GENERATOR Ka n ON C27 C45GEN GR WH 652 QRWA GENERATOR 5 lt OPTION E B1 BATTERY lt x 8 C1 8 C34SA BKWH 2 BRAUN PI uiu GLOW PLUG RELAY GLOW PLUG 8 Bo 6 Glow o PLUG 4 4 GLOW PLUG 8 000 G P FUEL VALVE OIL TEMPERATURE AND 5 OIL LED A 99 4 5 6 RBS EB 7 C33STR 4 ESSO KE Task 3 OIL TEMPERATURE SWITCH x T start a T m 5 a S DE i e ie o olei 5 15 C24TSTP o oo 8 5 ele 4 7 PRESSURE SWITCH a START a aja E 9 2 POWER RELAY i 3 zs 8 is avs 1 42 SIE 4 AUXILIARY 5 11 C21IGN WH fe lt lt WH m m E lt FUEL SOLENOID 1 1 5 7 lt R33STR 4 lt 5 5 B IGNITION START RELAY MU 9 1 x oz AUXILIARY 2 ed a Q EE STARTER MOTOR a
65. B 2 Du 2 gt 55 a SES SSS E 55 8 5 alu OSOE 5 5159 Ola HIF S E 5 3 3 5 125 O o u o ala al lt so ISIS gt lu ESS Eelam 66 3 e omma VSA Ak see 5 jc m 2 esz5asasassbossssspso p 86 amp SIE ss als ss 3 z u gu uj Xu uud lt lt gt 69 84 lt 955 5 5 lt GT lt 5 lt lt lt F alo E S est SiS S a S Joo J IANS 555 555 WH RD 2 SPLICE C32BRK OR RD R40LS2 SPLICE TO R40LS2 CR30 DETAIL WORKLIGHT DRIVELIGHT OPTION P E i gi 9 GND STUD i 26 85 2 26 5 9 1 1818 C7P 1 7 2 9 1
66. LIFT DRIVE OPTION 9 5 7 C9 JIB OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BR C RD H1 TILT ALARN GND STUD 19 18 CONTROL CABLE benennen RDLS IE BATGND 5 GND STUD m m m 2 WEIS 4 WH TS1 S 9 9 25999 8 5958 2 e PERS dl 98 o pa o gt 2 6255 Z 2 2 2 9 2 5 ala ER 28 5 55 5525 5 ERA 5 0 Pegi 26 EE 8 BE i fa h In T 7 1 5 5 8 axe i g 2 amp 3 5 5 SPLICE C32BRK ExRET 5 CR13 2 BOOM H 6 1 7 7 7 1 e LR RETRACT 6 JIB 6 CUTOUT OR RD R40LS2 5 5 5 T gt SPLICE TO R40LS2 4 gt 4 E TS15 4 3 N 3 DRIVE w 2 y L 1 012 JC2 PRIMARY BOOM CR26 11 11 UP DOWN AND AXLE CUTOUT DETAIL WORKLIGHT DRIVELIGHT DETAIL B GENERATOR 7 TURNTABLE 12050024040 de E 187 an x 14 RDWL2 mE JIB BOOM L1 5 ono
67. a mE R3 DRIVE LIGHT OPTION RELAY TB24AB 15AMPFUSE CR23 GR BK C2B 6 RDC4B 11 RD C4B 12 BRN GND LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS51 AUXILIARY POWER TOGGLE SWITCH TS52 ENGINE START TOGGLE SWITCH TS53 LP GAS SELECT TOGGLE SWITCH TS54 FUNCTION ENABLE RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 BOOM UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH CB1 CIRCUIT BREAKER ENGINE 15 CB2 CIRCUIT BREAKER CONTROLS 15A CB3 CIRCUIT BREAKER OIL COOLER OPTION 20 G1 VOLT METER GAUGE OPTIONAL G2 OIL PRESSURE GAUGE OPTIONAL G3 WATER TEMP GAUGE OPTIONAL G6 HOUR METER L2 CHECK ENGINE LED R2 TURNTABLE ROTATE LIMITING RESISTOR 10 OHMS R3 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS APU CR2 IGNITION POWER RELAY CR5 HORN RELAY CR17 HYDRAULIC COOLER RELAY 19 TURNTABLE ROTATE LIMITING RELAY CR23 DRIVE LIGHT RELAY OPTIONAL CR29 AXLE EXTEND LED RELAY IGNITION START MODULE CIRCUIT DESCRIPTION FROM TO 12 DRIVE ENABLE BL WH 6 12
68. 7 17 HYDRAULIC COOLER FAN RELAY BL RD C6 13 TS54 19 TURNTABLE ROTATE LIMITING RELAY 5 HIGH LOW H CR23 DRIVE LIGHT RELAY OPTION EE OR C6 33 en 2 CR29 AXLE EXTEND LED RELAY 2 ENGINE des CONTROLS ER TS59 557 R2 TURNTABLE ROTATE LIMITING RESISTOR 10 OHMS WH 21B R3 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS APU 1 RD B1 20A PLATFORM PLATFORM 5 RD 24AD LEVEL ROTATE IGNITION START MODULE 5 6 WH C6 34 2 GR 17A 7 an GR WH 4 7 z GROUND STUD u BL RD C4B 1 BRN G6 RD BK 2B BRN GND CIRCUIT DESCRIPTION FROM TO WH 4A 12 DRIVE ENABLE C6 12 BLWH C3B 12 ALL WIRES WH BK 5A 19 JIB VALVE GR WH C4B 7 GRWH S P 5 WH RD 6A 25 OIL PRESSEURE SENDER BL BK 5 16 BL BK S P WIRING a HARNESS 26 WATER TEMP SENDER GR BK C5 14 GR BK S P 1 1 28 ALARM RD BK C1B 2 RD BK C6 28 CONTROL BOX CONNECTIONS 29 2WD 4WD RD WH 5 24 RD WH C1B 3 8 1 30 E D C REV WH C1B 4 WH C5 21 cato R3 31 E D C FWD 5 20 WH BK C1B 5 GROUND 36 STEER LEFT AXLE RETRACT 1 10 6 36 STUD 43 HORN GR 2 5 GR CR5 86 1 45 GR WH 2 7 GR WH C5 12 i 60 AXLE EXT RET SELECT OR RD C6 39 OR RD C2B 4
69. T 1 5 1 C28TTA RD BK C1P 2 CE LIFT DRIVE OPTION EN FR REPLACE WIRE WITH THIS WIRING DIAGRAM 1 BATGND 7 3 4 BRN BATGND GND STUD 1 039 CR13 BRN d 2 9 amp 10 18 12 Q Q C GAP ee ee re CR27 15 2 13 2 JIB OPT T WETS WH TS1 S 18 9 18 9 C H1 BRN N ad _ _ RD H1 GND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT WH RD CO2BRK ALARM SWITCH SPLICE TO C32BRK rao ES Ea FT H 188 6925885 9 58913 390 8 Ps g gi naots2 z FEES 2 8598 ss x Sgela Sie EFESE 9 SPLICE R40LS2 z 5 7 s nio el mu i m 0 _ n D I gt 2 e NDD axe 5 e gt m e 5 5 EXRET 8 JC1 e 9 i L sss BOOM 9 6 1 EXTEND 1 7 7 7 DETAIL 6 _ a 6 6 DETAIL WORKLIGHT DRIVELIGHT 5 Li 5 ORO 5 puru ud 1 Pa GE ES 7 2 8 4 51
70. TS9 PLATFORM LEVEL BK J1 2 T 7 6 5 4 3 2 1 JC2 PRIMARY BOOM UP DOWN AND TURNTABLE E OR C4P 2 TS7 PLATFORM ROTATE ROTATE NO HORN GN BK L4 RD C2P 6 RDLS18 OR BK C4P 3 GR C2P 5 P3 REVA 7 17 Genie S 80 amp Genie S 85 Part No 77832 CE MODELS SEE DETAIL A 2004 Section 7 Schematics rsi Platform Control Box Wiring Diagram S 80 Deutz FAL 913 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 80 Models Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 80 Models REV 1 Deutz F4L 913 Models after serial number 3576 A B G H 9 K L M N
71. 067 9182 24 E gt gt 2 ETER 5 E PRIMARY BOOM EXTEND P24FS WH e BOOM gt 4 5 RETRACT BKWH 068 C177 ESTEE S 8 4 BOOM RETRACT gt gt a 1 1 069 COPERFBKIRD BOOM FLOW CONTROL 2 7 12 C12DRE BL WH 8 s lt C2P 3 Ly C612 CI2DREBLWH 5 lt 06 29 RI6PBRBKWH z 6 7E 58 DRIVE ENABLE LIMIT SWITCH 8 6 38 C8PBRBKMH 6 2 ot l 1 5 1 gt 06 30 C23BAT RD 178 135 e lt 4 2 C14PLU OR 4 UP DOWN PLATFORM LEVEL E C4P 3 C15PLD OR BK C20 1 C20 2 2 06 14 8 i PLATFORM LEVEL UP ee PLATFORM LEVEL 8 one ie M tl PLATFORM LEVEL DOWN 2 1 21 1 21 2 i i 5 027 4 6 C18JD PRR GR BK 1 DOWN 1 JIBBOOM T 8t lt C4P 5 17JU PRL GR T GA dish D28 3 GR BK 18 M H l 1 8 gt lt lt lt PLATFORM ROTATE RIGHT JIB DOWN e yp JBBOOM 6837 t 1 SEITMH Al PLATFORM ROTATE LEFT JIB BOOM UP 22 1 22 2 aod RIGHT pLATFORM RIGHT PLATFORM
72. 1 60 AXLE EXT RET SELECT OR RD C6 39 OR RD C2B 4 p i 61 AXLE RETRACT BL BK C3B 11 BL BK C6 21 1 7 32 5 80 amp 5 85 77832 2004 Section 7 Schematics assswssarsssassss Platform Control Box Wiring Diagram S 85 Deutz F4L 913 Models before serialnumber 3577 COMPONENT INDEX P2 EMERGENCY STOP BUTTON P3 HORN SWITCH TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START SWITCH 156 GLOW PLUG OPTION TS4 HIGH RPM SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH 7814 LOW HIGH DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 AXLE EXTEND RETRACT TOGGLE SWITCH 7847 GENERATOR TOGGLE SWITCH OPTION TS48 WORK LIGHT TOGGLE SWITCH OPTION L1 DRIVE ENABLE LED 140 AXLE EXTENDED LED JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE CR13 JIB BOOM CUTOUT RELAY S 85 MODELS U13 ALC500 Hi TILT ALARM eters REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND GND STUD CR27 HEISE TA watsi
73. R2 5OHMRESISTOR OR 06 33 PLATFORM PLATFORM u IGNITION START MODULE RD B1 20A LEVEL ROTATE U33 PLATFORM OVERLOAD MODULE o WH 21B 2 86 56 sel RD 24AD OR 14A 1 7 2 cree cal GR UA 8 WH C6 34 GR WH 4 7 i 2 1 GR BK 18A i OWRD 420 CIRCUIT DESCRIPTION FROM 5 7 1 GROUND STUD BLRD C4B 1 12 DRIVE ENABLE BLMH C6 12 BL WH 12 I BRN WH 4A 19 VALVE GRWHC487 GRWF S P I RD BK 2B 1 25 PRESSURE SENDER BL BK C5 16 BUBK S P w l ALL WIRES Pd 26 OIL TEMP SENDER GR BK 05 14 GR BK S P 5 28 ALARM RD BK 1 2 RD BK 6 28 9 WIRING i 8 IS HARNESS 29 2WD 4WD RD WH 5 24 RD WH 1 3 8 8 2 30 E D C REV WH 1 4 WH 5 21 CONTROL BOX 5 CONNECTIONS 31 E D C FWD WH BK C5 20 WH BK C1B 5 I 1 mm pss 1 36 STEER LEFT AXLE RETRACT 1 10 BL C6 36 z 5 43 HORN GR C2B 5 GR CR5 86 5 sag n 45 GEN OPTION GRWHC2B 7 GR WH C5 12 60 AXLE SELECT OR RD C6 39 OR RD C2B 4 61 AXLE BL BK C3B 11 6 21 I 1 EA DE OE EN EE 1 7 42 5 80 8 5 85 PartNo 77832 Section 7 Schematics Deutz F4L 913 Models after serial number 3576
74. le o I SECONDARY 4 L HE m DEI 4 ee 1 1 BOOM EXTENSION CYLINDER A LS LL LL LL mm mm t MASTER Herzen PE EE GR Gee BREED 1 7 GPM REGEN 4 lo ig illl as 2 4 ACCUMULATOR 22 oo T pis el N lm NRI d L AUXILIARY 17 BT _ __ dl dl u Jo APRI I I LIP x my CE pes e ee I e ee dese 1 J m eem cx ol ue _ sees sd D 1 Paess m GO SALAM ATA i T PLATFORM 191 je mu Fi ROTATE 3 4 2505 L wi i H1 QD i N MANIFOLD 102 4 I 4 p 4 1 HIGH 7 ber f 1 0 6 gpm 669 1 EE GT Function PRESSURE ub es m 26 9 He 227 Lmin 69 E369 rule ED o PUMP ELE ETTER 5 L NONE AXLE E
75. 5 7 E 8t C23 1 C24 2 D28 GR BK 18 M H D i 1 trou gt PLATFORM ROTATE RIGHT JIB DOWN 18 BOOM t GR 17 M H 4 PLATFORM ROTATE LEFT JIB BOOM E C22 1 C22 2 i RIGHT PLATFORM RIGHT PLATFORM 9 1 9 LEFT ROTATE Te LEFT ROTATE En asss 1 l C6 19 2 17 DESCENTALARMOPTION 4 7 C19JSV GR WH ME E P MESES SERA 1 3 5 amp fral 5 u x a JIB VALVES JIB VALVES 2 e Tea S a a 7 47 Genie S 80 amp Genie S 85 PartNo 77832 2004 Section 7 Schematics LEE SS ZZ zu EE Electrical Schematic 5 85 GM 3 0L Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Box Wiring Diagram S 85 GM 3 0L Models after serial number 3576 Section 7 Schematics January 2004 LESS SSS Ground Control Box Wiring Diagram S 85 REV 1 GM 3 0L Models after serial number 3576
76. 9 C9PERF C3B 9 P C6 9 C9PERF BK RD gt FLOW CONTROL 1 6 C32BRK WH RD 1 6 l 2 e S S TURNTABLE ROTATE LEFT ore 4 C4TRL WH C3B 4 ES C64 C4TRL WH 1 gt 5 2 i x a A TURNTABLE ROTATE RIGHT um C3P 5 C5TRR WH BK C3B 5 C6 5 C5TRR WH BK 1 gt our sC ve 6 8 K i 12 5 2 iu S 60 or 8 TURNTABLE ROTATE BAN ar m C3P 6 C6TRF WH RD C3B 6 C6 6 WH RD 1 gt FLOW CONTROL lt gt i TO AY a EP cisuitb 5 m PRIMARY BOOM UP lt 8 2 5 7 Batty 9 cx CIPBU RD C381 PRIMARY BOOM DOWN 4 1 06 2 C2PBD RD BK 1 gt 2 C2PBD RD BK C3B 2 E 4 P22ESTOP Ek C2P 3 C41RPM OR BK C2B 3 1 PRIMARY BOOM 2 06 3 RD WH 5 FLOW CONTROL 3 RD WH C3B 3 4 2 2 S PLATFORM LEVEL UP gt 4 1 S3LED BU RD C4B 1 6 14 C14PLU 1 1 iz E c es 2 5 lt 2 2 250 PLATFORM LEVEL DOWN e 06 15 C15PLD OR BK 1 1 gt 1 ams 1 1 Ly 2 t ese E el ES PLATFORM ROTATE LEFT JIB BOOM UP ES C6 17 C17JU GR 1 5 e 2 3 SS PLATFORM ROTATE RIGHT JIB BOOM DOWN 5 C618 CI8JD GREK 1 I
77. MARS e a 2 5 m g 29 C2B 5 L C2P 5 C46HRN GR GR 11 HORN RELAY 7 1 GREK 22 C7B 1 214 0619 CHSHRNIBR HORN o S N e C132PLI BUWH lt gt HYDRAULIC OIL TEMPERATURE ues SWITCH OPTION 2 6 C2B 6 OR 32 HYDRAULIC COOLING FAN OPTION T MM and 5 RD m 06 134 RD FLASHING BEACONS OPTION N ng 2 BI C5 amp 2 CA1RPM OR BK t 3 1 z 1 C53 CIOTAFWH y gi a 5 ALTERNATOR 4 pode 5 e 1 e 85 1155 d a 1 e 4 BATTERY i P20BAT RD lt 8 v LO 2 gt 8 GRAY 2 4 BLACK 8 GREEN 8 BROWN gt ROCKER STEER OPTION ONLY gt ADD 040 ONLY IF UNIT HAS 14 AND 148 Part No 77832 Genie S 80 amp Genie S 85 7 34 Section 7 Schematics 2004 Electrical Schematic 5 85 Deutz F4L 913 Models after serial number 3576 REVA
78. y PLATFORM LEVEL 1 Q DOWN C4P 3 C15PLD OR BK I 1 20 1 C20 2 I2 E 1 i 8 UP Al PLATFORM LEVEL UP e PLATFORM LEVEL DOWN 6 15 154 t i Al PLATFORM LEVEL DOWN 2 21 1 C21 2 9 5 2 4 6 C18JD PRR GR BK BOOM C17JU PRL GR 2 4P 5 7 5 8t P 254 C23 1 C24 2 D28 18 tro I i PLATFORM ROTATE RIGHT JIB DOWN up 8800 0617 BERE PLATFORM ROTATE BOOM UP 22 1 22 2 E RIGHT PLATFORM RIGHT PLATFORM LEFT ROTATE T Te LEFT ROTATE ee se ee ed E C6 19 DESCENTALARMOPTION 4 7 C19JSV GR WH aj ERR REN OD E NE SPESE CN RR OR 4 3 s J Je mox Zaa x I JIB VALVES Egg JIB VALVES lt E z 0 2 amp amp amp E o a 7 35 Genie S 80 amp Genie S 85 PartNo 77832 2004 Section 7 Schematics Gum Electrical Schematic S 85 Deutz 241 913 Models after serial number 3576 REV A1 C28TTA RD BK
79. BK WH C3B 8 N lt izg 8 C3 BOOM RETRACT C6 8 C8PBR BK WH 1 I E XN 5 l BATGND1 BRN e BOOM EXTEND RETRACT ENE il 9 C9PERF BK RD C3B 9 C6 9 C9PERF BK RD gt FLOW CONTROL C1P 6 C32BRK WH RD C1B 6 5 oe e S TURNTABLE ROTATE LEFT 4 C4TRL WH C3B 4 C6 4 C4TRL WH 1 gt E 15 2 lt E 2 ra TURNTABLE ROTATE RIGHT iu C3P 5 C5TRR WH BK C3B 5 C6 5 5 WH BK 1 2 a k PwR eC gt 6 8 L TURNTABLE ROTATE BEN TI 6 C6TRF WH RD C3B 6 6 6 C6TTRF WH RD 1 gt FLOW CONTROL BZ 19 2 i AS a S PRIMARY BOOM UP 2 C6 1 FA C1PBU RD 1 gt 5 gt 8 m P 9 CaP CIPBUIRD Ser 4 PRIMARY BOOM DOWN l 4 P24FS WH z amp 6 2 C2PBD 1 7 OF C3P 2 C2PBD RD BK C3B 2 N x P22ESTOP BK C2P 3 C41RPM OR BK C2B 3 E PRIMARY BOOM 1 gt j s lt 6 3 FLOW CONTROL x 3 RD WH C3B 3 2 amp PLATFORM LEVEL UP 4 4 1 S3LED BL RD 4 1 C6 14 C14PLU OR 1 N 2 o PLATFORM LEVEL DOWN C6 15 C15PLD OR BK 1 gt a 2 5 PLATFORM ROTATE LEFT JIB BOOM UP L c6 17 C17JU GR 1 gt SI i 2 m e SS
80. START Gi VOLT METER GAUGE OPTIONAL 30 38 h 7520 G G2 OIL PRESSURE GAUGE OPTIONAL BK WH 06 29 BOOM Per G3 WATER TEMP GAUGE OPTIONAL a GEB GE OIL COOLER TS62 G6 HOUR METER gt 4 RD 24AA OPTION TURNTABLE 12 gt pe 5 OR BK 15A Same TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS RD B2 H1 1 e 1 6 a _ 16 TE CR2 IGNITION POWER RELAY OR RD 16C I CR3 HIGH IDLE CUTOUT RELAY OR RD 168 SS 5 HORN RELAY 5 9 BK7B BOOM FUNCTION CUTOUT 1 m BL RD C6 13 RPM CR17 HYDRAULIC COOLER FAN RELAY o 1 RD 66 27 RD 27D 1 042 CONTROLS 1559 1557 CR23 DRIVE LIGHT RELAY OPTIONAL OR 6 33 nr PLATFORM PI CR25 AXLE RELAY 1 RD B1 20A CR29 AXLE EXTEND LED RELAY H WH 21B 1 2 OR 14A CR38 FUNCTION gt 86 86 86 86 24AD 1 h H 82 BRITA CR39 AUXILIARY PUMP RELAY 4 Re gt WH C6 34 GR WH C4B 7 7 9 1 u IGNITION START MODULE 5 OR RD 42C GF BICTBA rd GROUND STUD gt ed CIRCUIT DESCRIPTION BRN Pes WH 4A 12 DRIVE ENABLE BLWHC6 12 BLWH C3B 12 WHIBK 5A 19 JI
81. u1 14 1 1 r 5 iil WH 41 5 o BL J1 4 z 1 gt 25 Sz ot Be OE ESTIS WHJ3 2 T 1 RD BK 1 1 a 2 5 5 eq 5 SEN x m a i S 2 26 9 1 TS2 P25STR RD C9 3 J3 P24CONT WH C9 2 P2 P23SWBAT WH 7 2 BK RD C1P 9 P2 P22BAT BK C7P 1 1 7 JIB CABLE C19JSV GRAWH C4P 7 TS7 C18JD GR BK 4 6 BURD J1 16 TS7 C17JU 4 5 TS9 C15PLD C4P 3 BRN GND TS9 C14PLU 4 2 L40 S3LED BL RD C4P 1 C 7 z GN BL 10 r amp BLWH J1 6 SI TS16 C61AX C3P11 m GED 2 TS48 WL1 RD C2P 12 2 Me 7 4865 TS48 WL2 RD C2P 11 TS47 C45GEN GR WH C2P 7 S BKWH C1P 8 GR BK C2P 6 P3 C43HRN GR C2P 5 5 J1 8 TS16 C60AX OR RD 2 4 1 l o Lory1 9 i lt 5 Tyevut 3 C40LS1 OR 2 2 9 CETRF WHIRD C3P 6 ol sola e C7PBE C3P 7 9 Ze C12DRE BLWH C3P 12 u 559 l 5 1 C3P 8 5508686 5 e R40LS2 OR RD C4P 4 M 9 m
82. 1 2 TACHOMETER BRN GR49885 M po UP DOWN CB2 CIRCUIT BREAKER CONTROLS 15A I 5 BRN GND STUD RD 27B 1 ui I CIRCUIT BREAKER OIL COOLER OPTION 15 OQ 2 235 BRN GND G1 VOLT METER GAUGE OPTIONAL DE m 5 GROUND IGNITION 24 6 BATTERY START RD 1A G2 OIL PRESSURE GAUGE OPTIONAL WH 23B z KEY PWR MODULE m G3 TEMPERATURE GAUGE OPTIONAL jc 206 WH CR2 86 5 KEY ie n BK 33 7852 06 HOURMETER 7 BL RD 12 5 ENGINE DIECOO E 12 CHECK ENGINE LED 10 ENG FAULT START OPTION 24 50 L45 PLATFORM OVERLOAD LED BK RD 35B I CR2 IGNITION POWER RELAY I ago HIGH IDLE CUTOUT RELAY GR C2B 5 7856 BK WH 34A GLOW PLUG 1362 CR5 HORN RELAY CR2 CRS 6 RD244A ROTATE CR17 HYDRAULIC COOLER FAN RELAY 86 86 g m ARES CR23 DRIVE LIGHT RELAY OPTION 8 1 8 6 16 TI CR25 AXLE RET L O RELAY C5 18 1 1 CR28 TROMBETTA PULL IN RELAY m OR RD 168 1 CR29 AXLE EXTEND LED RELAY 9 BK 7B mum d m CR38 EXTEND FUNCTION CUTOUT RELAY BL RD 6 13 a J CR39 AUXILIARY CB1 5 CON
83. 8 6 WH RD 2 po E Ex C3P 5 WH BK 59 C3P 4 5 8 ise 10 a B igs s lt ex C64 CATRL WH 0151 6 615 2 44 TURNTABLE ROTATE LEFT 12w 5 2 Ed TURNTABLE ROTATE GEB C141 HE 014 2 C5TRR WH BK In 91 8 ROUTES RD 8 TURNTABLE ROTATE RIGHT S Pwr 3 lt oR gt gt 11 5 BZ 5512 C6 6 C311 031 2 iio C6TTRF WH RD TURNTABLE ROTATE ET iC FLOW CONTROL Ie 8 Em PRIMARY BOOM UP CUTOUT RELAY C64 C121 A 12 2 CIPBURD PRIMARY BOOM UP PRIMARY BOOM C6 2 C13 1 13 2 s lt C2PBD RD BK 4 5 PRIMARY BOOM DOWN y E C29 1 C29 2 16 lt epa RD WH PRIMARY BOOM ig sc M N FLOW CONTROL 5 E E our 52 ve lt gg xi 918 rd IE pwr 08 35 9 7 2 C2PBD RD BK lt 19 2 lt iS 3 RD WH i 84 E RN 5 9 C9PERF BK RD E 2 9 EE 8 C8PBR BK WH 5 4 PRIMARY BOOM EXTEND CUTOUT RELAY 2 BRN 7 32 lt 7 9 C67 C7PBE BK cist Clo PAFS WH ss lt lt PRIMARY BOOM EXTEND P24FS WH a Sal 2 B C171 C172 1 9 8 ees pene Il PRIMARY BOOM RETRACT gt 8 8 069 2721 De BOOM 3 FLOW CONTROL 12 C12DRE BLWH 8 Eps C612 CI2DREBUWH
84. 999 F l uu e G LL _ 5 5 SZ O gt gt gt o 3 SS S gt az 9 uk a mI gt 55 lt 8 1 5 9 DIS 2 2 uuu lt lt lt lt 9 a user 5 9666 Og 58 se 215 2 52 2 gt lt or EI 1 EIEIE al oic 1 x gels bela EY ER EE amp B 26 8 gt 6 9 2 053 5 m 5 Bi o ELFEgOISISBSZS5rIrzSi9z sooo z tc E 215 55 mi gt 25 05 SIEKTES IE E ola saals i D I 2 SO u uj X lt lt S F J m tr a lt 895 055 6 2 25 2 8 5 e lola gaia gg RRISE S lag gelas 2 Ie BE eaa 55 5 E RDLS18 i 7 1 S 1 l 1 WH C7P 2 1 o9 BK C9 1 RO 2 OF i HE GN BK
85. C n 61 AXLE RETRACT BL BK C3B 11 BL BK C6 21 Mad A a ER 4 7 26 Genie S 80 amp Genie S 85 PartNo 77832 2004 Section 7 Schematics Platform Control Wiring Diagram 5 80 Perkins 704 30 Models before serialnumber 3577 REV N M L COMPONENT INDEX P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 HIGH RPM TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH 7514 LOW HIGH DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 AXLE EXTEND RETRACT TOGGLE SWITCH 847 GENERATOR TOGGLE SWITCH OPTION TS48 WORK LIGHT TOGGLE SWITCH OPTION L1 DRIVE ENABLE LED L24 GLOW PLUG LED L40 AXLE EXTENDED LED JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE U13 ALC500 H1 TILT ALARM EE EA EE 1 CE LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BATGND GND STUD CR27 WEIST e II wasi WH RD C32BRK SPLICE TO C32BRK OR RD R40LS2 SPLICE 8401852
86. G Proportional solenoid valve 12V DC 4060 schematic items W MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 the coil for resistance See How to Test Coil Part No 77832 Genie S 80 amp Genie S 85 Section 5 Repair Procedures January 2004 MANIFOLDS 2 Connect 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 10Q Genie part number 27287 The battery should read 9V DC or more when measured across the terminals 1 COIL AMMETER T 7 9 ib VV Pilli 100 RESISTOR BATTERY iaar N multimeter 9V DC battery 100 resistor coil Dotted lines illustration
87. amp P116HYD RD 8 93 E M T 4 leur 2 RD RD gt 4 F APU BATTERY OPTION K e U m BATGND BRN BATGND BRN 1 I T
88. temperature terminal switch normally open Gauge Circuits crossing Ne no connection Toggle switch SPDT Oil pressure switch normally closed Diode Hour meter L3 z sending unit LED B 3 8 Toggle switch DPDT 25 aad Fuse 29 with amperage naa rm DT E Battery separator Control relay contact Fuel or RPM normally open solenoid CB1 Starting aid glow plug Circuit breaker flame ignitor with amperage Coil REVA FS1 BLK Foot switch P1 s Emergency Stop button normally closed Hydraulic oil cooling fan Auxiliary pump 510 Resistor with ohm value Tilt sensor 7 4 Genie S 80 and Genie S 85 Part No 77832 2004 Section 7 Schematics 25 psi 1 7 Filter with bypass valve relief setting fixed displacement c bi directional variable displacement bi directional 44 Motor 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder vv Accumulator 035 0 89 with size Shut off valve n n Check valve 200 psi 13 8 bar Relief valve with pressure setting
89. 06 29 RI6PBRBKWH 658 DRIVE ENABLE LIMIT SWITCH d 24 C6 38 C8PBRBKWH N g 2 JE 8 C6 30 C23BAT RD 5 2 sup o PLATFORM LEVEL Down C4P 3 C15PLD OR BK 20 1 20 2 C614 OR 14 MH PLATFORM LEVEL UP PLATFORM LEVEL C615 OR BK 15 MH He lt lt 4555 PLATFORM LEVEL DOWN 2 21 1 21 2 027 4 6 1 PLATFORM ROTATE p Lem cars C23 1 C24 2 SRBICIS Mie D 4 PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE C6 17 17 ti PLATFORM ROTATE LEFT JIB UP E C22 1 22 2 m 06 19 L1 DESCENT ALARM OPTION x le x u m x S RAAE N TAAR ORA IO m 7 23 Genie 5 80 amp Genie 5 85 77832 2004 Section 7 Schematics man i Electrical Schematic S 80 GM 3 01 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Box Wiring Diagram S 80 GM 3 01 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 80 REV A1 GM 3 0L Models after serial number 3576
90. 3 5 go 013 PLATFORM CONTROLS CIRCUIT BOARD ALC500 9958 359878295 598999 85 89 25592 2893 3555 TILT ALARM 5599 5 3580 5028 2959 k 5 211219 s Y 3 e C28TTA RD BK C1P 2 E a a a a EE BATGND C7P 3 CR13 BRN C2P 9 amp 10 lol lo fo _ 2 13 2 12 19 9 JIB ORT H1 BRN gt GROUND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH 5 a a enn lg gg gn ng gg ggg gg mE Doe m lt 2 S 9 2 528906 E 22525 288 BE amp 2180 5 210305 2 lt lt 2 1 E o 2 ZS ste 5 S lt E x I amp mt oo v P 2 019 2 x oz a ID 5586 AXLE m D ex 2 2 ExrEND amp 2 2 gt 5 5 d 5 5 547 6 GENERATOR 1 7 7 7 CE LIFT DRIVE OPTION oc 6 6 He 5 JC1 c qu REPLACE WIRE WITH THIS WIRING DIAGRAM TURNTABLE be E ROTATE ie 4 EXTEND t TS15 DRIVE STEER UP DOWN 113 3 DRIVE
91. 5 ES 4 c f mee EIS X 25 psi espsi MEDE 1 1 4 4 5 2509 Z COOLER 1 mE AUX lo Y TA m 29150 v T2 STi 572 me LIM SW RESERVOIR COUNTERBALANCE VALVE RATIO PRESSURE A 31 1000 5 A 3 1 2000 PSI 5 A 3000 PSI PA a 5 A 31 3300 PSI S 2721 7 7 A 3500 PSI 1 HYDRAULIC ROTARY COUPLER A 5 1 3500 PSI L a Jes a t TT aal vi B STEERING Axte SELECT n 6 i CYLINDERS MANIFOLD Ter A B RIGHT A 3 63 FRONT AXLE EXTEND Fe ys TEE 69 CYLINDERS OSCILLATE VALVE 89 L d Id n eh 50 FLB UH 1 ade i 7 E 2g seo f 193 ber B X OSCILLATE CYLINDERS 7 6 Lmin p 169 ze min 6 X BU 50 50 N 1 Co en L 508 i II 69 paid ro F ct 2 bar t 04 PER IE a puli 6 ER 7 6 Lmin EV o co 71 TIEROD ar 1 FRONT I 8 REAR 1 2 LEFT a Bii 4i LEFT L tJ DRIVE MANIFOLD A A L 77832 Genie 5
92. BATGND 2 N MOTOR STROKE 05 24 C29MS RD WH 1 gt 2 S DRIVE BRAKE VALVE H C5 23 C32BRK WH RD 1 2 gt 1 9 C35ESPD BK RD C1B 9 HIGH RPM FS Oe ee eg a eS eee a a csal 3 DRIVE EDC FORWARD IX 5 C5 20 C31EDC WH BK D NGINE SP ED DRIVE REVERSE HIGH RPM C6 28 C28TTA RD BK WH i e 6 23 P23BAT RD A RD l LEVEL SENSOR x GENERATOR lt lt i el le SWITCH ON 2 7 C45GEN GR WH C2B 7 4 GND1 ne LEVEL SENSOR sg VBAT1 RD Ka 58 2 1 C39LP BURD 2 1 1 IP lt GAS GENERATOR 5 12 C45GEN GRWH lt 9 9 1 7 C33STR E E N N e E ENGINE START a 7 2 VN ENAA m C6 24 P23FB RD E y FLASHING BEACON 5 7 AUXILIARY S COTAUX HD 2 C6 82 C32TA WH RD TRAVEL ALARM e m E n 06 19 lt C2DA DESCENT ALARM a 1 2 C28TTA RD BK C1B 2 06 16 C43HRN BK i pe lt lt lt HORN 5 BATGND e LE o 2 5 C43HRN GR C2B 5 a P23BAT WH 22 C7P 3 BATGND BRN BATGND
93. STEER LEFT CDE1 BL WH E C5 21 C30EDC WH A 15 ee Ne DRIVE EDC FORWARD RKOUT 6 5 20 C31EDC WH BK 6 5 YOUT 5 T C1P 5 C31EDC WH BK D 2 DRIVE REVERSE 915 A 5 Ee v Z va wy 06 32 TRAVEL ALARM OPTION 12 An 4 05 23 C26 1 C26 2 C32BRK WH RD M d 19 lt CiP6 CODE MED BRAKE RELEASE VALVE C1P 3 C29MS RD WH C524 RDWH 0281 C28 2 lt MOTOR STROKE p _ IR C3P 6 C6TRF WH RD 69 Ex 5 CSTRR WH BK 59 igu C3P 4 C4TRL WH z lt lt x i SE C64 CREW 15 1 A 15 2 E9 TURNTABLE ROTATE LEFT 22 2 2 4 8158 LEFT C6 5 14 1 C14 2 51 8 AD s t Cornel WGK TURNTABLE ROTATE RIGHT 5 2 lt 12 EZ 6 6 cerrar wup _ 3171 6312 TURNTABLE ROTATE LE ER H FLOW CONTROL R2 Em 4A PRIMARY BOOM UP CUTOUT RELAY C64 C124 A C122 CIFBURD PRIMARY BOOM UP PRIMARY BOOM C13 1 13 2 C62 s s CERBORDIBK MK 4 PRIMARY BOOM DOWN EER i i E lt _ 663 _ C 91 Jp 0292 PRIMARY BOOM ig lt FLOW CONTROL 3 3 s z 1 C1PBU RD 8 58 5 pwr lt gt 9 7 2 C2PBD RD
94. WH 23B HS 7 KEY PWR MODULE 1 1 O s KEY BYPASS i G2 OIL PRESSURE GAUGE OPTIONAL _ WH CR2 86 JGNJFUEE ON BK 33 TS52 PES UN 03 TEMPERATURE GAUGE OPTIONAL T 25 8252 LB LO 10 ENG FAULT a OPTION 06 HOURMETER 248 TS58 1 5 12 CHECK ENGINE LED BK RD 35B Boom 3 145 PLATFORM OVERLOAD LED 4 GR C28 5 1556 IGNITION POWER RELAY 5 4 CR2 CRS BK 22B BD GLOW PLUG CR3 HIGH IDLE CUTOUT RELAY 6 m 86 86 86 OR BK 15A ROTATE CR5 HORN RELAY m 1 RD B2 H1 CR8 BOOM FUNCTION CUTOUT RELAY 18 Boere 3 BRDSEA HYDRAULIC COOLER FAN RELAY 5 1 ETE CR23 DRIVE LIGHT RELAY OPTION 5 1 TS54 TO 1 CR25 AXLE RET L O RELAY ee i Q d CR28 PULL IN RELAY 5 C6 13 GE en 19 CR29 AXLE EXTEND LED RELAY 5 pe ENGINE CONTROLS a TET CR38 FUNCTION RELAY OR 66 33 RD 24A PLATEORM PLATFORM CR39 AUXILIARY PUMP RELAY 1 RD B1 20A LEVEL R2 5OHMRESISTOR H WH 21B 1 2 m a ra ORJAA Ui IGNITION START MODULE GR 17A H Ice 5 8 L 4 WH C6 34 GR WH C4B 7 5 OR RD 42C GR BK 18A I rd er CIRCUIT DESCRIPTION FROM 1 12 DRIVE ENABLE GROUND STUD BLWH
95. al a 2 5 e B 485 5 g E AUXILIARY 9 lt 4 x z lt ZU 7 8 00129 PEE Sz0r IOKE GRESO 5355 ce C27AUX RD 58g 6 lt lt EE a Ss x 208 JO Tao Q l Q Z 8 5 EE m a 8 STARTER MOTOR o o 55 v A A Es E Sit L AUXILIARY POWER fo id r x RD 52 4 0627 HD 4 AUXILIARY POWER RELAY e I 5 al AUXILIARY PUMP zo gt t2 7 2 P23BAT WH e rp en B 5 WH a Y C1P 2 C28TTA RD BK C6 28 C28TTA RD BK WHI ALARM LI fe 1 N C6 23 F2SBAT RD PD hae 5 LEVEL SENSOR Y AM E C2P 5 C46HRN GR GR HORN RELAY d 20 GE 7 1 22 7 1 as C6 16 C43HRN BK 4 HORN M a I C132PLI BL WH A C6 34 lt R21IGN WH 4 HYDRUALIC OIL TEMPERATURE C1B 12 SWITCH OPTION P134PWR GR BK lt B G lt poU 1 e 06 33 HYDRAULIC COOLING FAN OPTION AA RD 6 24 C134 E H 4 FLASHING BEACONS OPTION 7 N z lt on oF 9 oje Q5 ALTERNATOR 5
96. 1 RNC NM ee CO SI DM EE E GANG 1 i B A PRIMARY BOOM UP RD C3B 1 RD C6 1 1 RD S P VOLT PRESSURE COOLANT TEMPERATURE 1 BOOM DOWN 14 029 RD BK C3B 2 amp C6 2 2 015 RD BK S P PRIMARY BOOM RD WH 3 RD WH 6 3 RD WH S P TURNTABLE ROTATE RIGHT WH C3B 4 WH C6 4 4 WH S P 5 1 TURNTABLE ROTATE LEFT WH BK C3B 5 WH BK 6 5 5 WH BK S P i TURNTABLE ROTATE WH RD 6 WH RD C6 6 6 WHIRD S P I DRIVE LIGHT OPTION RELAY BOOM BK C3B 7 BK C6 7 7_ cRe e6 stud 5 61 BK WH C3B 8 6 8 8 057 BK WH S P EXTEND RETRACT BK RD C3B 9 BK RD C6 9 9 BK RD S P 24 SBD DESCENT ALARM EF BL C3B 10 10 BL S P 15 AMP FUSE 2 11 5 16 sel LEVEL UP C4B 2 6 14 14 OR S P CR23 PLATFORM LEVEL DOWN OR BK C4B 3 OR BK C6 15 15 OR BK S P 30 1 PLATFORM LEFT mE GR 66 17 16 GRSR 1 2 6 1 lt 17 1 1 1551 PLATFORM ROTATE RIGHT GRIBK C4B 6 GRIBK 6 18 18 GRIBK S P EMERGENCY I i RD C4B 11 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD BI SP STOP AUXILIARY PU
97. BRN gt gt 14 gy a as ama m lt C32BRK WH RD 5 23 62621 m puc 19 HIED BRAKE RELEASE VALVE C29MS RD WH C5 24 C 9MSRDWH 28 1 28 2 20 lt lt MOTOR STROKE 2 1 8 6 WH RD 125 972 D E EE C3P 5 C5TRR WH BK 2 5 BO lt C3P 4 CATRLWH 5 az E C6 4 C151 C152 s lt WH TURNTABLE ROTATE LEFT 8 gt re LEFT C6 5 C14 1 C14 2 Rura gt 3 OSTER WEBI TURNTABLE ROTATE RIGHT Pwr gt m E eNp 2 lt gt 12 E C6 6 cerrar 2311 31 2 TURNTABLE ROTATE FLOW CONTROL x 5 TY 8 Ra PRIMARY BOOM UP zh 1 CUTOUT RELAY 12 1 12 2 Pus C1FBA RD PRIMARY BOOM UP m PRIMARY BOOM C13 1 C13 2 DOWN 06 2 s CORGDHDIBK PRIMARY BOOM DOWN 1 k T 5 7 lt z i 06 3 291 E 0292 PRIMARY BOOM FLOW CONTROL s lt i 5 N 3 5 1 C1PBU RD 8 5 1 8 lt BZ 5 gt 2 C2PBD RD BK 9 GND 24 BRN gt gt 10 8 C3P 3 RD WH 2 8 9 C9PERF BK RD i lt E 2 E C3P 8 C8PBR BK WH i PRIMARY BOOM EXTEND 3 lt CUTOUT RELAY BRN 5 7 7 1 8
98. BU 13 Check valve 5 psi 0 34 bar BY oss 14 Flow divider combiner valve BW Plug Torque Specifications Function Torque 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 130 140 ft lbs 176 190 Nm 25 30 ft lbs 34 41 Nm 35 40 ft lbs 47 54 Nm Charge pressure circuit Drive motor anti cavitation Controls flow to flow divider combiner valves BQ and BW Drive motor anti cavitation Drive motor anti cavitation Charge pressure circuit that gets hot oil out of low pressure side of drive pump 15 18 ft lbs 20 24 Nm 25 30 ft lbs 34 41 Nm Drive motor anti cavitation Controls flow to steer end drive motors in forward and reverse 130 140 ft lbs m 176 190 Nm Drive motor anti cavitation 25 30 ft lbs 34 41 Nm Equalizes pressure on both sides of flow divider combiner valve BQ 35 40 ft Ibs 47 54 Nm Equalizes pressure on both sides of flow divider combiner valve BL 35 40 ft Ibs 47 54 Nm Equalizes pressure on both sides of flow divider combiner valve BW 35 40 ft Ibs 47 54 Nm Drive motor anti cavitation 25 30 ft Ibs 34 41 Nm Controls flow to non steer end drive motors in forward and reverse 130 140 ft lbs 176 190 Nm Description Hex size Torque SAE No 4 3 16 13 ft Ibs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm 8 5 16 50 ft lbs 68 Nm 5 56 Genie 5 80 amp Genie 5 85 778
99. Down C4P 3 C15PLD OR BK C4B 3 o E C3P 10 JDALARM BL 3 lt C3B 10 C4P 5 C17JU GR C4B 5 BATGND BRN 2 UP e e s e JIBBOOM D27 SS STEER RIGHT AXLE RETRACT DOWN C4P 6 C18JD GR BK C4B 6 C6 37 C37STC BL BK 1 gt B T RIGHT PLATFORM ROTATE re STEER LEFT AXLE EXTEND eLEFT 2 Loer t SAL e AXLE NOT EXTENDED E 4 7 lt C19JSV GRAWH 7 A PRESSURE SWITCH 30 OPEN WHEN AXLES ARE 7 FULLY BATGND 2 MOTOR STROKE 5 gt j 5 24 C29MS RD WH 1 2 JIB VALVES 4 2 DRIVE BRAKE VALVE E 5 C5 23 C32BRK WH RD 1 gt 1 9 BK RD HIGH RPM FS 5521 GEDEDE WH DRIVE FORWARD ry p C5 20 C31EDC WH BK D pog ENGINE SPEED m DRIVE EDC REVERSE 1 e B HIGH RPM 6 28 C28TTA RD BK WH SESSE 5 e E In OFF 9 b GENERATOR 2 06 23 P23BAT RD A RD dA SENSOR 1 C2P 7 C45GEN GR WH C2B 7 4 GND1 LEVEL SENSOR E ee ee AY c rr ee 1 RD lt 8 C2P 1 C39LP BURD C2B 1 FUEL 4 ER Y GAS GENERATOR C5 12 C45GEN GR WH lt 1 D 1 7 C33STR C1B 7 e ENGINE START m
100. OIL PRESSURE SWITCH 4 ENGINE Jr ee amp RBS 4 START i ag gt POWER RELAY n 8 m C5 11 7 C21IGN WH RD He 2 o WH 62 5 NTind H m C27AUX RD FUEL SOLENOID lt J S 927 R33STR 3 5 5 IGNITIOIN START RELAY 3 2 1 I Q AUXILIARY u EN 9 cs POWER Ss K _ STARTER MOTOR 55 RD L da d IEB 2 782 D 9 aar WH amp Bo a g C1B 2 ER 06 27 C27AUX RD POWER RELAY a 1 2 C28TTA RD BK AUXILIARY rt E 8 dd C25PSR BL BK OIL PRESSURE adi 97 L SENDER OPTION Nt 5 4 VOLT METER C26TSR GR BK OIL TEMPERATURE SENDER OPTION 8 Cet C28TTA RD BK 4 C3P 10 C133PLABL d 28 PM TERALABM 3 134 6 23 lt LEVEL SENSOR lt BEE EE T C2B 5 ps GR IA RELAY d A 7 1 GNE en Z 0616 C43HRN BK sh g T n le 9 e C132PLI BL WH lt gt 11 GES RZIIGN WH HYDRAULIC OIL TEMPERATURE einen 2 SWITCH gt 3 C2P 6 C2B 6 a Ba C693 MEM 1 HYDRAULIC COOLING F
101. RD WL1 i 114 1 z AORDWL2 1 3 7815 3 I f TS15 DRIVE z L48 I 5 i 2 L40 2 2 i 1 012 1 1 N JC2 1 1 JC3 5 oo PRIMARY BOOM qp UP DOWN AND AXLE CUTOUT TS48 TS49 7 1 i 1 ROTATE TS7 EG PLATFORM 012 188 Ee pis 1 3 Gp 010 HO NO O GE Oo ORO c RO Um HORN PIG TS1 O 0 O We NC 1 AUXILIARY PUMP TS4 TS3 7514 FUEL SELECT 159 HIGH LOW DRIVE START 8 PLATFORM RPM LEVEL SPEED 2 STOP Teater CHEN EE ee ENE De dep Ego EOM m Re Medo N ERKENNEN EER de EHI HF Ep RE dE MODELS SEE DETAIL PartNo 77832 Genie S 80 amp Genie S 85 7 49 2004 Section 7 Schematics s WdhisIrrr i Platform Control Box Wiring Diagram S 85 GM 3 0L Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 85 Pe
102. TB33A 27 051 RD C7P 2 P23BAT WH C5 5 The BK R1 E H IGNITION START RELAY STARTER MOTOR C7B 2 1 e P24FS WH WH 2 28 RD BK 02 TB24 C1B 2 AUXILIARY POWER RELAY C6 27 C27AUX RD r H1 BK J RD C3B 10 C3P 10 C133PLA BL WH G AUXILIARY PUMP 2 OIL PRESSURE SENDER OPTION TB28 VOLT METER OPTION C25PSR ER C26TSR GR BK C28TTA RD BK WH OBS WATER LEVEL SENSOR at P134 RD RD HORN RELAY q HORN C7P 1 P22BAT BK C7B 1 C43HRN BK January 2004 C328 lt C132PLI BL WH P134PWR GR BK KT H2 HORN 24 12 p C6 34 R21IGN WH HYDRAULIC OIL TEMPERATURE SWITCH OPTION 9 HYDRAULIC COOLING FAN OPTION TB134 22 51 9 GRR 6 134 FLASHING BEACONS WH 5 2 lt C41RPM OR BK Perkins 704 30 Models after serial number 3576
103. t 96 13 S3LED BURD AXLE EXTENDED 4 7 lt C19JSV GR WH C4B 7 T PRESSURE SWITCH 29 OPEN WHEN AXLES ARE FULLY EXTENDED BATGND 2 Ld N MOTOR STROKE 05 24 C29MS RD WH 1 gt 2 a 8 DRIVE BRAKE VALVE Fl 5 23 lt lt WH RD 1 lt 2 gt 9 BK RD C1B 9 HIGH RPM FS i 4 e a 5 21 WH L DRIVE EDC FORWARD 7 5 20 C31EDC WH BK D 18 NGNE SREED lt iV DRIVE EDC REVERSE i 1 HIGH RPM C6 28 C28TTA RD BK OFF T eT C6 23 P23BAT RD RD i rn LEVEL SENSOR ENE GENERATOR SWITCH 1 2 7 C45GEN GR WH C2B 7 4 GND1 BRN B 75225242523 LEVEL SENSOR E 8 1 8 34 BK WH C1B 8 Qi v GLOW PLUG RD lt m i lt lt GENERATOR OPTION 5 12 C45GEN GR WH lt e AMO 1 7 C33STR C1B 7 ENGINE START yN e 4 C6 24 P23FB RD us ENA 0 E 4 FLASHING BEACON e m AUXILIARY PUMP CES RD 2 C6 32 C32TA WH RD TRAVEL ALARM a 2 c6 19 C2DA RD BK F DESCENT ALARM a amp Z 1 2 C28TTA RD BK 1 2 ma 6 16 C43HRN n HORN 4 2 C2P 5 GR C2B 5 OPE e 1 ER 4 5 22 C34SA BK WH i a
104. 8 5 9 gt c2 1 C39LP BL RD ELE LP FUEL SELECT E Y HOUR METER Gas 2 B o FUEL SELECT Gas m BRN 9 7 C8 9 YE BK 5 13 C87 WH BL u 5 18 8 2 LTBL 5 2 C41RPM 8 8 C5 19 P23BATSA RD C84 PU ENGINE lt lt HARNESS 1 7 C33STR 2 C5 10 C39LP BL RD C8 1 ul 4 C5 5 C33STR BK C8 3 RD BL 5 START C5 6 C27AUX C8 5 GR BK 9 5 TER C21IGN WH 086 20 RD 5 8 8 11 5 9 p C8 12 BK am Ee x o 5 NES x 6 ag 2 x 8 B aco 5 Ed Fle lt E AUXILIARY g 3 POWER E Li d N 1 5565 8 5283 5 E gt C27AUX 025295 lt lt gt gt oo 9 x z gt Heat oe pet IN 2 1 8 I 8 STARTER MOTOR Qo I i ig 5 leenen Ri L AUXILIARY D POWER u x RD Q 9 lt lt 0627 G27AUX RD jjj AUXILIARY POWER RELAY e l tie AUXILIARY PUMP d C7P 2 P23BAT WH e s Em E 3 e 6 5 vA WH SU 8 B s C28TTA RD BK 1 2 28 C6 28 lt ALARM
105. Electrical Schematic S 85 Section 7 Schematics 5 3 _ C107AF WH gt y IND 02 w REGULATOR o P20BAT RD OPTION ALTERNATOR START BATTERY No 77832 Genie S 80 amp Genie S 85 7 52 Section 7 Schematics 2004 Electrical Schematic 5 85 Perkins 704 30 Models after serial number 3576 REVA C28TTA RD BK N 10 er BRN GROUND 4 C6 13 S3LED a o AXLE EXTENDED PRESSURE SWITCH 1 531 BL RD 1 IT D a OPEN WHEN AXLE FULLY EXTENDED l Mi AXLE EXTEND RELAY C6 39 C60AXOR RD C344 C342 ge SEN 25 COIAX BLER lt lt AXLE EXTEND RETRACT SELECT
106. J3 3 GN BK H1 039 BK RD H1 BRN J1 14 OR J1 13 WH J1 5 ojoj BL J1 4 JC3 DRIVE WH J3 2 TS4 HIGH LOW RPM RD BK H1 RD LS CABLE TS2 P25STR RD C9 3 J3 P24CONT WH 9 2 P2 P23SWBAT WH C7P 2 P2 P22BAT BK C7P 1 TS7 C18JD GR BK C4P 6 TS7 C17JU GR 4 5 TS9 C15PLD C4P 3 TS9 C14PLU OR C4P 2 L40 S3LED BL RD 1 HI C133PLA GN BL C3P 10 TS16 C61AX BL BK C3P11 TS48 WL1 RD C2P 12 TS48 WL2 RD C2P 11 TS47 C45GEN GR WH 2 7 DLITE GR BK C2P 6 GR C2P 5 TS16 C60AX OR RD C2P 4 40151 OR C2P 2 C6TRF WH RD C3P 6 C7PBE BK 7 C12DRE BLANH C3P 12 C8PBR BK WH C3P 8 R40LS2 OR RD 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 12 C1P 9 1 7 RD 9 3 BL RD 91 16 82 5 BL BK J1 7 BK WH 8 BL WH 1 6 TS15 DRIVE ENABLE TS6 W PLUG OPTION RD WH 1 8 BRN J1 10 OR J1 9 YEL J1 3 FOOT SWITCH C1P 4 RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C37STC C1P 11 JC1 BOOM EXTEND RETRACT RD C1P 1 2
107. TB41 5 19 46 08 GLOW PLUG TB23 IGNITION START MODULE START RELAY 6 BATTERY 10 ENG FAULT E L5 BL RD C5 15 1 24 BURD OIL PRESSURE LED WATER TEMPERATURE SWITCH 2 TACHOMETER H9 3 START INPUT TB33 C27AUX RD lt lt a NC a o OIL PRESSURE SWITCH 06 6511 WH WH RD 22 wH 1 m NI TING G POWER RELAY FUEL SOLENOID TB27 RD pessar 782 24 WH 2 WH C1B 2 C28TTA RD BK L WK lt TB23 LE gt s BK hd RD C2P 5 10 lt 10 28 24 5 5 lt BK R D51 1 IGNITION START RELAY STARTER MOTOR 6 27 C27AUX AUXILIARY POWER RELAY C21IGN WH C25PSR BL BK AUXILIARY PUMP OIL PRESSURE SENDER OPTION C6 28 C26TSR GR BK VOLT METER OPTION WATER TEMPERATURE C28TT
108. lt A Is 7 9 REPLACE WIRE WITH THIS WIRING DIAGRAM BRN TILT 12VDC __________________________ LS CABLE ___ ALARM GND STUD 19 18 CONTROL CABLE Barreny FOOT SWITCH BATGND 5 GND STUD 72224 CR27 dr w o ss w m lt o z z w Dis c Weier Hl WH TS1 gt A OlD DIC z m h 5 TYD ox g s B o sZ 352 o 5 9 Z z doo 15 15 S 5 o 5 Fig 2 rr gez 2 e xm A 9 WH RD C32BRK l gt U D Qr 79 7 T l 5 a aia Pz 5 S 9 9 axe S sales a 5 3 z 3 nh SPLICE C32BRK 9 EXRET 8 301 9 e BOOM CR30 H 6 EXTEND 7 7 7 g RETRACT 6 6 I 5 OR RD 8401 52 T 1 3 SPLICE R40LS2 lt gt 4 4 1515 l4 y 3 DRIVE D 3 2 140 3 ENABLE 148 gt L 1 012 JC2 JC3 PRIMARY BOOM 1 cR 1 S 1 7 AXLE CUTOUT DETAIL WORKLIGHT DRIVELIGHT DETAIL GENERATOR 1 3 1 are 1
109. n ES 5 C5TRR WH BK C3B 5 C6 5 CSTRR WH BK 1 5 s ve 6 a a E 5 2 55S 6 TURNTABLE ROTATE GND BRN T 6 C6TRF WH RD C3B 6 C6 6 C6TTRF WH RD 1 gt FLOW CONTROL 2 em 2 s fece lt N PRIMARY BOOM UP C6 1 C1PBU RD 1 gt GND gt 9 2 M E 1 C1PBU C3B 1 1 PARS NA 2 amp CO PRIMARY BOOM DOWN z 9 C62 C2PBD RD BK 1 gt 9 2 C2PBD RD BK C3B 2 B 5 4 22 5 C2P 3 C41RPM OR BK C2B 3 PRIMARY BOOM 5 6 3 RD WH gt FLOW CONTROL x x C3P 3 RD WH C3B 3 2 d v S PLATFORM LEVEL UP l 1 S3LED BL RD C4B 1 C6 14 C14PLU OR 1 2 Y PLATFORM LEVEL DOWN C6 15 C15PLD OR BK 1 gt u PLATFORM ROTATE LEFT LL 06 17 C17JU GR 1 gt z 2 m d EN C4P 2 C14PLU OR C4B 2 Y 2 59 PLATFORM ROTATE RIGHT e PLATFORM LEVEL 06 18 C18JD GR BK 1 a P DOWN C4P 3 C15PLD OR BK C4B 3 li o 10 4 JDALARM BL 3 lt C3B 10 5 C17JU GR C4B 5 48 N 2 STEER RIGHT AXLE RETRACT C4P 6 C18JD GR BK C4B 6 4 06 37 C37STC BUBK 1 gt 2 RIGHT e ROTATE m STEER LEFT AXLE EXTEND C6 36 BL 1 gt B
110. 23 2005 229258 05598 3 99245 3598293967 0888989 es 2858 59854 299 T 1 STOSI PPPQOS 1 1 S 3 2235 a a p og L 5 amp x 4 e C28TTA RD BK C1P 2 BATGND C7P 3 CR13 BRN C2P 9 amp 10 N gt 5 12 2 12 5 7 9 H1 BRN sed ALARM GND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH 5 r 2 w gm c u lt 2 m w 9 o w 9 9 9 Begg 9 5858 EE 25922 2 83 ARBRES 2 S2o rs 3 580908 5 25 1516 9 Sz m rz EE D i k 1 Ac 1 A 595 AXE alz 3 S Mr a ja 2 2 EXTEND so i En 7847 6 E GENERATOR 7 S 7 OPTION b 7 6 e 6 4 2 6 JC2 5 mE JC1 5 SRO 5 i BOOM JC3 P UP DOWN AND Er TS15 DRIVE STEER TURNTABLE 3 RETRACT DRIVE ENABLE 3 I L40 2 2 1 7 1j D CR26 1j A L AXLE CUTOUT 7548 787 WORKLIGHT 5 L1 Lo P3 NO OG P NC D1 HORN L lo TS1 O Gd 8 AUXILIARY
111. C3B 3 06 3 RD WH S P E RD C4B 11 2 TURNTABLE ROTATE LEFT WH 4 WH 6 4 WH S P gt RDC4B 11 TURNTABLE ROTATE RIGHT WH BK 5 WH BK 5 5 WH BK S P BL BK 5 16 TURNTABLE ROTATE F C WH RD C3B 6 WH RD C6 6 6 WH RD S P I GRIBKC5 44 RD C4B 12 BOOM EXTEND BK C3B 7 BK C6 7 7 _ eno 5 RD 23 6 RETRACT BK WH C3B 8 BK WH 6 8 8 BK WH C6 38 BK WH S P GND EXTEND RETRACT FLOW CONTROL BK RD C3B 9 BK RD 6 9 9 BK RD S P SBD DESCENT ALARM 10 22 I 1 11 I I PLATFORM LEVEL UP OR C4B 2 OR 06 14 14 OR S P SS SSS SSS SSS ES PLATFORM LEVEL DOWN OR BK C4B 3 OR BK C6 15 Daa 15 OR BK S P AXLE DUMP VALVE OR RD C6 11 OR RD CR38 87A gt 16 CR8 87A PLATFORM ROTATE LEFT GR C4B 5 GR C6 17 17 GR S P PLATFORM ROTATE RIGHT GRIBK C4B 6 GR BK C6 18 18 GR BK S P I Bue EIER TS51 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD Bt S P STOP KS1 AUXILIARY 1 3 IGNITION POWER WH 86 WH 5 3 amp 5 11 21 bs2 sm wis KEY SWITCH HORN 23 4 22 BK CR5 30 BK S P IO al IT KEYSWITCH PWR PWR TOPLAT WH 7 2 RD C6 30 23 WH 15 7 WH S P D2 I FUSED 12V DC RD CR28 30 CR39430 24 RD CR2430 RD S P CB1 OIL COOLER FAN 24A RD CR17 30 RD S P CB3 1 AUXILIARY PUMP RD
112. Directional valve mechanically activated TARAS Pilot operated 3 position 3 way shuttle valve 7 7 or y Y 5096 50 SR Flow divider combiner valve with pressure balancing orifice and flow percentages Differential sensing valve Hydraulic Symbols Legend IERE Solenoid operated proportional valve E Priority flow regulator valve Solenoid operated 2 position 3 way directional valve 3000 psi 206 8 bar RE 3 1 ae Counterbalance valve with pressure and pilot ratio H H 2 position 2 way solenoid valve gt m 1 Directional valve pilot operated 2 position 2 way H Solenoid operated 3 position 4 way directional valve d 2 position 3 way shuttle valve Hydraulic oil cooler Brake Part No 77832 Genie S 80 and Genie S 85 Section 7 Schematics January 2004 This intentionally left blank 7 6 Genie S 80 and Genie S 85 77832 Section 7 Schematics January 2004 TE REV A GM 3 0L Engine Wiring Harness
113. GREK 14 10 AMP BOOM EXTEND C3B 7 C67 7 stud 8 2 BOOM RETRACT C3B 8 06 8 8 C6 38 BEWESE CR23 EXTEND RETRACT BK RD C3B 9 BK RD C6 9 p BK RD S F SBD DESCENT ALARM 10 GR BK C2B 6 PLATFORM LEVEL UP OR C4B 2 OR 06 14 14 1 PLATFORM LEVEL DOWN OR BK C4B 3 OR BK 6 15 042 15 RD C4B 11 AXLE DUMP VALVE C6 11 OR RD CR38 87A gt 16 OR RD 8 87 PLATFORM ROTATE LEFT 4 5 GR C6 17 17 C4B 12 PLATFORM ROTATE RIGHT GR BK C48 6 GRIBK C6 18 18 ME AUS 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 I an UNE BRN GND IGNITION POWER WH CR17 86 WH C5 3 amp 05 11 21 srup KEY SWITCH HORN 023 4 22 BK CR5 30 KEY SWITCH PWR PWR PLAT WH C7B 2 RD 06 30 23 RD 5 19 3 FUSED 12V DC CR39 30 24 RD CR2 30 RD S P CB1 Y mE r Im A sUIUH OIL COOLER FAN 24A RD 17830 RD S P CB3 1 AUXILIARY PUMP RD 9 868 1 1 RD C5 6 27 RD 80 5 2 BRAKE WT RD 5 23 WH RD 6 32 06 32 2 ENGINE START BK C5 5 1 7 33 5 I START RELAY GLOW PLUG BK WH 05 22 BK WH C1B 8 34 1 ENGINE RPM BK RD C1B 9 35 BK RD CR3 30 BK RD S P 1 27 STEER RT AXLE E
114. J P mox z x JIB VALVES Egg JIB VALVES lt o o 2 al SN N S a 2004 Section 7 Schematics sss ocIsssssCcwW WCss Electrical Schematic S 85 with Dual Battery Option Deutz F4L 913 Models after serial number 3576 January 2004 Section 7 Schematics REVA Electrical Schematic S 85 CE Models Deutz F4L 913 Models after serial number 3576 C28TTA RD BK x Q HOUR METER wn 8 5 1 9 C35ESPD BK RD d RPM RELAY HIGH FS m I 5 RP o n ENGINE SPEED gt wil RPM SOLENOID 3 E PULLIN 9 Ee m a lt lt
115. ge LEET 17 59 9 STEER LEFT gt 6 CDE1 BL WH pem C5 21 WH lt 15 ors COOEDGEWH DRIVE EDC FORWARD RKOUT 6 19 12 5 20 gt 5 1 5 C31EDC WH BK C31EDC WH BK gd ES wpe 0 DRVEEDOREVERSE CI PARE 5513 C6 32 2 TRAVEL ALARM OPTION 1g gt gt 14 Ab EE Ah AE TER 1g 2 1 1 lt m 5 23 26 1 26 2 4 C32BRK WH RD Fatsa 19 lt CIES SSA WED BRAKE RELEASE VALVE 1 3 C29MS RDWH C524 CogMS RDIWH 028 1 28 2 lt MOTOR STROKE bo 8 C3P 6 WH RD 2 4 C3P 5 C5TRR WH BK 5 3 EK lt 4 WH x x SE 10 m a 8 s lt ex lt C64 C4TRL WH 0151 0152 7 TURNTABLE ROTATE LEFT 24 55 2 E TURNTABLE ROTATE 2 36 i2 8 88 1 g 19 LEFT eos GSTRR WEEK In S TURNTABLE ROTATE RIGHT 5 4 Pn 3 on gt 1 5 GND 2 lt D 12 1 C6 6 31 1 31 2 TURNTABLE ROTATE Es X FLOW CONTROL pe 4 8 Em PRIMARY BOOM UP CUTOUT RELAY C6 1 C12 1 4 C12 2 000 PRIMARY BOOM UP ee PRIMARY BOOM 13 1 44 2 ge DOWN 6 2 N git GEFED RIYBK lt lt 4445 4 PRIMARY BOOM DOWN P ES a 1 j ji E lis _ 0291 De 929 2
116. gt 27 M tn DIS 1 aq kose T B EON START BATTERY 1 1 2 1 1 gx d d La RD li w N LO Part No 77832 Genie S 80 amp Genie S 85 7 22 Section 7 Schematics Electrical Schematic 5 80 GM 3 0L Models after serial number 3576 January2004 C28TTA RD BK REV 7 erg GROUND C6 13 __ S3LED lt 2 gt AXLE NOT EXTENDED PRESSURE SWITCH SSEEDIBERD p OPEN WHEN AXLE FULLY EXTENDED 82 AXLE EXTEND RELAY C6 39 C60AXOR RD 34 1 Bi C342 yy COTAS BLIEK AXLE EXT RET SELECT 4 lt EXTEND mE C6 11 C42AXDPWH _ 6354 I 0852 AXLE DUMP VALVE 5 D 6 OR RD 4 9 RETRACT
117. t t RD 7 2 7 2 PesBATWH 5 ES u m0 x 1 WH E FL 67 1 2 0192 4 mE D AUXILIARY POWER RELAY a 9 i AUXILIARY PUMP 18 Le Lj OIL PRESSURE gt e 8 C2SRSR RA p N HE VOLT METER OPTION 8 C26TSR GR BK 4 OIL TEMPERATURE 5 8 g SENDER OPTION C3B 10 aaa emee wi 77775 28 RD BK WH 4 gt 4 C8P 10 C133PLA BL C6 28 ENT o TT 06 23 P134 RD RD f f PE LEVEL SENSOR 9 LL l a Dee N p5 T gz C2B 5 m ol 2 5 C46HRN GR ty HORN RELAY AG GR BK l EZ P22BAT ag CASHIN HORN n N e C132PLI BL WH gt 9898 IA 66 34 4 HYDRAULIC OIL TEMPERATURE 1 12 C1B 12 5 SWITCH OPTION P134PWR GR BK 2 49 lt gt 5 2 6 C2B 6 HYDRAULIC COOLING T FAN OPTION z 9 RD mi 5 C6 134 RD Y FLASHING BEACONS 10 BK er OPTION Ps N 1 eo B 5 2 41 OR BK a 80 nJ 67 Jee C g 4 4 4 2 3 5 3 C107AF WH PANE ag X 5 ALTERNATOR 2 2 E Co c z 3
118. 4 Coot pd ues 4 HYDRAULIC OIL TEMPERATURE SWITCH R116HYD OR 2 4 HYDRAULIC OIL COOLING FAN C21IGN WH 5 N inva C53 C107AF WH F 5 13n4 N9I 6 lt ssvdAg A34 8 O lt 5 8 7 m E 652 77 C41RPM OR BK ENGINE lt 9 4 START C33STR BK z m t 3 zg B indNiiHvis 9 H313WOHOVL AE gt er Avisuiuvis ALTERNATOR 4 1 1 i a 9 AUXILIARY POWER e G 6 a VEER 2 B o al m oe 1 5 T d C27AUX GR WH T 5 aj 1281 5 9v8L i 2 4 i 5 cea z a a I pes I B Se 8 55 a I m E BK ag o 85 4 H ENGINE STARTING 5 o5 8 C21IGN WH RD s 6 fa ovo 16 ME ee P116HYD RD lt i a 8 5 a5 I EE gt q BEES 24 APU a BATGND BRN BATGND BRN I
119. 5 20 WH BK C1B 5 GROUND 36 STEER LEFT AXLE RETRACT BL 1 10 BL C6 36 STUD IT 43 HORN GR C2B 5 GR 5 86 f 45 GR WH 2 7 GR WH C5 12 1 60 SELECT OR RD 6 39 OR RD 2 4 O 61 AXLE RETRACT C3B 11 BL BK C6 21 7 50 Genie 5 80 amp Genie 5 85 77832 2004 Section 7 Schematics REV A Platform Control Box Wiring Diagram S 85 Perkins 704 30 Models before serial number 3577
120. BATGND BRN 22 CTBA C35RPM BK RD RPM SOLENOID P23BAT WH Z EXTEND m BEE BOOM RETRACT C8PBR BK WH 4 66 27 77 C27AUX RD e e AUXILIARY RELAY i m GEE BL t BK RD B AUXILIARY PUMP E gt C4TRL WH z LEFT x NE RE t TURNTABLE ROTATE Code lt C25PSR BL BK OIL PRESSURE SENDER y 7 C5TRR WH BK OPTIONAL g 10 id OIL PRESSURE SWITCH 09 C6TRF WH RD 5 Y re ao a bog 5 15 7 C24TSPS BL RD l 9 9 WATER TEMPERATURE SWITCH 1 sur S C2PBD RD BK 5 14 Z C26TSR GR BK 4 WATER TEMPERATURE SENDER 2 OPTIONAL C14PLU WH 5 11 WH PD a UP lt PLATFORM LEVEL BK 4 DOWN C15PLD OR BK BK FUEL SOLENOID 8 lt o C17JU GR C18JD GR BK RIGHT j GEBR PLATFORM ROTATE LEFT i EI amp e C19JSV GR WH 5 LOW RPM 2 FUNCTION ENABLE 5 HIGH RPM C35RPM BK RD 5 gt D m C34SA BK WH BATGND BRN Muro 056 dd le STARTER RELAY 2 C25PSR 8 EM 5 4 STARTER MOTOR C26TSR GR BK Ps E BOE u a j R21lGN WH
121. E C8 6 RD ui o JIB BOOM D28 WHT C5 11 C21IGN WH 2 u DOWN gt C18JD GR BK BK WH 5 10 C39LP BL RD C8 1 2 1 BK RD 548 gt C35RPM BK RD 08 2 RIGHT C8 11 PU BK en PLATFORM ROTATE lt der c8 12 07 C19JSV GR WH dd 5 x m a Q2 x 5 LOW RPM 2 2 FUNCTION ENABLE BK RD wo y BATGND BRN el e STARTER RELAY C25PSR BL BK 6 1 1 m STARTER MOTOR C26TSR GR BK XL Ug R21IGN WH 09 94 4 HYD OIL TEMP SWITCH R116HYD OR c6 33 lt COOLING C21IGN WH 48 NE m C39LP BK WH 5 FUEL GAS i 8 ENGINE ae 4 STARI C33STR BK be Que gt tr N ALTERNATOR F3 r I lt 2 1 5 22 9 AUXILIARY POWER gt 1 i lt a ee ol i 5 o8 lt C27AUX GR WH 1 7 sl gt e zal 5 oral P23BAT t 41 e e 3 2 5 lt 8 a BE 80 5 Pe ES 5 E Su B a 8 F gt E a 85 25 o 88 i 4 F ENGINE STARTING e C21IGN WH RD N CN M 3 o els
122. OQ og 205 88 5 5 2 38 2 3 9kog79899872 z200998o BS 82505 05129 99 24 21292229 2899528 F 85 SERA 98550 25887 22333 5552 8 Ting 55995 PE 21 Y P 5 C28TTA RD BK 2 ERA EER EE IE 4 L ee BATGND C7P 3 8 CR13 BRN C2P 9 amp 10 2 3 9 fe U 7 U U 2121214 Ex lt 3 2 2 TILT ALARM GND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH 5 mo lt 95 9 5898 5956 LER A 5 95 2 5 o 2 3 z 9 2 go TS16 8 x k o 5 N N T lt lo 60 o x 59 AXLE 5 5 5 n mu ss 2 2 TS47 5 6 RETRACT 1 GENERATOR 7 7 7 9 6 oO of 6 6 JC2 JC1 9 Ro O 5 5 5 BOOM UP DOWN EXTEND JC3 i TS15 AND TURNTABLE E DRIVE STEER 3 3 DRIVE ENABLE 3 2 140 2 5 2 7 f E CR26 1j 1j AXLE CUTOUT TS48
123. OT START RELAY VOUHMETER RES CIRCUIT BREAKER ENGINE 15A I 6 0 2 TACHOMETER BRN CR19 85 UP DOWN CB2 CIRCUIT BREAKER CONTROLS 15A 5 56 BANGND STUD aid 1 AU ON PT U1 1 1563 CIRCUIT BREAKER OIL COOLER OPTION 15A grie BK C23 BRN GND 1 G1 VOLT METER GAUGE OPTIONAL SES 1025 5 GROUND IGNITION OM as 2 TEES e BATTERY A RD 1A G2 OIL PRESSURE GAUGE OPTIONAL E 7 AER ad RD C23 7 I G3 OIL TEMPERATURE GAUGE OPTIONAL 8 l RD B1 20C N EN EUREN BK 33 Ta on G6 HOUR METER BURD 12 10 ENG FAULT aan OPTION CHECK ENGINE LED RD 24B TS58 G L45 PLATFORM OVERLOAD LED 5 I I BK RD 35B QOD eq BOOM ago CR2 IGNITION POWER RELAY GR C28 5 7556 zd CR3 HIGH IDLE CUTOUT RELAY 5 CRS BEIWE SAA GLOW PLUG HORN RELAY 6 a an ROTATE 1 CR17 HYDRAULIC COOLER FAN RELAY CR23 DRIVE LIGHT RELAY OPTION me 6 16 BK RD 35A CR25 AXLE RET L O RELAY BIRD 05 18 CR28 TROMBETTA PULL IN RELAY OR RD 168 1 5 TS54 9 CR29 AXLE EXTEND LED RELAY 8 6 BK 7B CR38 EXTEND FUNCTION CUTOUT RELAY BL RD C6 13 RPM 8 J 1 CR39 AUXILIARY PUMP RELAY m CB1 CB2 1 5 paz ENGINE CONTROLS
124. R3 DRIVE LIGHT OPTION RELAY TB24AB 15 CR23 GR BK C2B 6 RD C4B 11 RD 4 12 GND LABEL DESCRIPTION 5 KS1 KEY SWITCH 1851 AUXILIARY POWER TOGGLE SWITCH 1852 ENGINE START TOGGLE SWITCH 1853 LP GAS SELECT TOGGLE SWITCH TS54 FUNCTION ENABLE RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 1 CIRCUIT BREAKER ENGINE 15A 2 CIRCUIT BREAKER CONTROLS 15 CIRCUIT BREAKER OIL COOLER OPTION 20 G1 VOLT METER GAUGE OPTIONAL G2 OIL PRESSURE GAUGE OPTIONAL G3 COOLANT TEMPERATURE GAUGE OPTIONAL G6 HOUR METER 12 R2 TURNTABLE ROTATE LIMITING RESISTOR 10 OHMS R3 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS APU CR2 IGNITION POWER RELAY CR5 HORN RELAY CR8 BOOM FUNCTION CUTOUT CR17 HYDRAULIC COOLER FAN RELAY CR19 TURNTABLE ROTATE LIMITING RELAY CR23 DRIVE LIGHT RELAY OPTIONAL CR29 AXLE EXTEND LED RELAY U1 IGNITION START MODULE CIR
125. TS54 FUNCTION ENABLE TOGGLE SWITCH OR BK 41B 5 TACHOMETER 1 TS56 TS57 PLATFORM ROTATE TOGGLE SWITCH os BK 33B START GLOW PLUG 7558 JIBBOOM UP DOWN TOGGLE SWITCH 65 STUD PD 27B 4 Aux ON U1 G6 559 PLATFORM LEVEL TOGGLE SWITCH _ 5 GROUND IGNITION START HOUR METER 1861 1561 PRIMARY BOOM UP DOWN TOGGLE SWITCH 23 WH 23AB 6 BATTERY MODULE 1 1 TS62 TURNTABLE ROTATE TOGGLE SWITCH 2 2 WH 23B ES 7 kEY PRE BRN CR19 85 UP DOWN Per 7563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 5 KEY BYPASS TS63 CIRCUIT BREAKER ENGINE 15 RD B1 20C WH CR2 86 9 IGNJFUEL ON RD B1 20D BURD 15 1 RD 1A BOOM EXTEND CIRCUIT BREAKER CONTROLS 15 O 10 ENG FAULT T RD 248 I BK 33A i2 CIRCUIT BREAKER OIL COOLER OPTION 15A MM Bae ERNE EE Gi VOLT METER GAUGE OPTIONAL 1 BK RD 35B G2 OIL PRESSURE GAUGE OPTIONAL m GR C2B 5 FRO H H OIL TEMPERATURE GAUGE OPTIONAL 5 F CR2 CRS ons SERE ISMEO CB3 o E Qoo G6 HOURMETER RD BK C6 19 B RD CESE TS52 TS62 L2 CHECK ENGINE LED z m i RD 24AA ENGINE START SECO EH TS58 i CR2 IGNITION POWER RELAY a e OPTION 20A TURNTABLE 5 8 BK C6 16 OR BK 15A JIB BOOM ROTATE CR3 HIGH IDLE CUTOUT RELAY
126. lt 29965 5 2 lo 816 9 JIB BOOM 95 gt I i OG nou N 9 o P 2 s 9E le S So To 1 2 3 a IE p 5 S AXE 0 CUTOUT m a 3 T AL 52 7 bel 2 52 ExrEND P P 2 2 D 7 RETRACT gt P 2 6 1 2 m P OPTION 6 Lo 6 c 6 x MF JC1 OQO TURNTABLE ba 51 JC3 ROTATE AND 4 EXTEND 4 BOOM 2 1815 DRIVE STEER UP DOWN 13 RETRACT 3 DRIVE ENABLE 3 2 140 2 2 7 n 1 J X gt cR26 1j AXLE CUTOUT Die 7548 57 A WORK LIGHT PLATFORM TS8 leu L1 gt ad Vo D10 27 P3 NO G 2 NC NC 8 HORN oe TS1 OR 9 Kor AUXILIARY PUMP 52 TS3 514 89 FUEL SELECT DRIVE 754 P2 LEVEL D27 ee CE Lift Dirve Option SPEED HIGH LOW RPM EMERGENCY 5 BEER BOEDELS a Ses eee DERDE REDES eee ED DOER HE DERE DEE EE ESE Part No 77832 Genie S 80 amp Genie S 85 7 45 2004 Section 7 Schematics
127. m I 5 C29MS RD WH 1 12 BL WH C1B 12 5 I lt lt lt 1 7 DRELEDBURD 22 J1 WH 1 lt DRE BL BK C6 40 C40LS1 OR 4 Z WH gt 5 HEEN RETRACTED E DRIVE ENABLE 5 9 9 4 2 2 DRE BLWH 636 3 BK C1P 11 C37STC BL BK C1B 11 8 a N p35 C1P 10 ZZ C36STCC BL C1B 10 m lt gt J2 WH 1 Bene 2 2 C40LS1 OR 2 J5 4 Z WH 15185 c LL lt BOOM RETRACTED 19 GEES 2 E BL s lt C46PWR lt YOU s WH 8 15 N BUBK 6 20 C37STC WH 2 4 BRN 51 PWR lt OR 5 E D 1 4 C30EDC WH p 2 lt BAN rv lt AXLE DUMP VALVE C6 11 C42AXDP WH 87 s C1P 5 lt C31EDC WH BK lt lt C1B 5 24 1 K Gass lt C60AX OR RD 14 AXLE EXTEND RETRACT SELECT 1074 1 3 C29MS RD WH C1B 3 Der Pe BATGND2 1 lt zz zu 5 S BOOM EXTEND iS s lt 7 cag F C67 C7PBE BK gt gt Z Q your gt z 8 T 5 Hr ESE ei C3P 8 C8PBR BK WH C3B 8 2 r RD f 5150 xe 900797 EE BOOM RETRACT lt OR gt gt LL C6 8 C8PBR 1 eo l BEN pa 4 BATGND1 BRN Pe BOOM ENE
128. zx 1 HE 3 0 eu le 5 j zz 8 4 S59 zi i oz a 58 gl sss sa 358 K q 5 Li dos 885 SE 2 P20BAT RD 5 Y tr 9 8 1 AO 5 08 mA Zr 1 LO N N Section 7 Schematics 2004 Electrical Schematic 5 85 Models Deutz F4L 913 Models after serial number 3576 REVA C28TTA RD BK P26ESTP BK N LO N EA 1 7 3 BEN GROUND 4 8 9 06 13 S3LED BURD lt i C4P 1 S3LED BL RD 5 AXLE EXTENDED PRESSURE SWITCH V OPEN WHEN AXLE FULLY EXTENDED 29 o2 AXLE EXTEND RELAY C6 39 C60AXOR RD C894 034 2 g CP TE ee EK lt
129. 1 7 BK ISM 3 BK S P a START RELAY 051 5 5 GLOW PLUG BK WH 5 22 BK WH C1B 8 34 BK WH S P ENGINE RPM BK RD 1 9 35 BK RD CR3 30 BK RD S P 1 RD 27A LABEL DESCRIPTION STEER AT AXLE EXT BL BK 6 37 1 11 37 06 20 RD WH 3A RED EMERGENCY STOP BUTTON 38 1 RD BK 2A 1 LP 39 TER 1 KS1 4 LIMIT SWITCH 1 WH 2 2 06 40 40 6 10 eT wes AURAPARYTOGGUESWIT H ENGINE RPM C2B 3 5 2 41 OR BK ISM 2 145 LIMIT SWITCH 2 OR RD C4B 4 OR RD 29 86 42 OR RD C622 BK RD 9A PLATFORM TS52 ENGINE START TOGGLE SWITCH 12 OVERLOAD 7554 FUNCTION ENABLE TOGGLE SWITCH LIMIT SWITCH POWER RD C6 31 46 07 lt gt lt i CHECK ENG LED LED 1 1 KEY SWITCH POWER RD C6 23 C26 7134 RD H6 RD KSI SP BL RD ISM 10 7 1557 PLATFORM ROTATE TOGGLE SWITCH REY SWITCH POWER ae TS58 BOOM UP DOWN TOGGLE SWITCH GR BK H6 I TS59 PLATFORM LEVEL TOGGLE SWITCH i i TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH 1 1 1 WH 21A 7862 TURNTABLE ROTATE TOGGLE SWITCH I i TS61 1 START RELAY HOUR METER se TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 2 TACHOMETER BRN GND _ Q oo UPDowNn CIRCUIT BREAKER ENGINE 15 5 e i BRN GND STUD RD 27B 5 StarNet Ut n 2
130. 12 C12DRE BL WH C3B 12 2 BRN J3 WH 1 RD 91 C4P 4 R40LS2 OR RD 048 4 2 ALARM lt BK 4 WH 3 LS2AS 5 ce 9 BOOM ANGLE DRIVE MODE E BK 4 SAFETY C29MS RD NH pue 1 12 C38ESL BUWH C1B 12 7 lt lt lt 2E PAN DRELEDBURD 22 9 J1 WH 1 lt DRE m 9 C6 40 C40LS1 OR 4 WH 22 4 a LSIRO O 5 BOOM RETRACTED 2 EE EE 9 4 BE 2 OPERATIONAL 536 1 11 C37STC BUBK C1B 11 81 e lt gt me gt 1 1 10 7 BL C1B 10 J2 WH 1 m 2 2 C40LS1 C2B 2 doek c 18189 pl BOOM RETRACTED 19 Rkour s 4 BL s SAFETY lt C46PWR RD 3 M 9 lt 8 15 BUBK 6 20 C37STC WH 2 BRN S es 6 PWR lt 6 5 E 28 5 CiP 4 7 C30EDC WH C1B 4 8 GND 2 BRN gt vb lt AXLE DUMP VALVE c6 11 C42AXDP WH L di y Z 1 5 C31EDC WH BK 1 5 lt lt OH RD AXLE EXTEND RETRACT SELECT BREI loa lt C1P 3 C29MS RD WH C1B 3 Ds noter 4 lt BOOM EXTEND h s lt 7 7 F C6 7 C7PBE BK gt 2 488 BE m w D 8 2 C3B 8 5 XOUT L pieta gt Ei 5 HERR BER 8 cl
131. 19 VALVE 7 GRWr S P RD BK 2B WH BK SA 25 OIL PRESSURE C5 16 BL BK S P i 26 TEMP SENDER GR BK 5 14 GR BK S P ALL BRN WIRES l 6 4 WH RD GA W 28 ALARM RD BK 1 2 RD BK C6 28 z 9 rd 29 2WD 4WD C5 24 C1B 3 gz a 2 TOBASE 30 E D C WHC1B 4 WH C5 21 8 8 5 CONNECTIONS i 31 E D C FWD WH BK C5 20 WH BK C1B 5 5 i 36 STEER LEFT AXLE RETRACT BL CB1 10 BL C6 36 2 mi 1 28 5 GR CR5 86 5 I J 43 HORN GRC 1 45 GEN OPTION GR WHC2B GR WH C5 12 60 AXLE EXT RET SELECT OR RD C6 39 OR RD C2B 4 61 AXLE RETRACT BL BK 11 BL BK C6 21 1 NEE ON EET MEE eee SEN WE EEE EN ee LN EED i 7 16 5 80 8 5 85 77832 Section 7 Schematics BATGND GND STUD WH TS1 DETAIL B GENERATOR OPTION CE LIFT DRIVE OPTION BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE WH TS7 Platform Control Box Wiring Diagram S 80 Deutz F4L 913 Models after serial number 3576 January2004 z 5 E 5 5 z
132. 2 5 245 19 RETRACT BKWH 068 6171 D 26 2 8 PRIMARY BOOM RETRACT 3 8 I gt BK RD i c69 coPERFBK Rp 027 1 4 m 4 BOOM EXTEND RETRACT I FLOW CONTROL 12 C12DRE BLWH 8 sS C612 C12DREBLWH _ s lt 6 29 R16PBR BK WH z lt lt 1 e 58 DRIVE ENABLE LIMIT SWITCH T C638 C8PBRBKWH o gt 1 1 r 94 ED 5 C630 C23BAT RD a 1 I 4 2 C14PLU OR UP I y PLATFORM LEVEL l DOWN 3 C15PLD OR BK C20 1 C20 2 2 2 06 14 14 1 sup Al PLATFORM LEVEL UP ee PLATFORM LEVEL DOWN 6 15 454 t i ORDE IE Al PLATFORM LEVEL DOWN 2 21 1 C21 2 i 1 4 6 C18JD PRR GR BK UP JIB BOOM 1 1 2 4 5 7 i 2 7 B 2546 23 1 C24 2 D28 18 8 toow I i PLATFORM ROTATE RIGHT JIB DOWN e JIB BOOM 1 UP C6 17 t Il PLATFORM ROTATE LEFT JIB BOOM UP 22 1 C22 2 B AF RIGHT PLATFORM RIGHT PLATFORM i LEFT ROTATE T Te LEFT ROTATE esse zimmer 8 E C6 19 DESCENTALARMOPTION 4 7 C19JSV GR WH fa be 5 De DAE RESP ERSTER HH a eee 3 s
133. 24 TS2 59 TS14 GLOW PLUG LED ENGINE START TS4 PLATFORM aan DRIVE P2 LEVEL ee CE Lift Dirve Option SPEED STOP O OE EE 52 52 55 EE N a N 1 Part No 77832 Genie S 80 amp Genie S 85 7 27 2004 Section 7 Schematics Platform Control Wiring Diagram 5 80 Perkins 704 30 Models before serialnumber 3577 January 2004 Section 7 Schematics REVA Electrical Schematic S 80 Perkins 704 30 Models after serial number 3576 C28TTA RD BK P26ESTP BK P26ESTP BK 012 RD RD RD OR BK C35ESPD BK RD HIGH FS ENGINE SPEED 7 2 7 HIGH RPM 9 dLOWRPM C41RPM OR BK 042 14 46 23 RD 21 HOUR METER C21IGN WH BK RD RPM RELAY RPM RELAY C27AUX RD C45GEN GR WH 013 5 RPM SOLENOID GENERATOR OPTION 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION gt ROCKER STEER OPTION ONLY 5 gt ADD 040 ONLY IF UNIT HAS 14 148 NOTES L24 C34SA BKWH L28 5 22 BK WH 1 7 7834 C33STR 1 D 25 5 RD 24 5 WH 26 P25FS RD C7P 2 TS52 rl
134. 6 1 1 RD S P VOLT OIL PRESSURE OIL TEMPERATURE i PRIMARY BOOM DOWN 14 029 RD BK C3B 2 amp C6 2 2 015 fap CR8 30 RD BK S P PRIMARY BOOM RD WH C3B 3 RD WH C6 3 3 RD WH S P TURNTABLE ROTATE RIGHT WH 4 6 4 4 WH S P SEN 1 M TURNTABLE ROTATE LEFT WH BK C3B 5 WH BK C6 5 5 WHIBK S P TURNTABLE ROTATE WH RD 6 WH RD 6 6 6 WH RD S P 1 1 DRIVE LIGHT OPTION RELAY BOOM EXTEND BK C3B 7 BK C6 7 7 cResse stud BK S P G1 G2 G3 BOOM RETRACT BK WH C3B 8 BK WH C6 8 8 D57 BK WH S P 1 EXTEND RETRACT BK RD 9 BK RD 6 9 9 BK RD S P i 2 SBD DESCENT ALARM gt BL C3B 10 10 BL S P i 24 11 5 16 1 15 FUSE PLATFORM LEVEL UP OR C4B 2 OR C6 14 14 OR S P GR BK 5 14 PLATFORM LEVEL DOWN C4B 3 6 15 15 CR23 AXLE DUMP VALVE OR RD C6 11 16 OR RD CR8 87A po PLATFORM ROTATE LEFT GR 4 5 GR C6 17 17 1 d TS51 85 GR BK C2B 6 PLATFORM ROTATE RIGHT GRIBK C4B 6 GRIBK 6 18 18 EMERGENCY STOP 87 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 gt Z AUXILIARY PUMP 4 11 1 had adii IGNITION POWER WH CR17 86 WH C5 3 amp C5 11 21 052 STUD lO ne nS o HORN BK C7B 1 22
135. 7 C33STR BK C1B 7 GAN e ENGINE START Ye 7 Y LAFA a C6 24 P23FB RD eo 6 A FLASHING BEACON m AUXILIARY PUMP C27AUX RD 2 2 N N 6 32 2 WH RD m a TRAVEL ALARM si S 4 g c6 19 C2DA RD BK Q DESCENT ALARM c 4 1 2 C28TTA RD BK C1B 2 N c6 16 lt n HORN d 5 l BATGND e ME 89 o EG 2 5 C43HRN GR 2 5 ub 65 22 Z C34SA 5 o 7 P23BAT WH m 1 65 19 Z P23BAT RD 55 GLOW PLUG RELAY C7P 1 P22BATBK C7P 8 BRN 4 2 eg 1 BATGND 27 HE EE 22 C35RPM BK RD RPM SOLENOID P23BAT WH EXTEND m co BOOM g RETRACT C8PBR BK WH 4 66 27 77 C27AUX RD e e AUXILIARY RELAY DR CSPERFIBK RD B AUXILIARY PUMP E gt WH LEFT T EE c5 16 7 C25PSR BL BK 1 Sit RESSURE SENDER OPTIONAL gi RO e o OF C6TRF WH RD OIL PRESSURE SWITCH 5 Ni e 1 Benz c5 15 Z C24TSPS 4 ge 1 9 WATER TEMPERATURE SWITCH 1 ES sur S C2PBD RD BK v 2 C26TSRGR BK
136. 7561 AUXILIARY TOGGLE SWITCH 4 LIMIT SWITCH WH C2B 2 ORG OR C6 10 i i 6 40 40 b I TS52 ENGINE START TOGGLE SWITCH ENGINE RPM OR BK C2B 3 ORIBK 5 2 41 ISM 2 1 LIMIT SWITCH 2 ORMD OR MD CR29858 42 OR RD C6 22 x BK RD 9A PLATFORM 7556 GLOW PLUG TOGGLE SWITCH LIMIT SWITCH POWER RD C631 46 07 lt Gh is 7554 FUNCTION ENABLE TOGGLE SWITCH 1 KEY SWITCH POWER RD C6 23 C26 134 RD H6 RD KSI SP BL RD ISM 10 S cd 7557 PLATFORM ROTATE TOGGLE SWITCH 1 KEY SWITCH RD C6 24 4 1559 LEVEL TOGGLE SWITCH 2 i GR BK H6 i 7561 PRIMARY BOOM UP DOWN TOGGLE SWITCH 1 1562 TURNTABLE ROTATE TOGGLE SWITCH WASIA 7563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH G6 TS61 HOEKE 21 CIRCUIT BREAKER ENGINE 15 eek 2 TACHOMETER _ Yo UPIDOWN CIRCUIT BREAKER CONTROLS 15A ez START INPUT 5 2 BRN aND STUD 3 STAAT IN U1 CIRCUIT BREAKER OIL COOLER OPTION 15A BK C23 _ BRN GND 16 S GROUND IGNITION I G1 VOLT METER GAUGE OPTIONAL EIS 1 5 RETRACT 1 25 al EO 6 BATTERY START I RD 1A G2 OIL PRESSURE GAUGE OPTIONAL ad 23 LO 7 KEY PW
137. BK RD 5 18 1 RD B2 H1 5 RELAY 5 1 6 2 OR RD 168 BK RD 35A CR17 HYDRAULIC COOLER FAN RELAY I BK 7B 1 CR23 DRIVE LIGHT RELAY OPTION BURD TS54 gt CR28 TROMBETTA PULL IN RELAY o 5 HIGH LOW r4 1 CR29 AXLE LED C 1 RPM LO R2 10 OHM RESISTOR T OR C6 33 CB1 CB2 R3 5 RESISTOR RD 24A ENGINE 15A CONTROLS 15A TS59 TS57 14 TGNITIONSTART MODULE 2 RD B1 20A PLATFORM PLATFORM 5 RD 24AD 1 LEVEL ROTATE I 1 5 19 WH C6 34 Siaki 7 gt 1 GR 17A 2 ORD ZC GR WH 4 7 i LL 5 BK C5 7 i GR BK 18A GROUND BL RD C4B 1 BRN G6 i 1 BPN RD BK 28 BRN GND 1 WH 4A CIRCUIT DESCRIPTION FROM TO 6 ALL BRN WIRES WH BK 5A 12 DRIVE ENABLE BLWH C6 12 BLWH C3B 12 8 WH RD 6A 19 GR WH 4 7 GR WH S P Wr 2 hy EA m 25 OIL PRESSEURE SENDER 5 16 BL BK S P TO BASE 26 WATER SENDER GR BK C5 14 GR BK S P 1 1 CONTROL BOX 1 1 28 TILT ALARM RD BK C1B 2 RD BK C6 28 8 CONNECTIONS W L l 29 2WD 4WD RD WH 5 24 RD WH C1B 3 CR19 R3 30 E D C REV WH 1 4 5 21 1 31 ED C FWD WH BK C5 20 WH BK C1B 5 HIHI 36 STEER LEFT AXLE RETRACT BL CB1 10 BL C6 36 43 HORN GR C2B 5 GR CR5 86 45 GR WH 2 7 GR WH C5 12
138. CR5 30 ET 75 4 12 KEYS WITCH PWR PWR PLAT RD C623 RD C6 24 23 RD ISM 7 KS1 9 KEYS WITCH PWR PWR PLAT WH 7 2 RD C6 38 11234 C6 30 D nc i FUSED 12V DC RD CR28430 RD ISM 46 24 RD CR2 30 zi OIL COOLER FAN 24A RD CR17 30 5 AUXILIARY PUMP RD C6 27 amp C1B 1 RD 27 RD ISM 4_ of 06 02 5 lt x 3 WT RD 5 23 WH RD 1 6 32 WH RD C6 32 RD 23A SS 9 SS ee a u ENGINE START 1 7 33 BK ISM 3 BK S P START RELAY 51 5 5 33A BK CR28 86 ISM 1 22 f GLOW PLUG BK WH C5 22 BK WH 1 8 34 BK WH S P EE ENGINE RPM BK RD C1B 9 35 BK RD CR3 30 BK RD S P RD 27A STEER RIGHT AXLE EXTEND C6 37 BUBK C1B 11 37 BL BK 6 20 RD WH 3A 38 RD BK 2A LP 39 LABEL DESCRIPTION LIMIT SWITCH 1 WH 2 2 OR 6 40 40 OR 06 10 BEER ENGINE RPM OR BK C2B 3 OR BK 5 2 OR BK ISM 2 EER 1_ RED EMERGENCY STOP BUTTON LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD C6 22 034 x KS1 KEY SWITCH LIMIT SWITCH POWER RD C6 31 46 08 TS51 AUXILIARY TOGGLE SWITCH 4 1 BES 1552 ENGINE START TOGGLE SWITCH BASE TERMINATION BLOCK I TS56 GLOW PLUG TOGGLE SWITCH 5 OTT START RELAY 7554 FUNCTION ENABLE TOG
139. Chime Tone 45482 Floyd Bell Inc 09 525 1 is Joystick Single Axis 62391 Sauer Danfoss K26520 EE 1 2 JC3 Joystick Multi axis 62390 Sauer Danfoss K26519 2 Contact Key Switch 66816 Telemecanique ZBE1012 es 4 L1 L2 128 and 140 LED Red 12V DC 56298 Campell LE67C39007 3 Planes Contact N C platform controls 29732 Telemecanique ZB2 BE102 2 This list continues on the next page 7 2 Genie S 80 and Genie S 85 PartNo 77832 2004 Section 7 Schematics TE a a ae REVA ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number 2 ground controls 66818 Telemecanique ZBET02 eese 2 Contact N O 45081 Telemecanique 2 2 101 1 Fio si Resistor 100 25 watt 27287 Dale RH25 10R 1 1 ET Resistor 50 20 watt 40614
140. ENGINE HARNESS 7 N a GROUND TERMINAL 8 AUX TACH SIGNAL Z 090 2002 8 9 MID SPEED REQUEST GROUND ENABLES o _ 10 IS 11 12VDC OUTPUT TO GASOLINE FUEL PUMP 6 OES 12 GROUND TO GASOLINE FUEL PUMP oO E 9 1002 m 200 RED BLACK e 1000 BLACK e e 1000 BLACK CONNECTOR Wr 2 GASOLINE TO 12V DC BATTERY INJECTOR STARTER COIL POWER FUEL SUPPLY MAIN STUD ON STARTER CONNECTOR INTERLOCK RELAY SELECT RELAY POWER RELAY RELAY 20 AMP CAVITY B 8 ABCD 87 87 87 a 7 5 85 85 T MOLD 4 su 30 2000 BLACK WHITE 4 5002 4002 RED 1007 PURPLE 1004 YELLOW x 3002 RED BLUE 1009 WHITE BLACK 8 2004 YELLOW BLACK 2006 BLUE WHITE 6002 RED WHITE 2007 PURPLE 7012 18 FUSE LINK 3002 RED BLUE 7002 77832 Genie 5 80 8 Genie 5 85 7 7 2004 Section 7 Schematics E GM 3 0L Engine Wiring Harness Section 7 Schematics January 2004 A Ground Control Box Wiring Diagram S 80 Deutz F4L 913 Models before serial number 3577 Section 7 Schematics 2004 Ground Control Wiring Diag
141. RD BK S P 1 1 HEER PRIMARY BOOM FLOW CONTROL RD WH C3B 3 06 3 3 RD WH S F 1 87 2 TURNTABLE ROTATE LEFT WH C3B 4 WH C6 4 4 WH S P E _ 4 11 TURNTABLE ROTATE RIGHT WHIBK 5 WH BK C6 5 5 WH BK S P BL BK C5 16 TURNTABLE ROTATE F C WH RD C3B 6 WH RD C6 6 6 WH RD S P 1 I RD C4B 12 BOOM EXTEND BK C3B 7 BK 06 7 7 stud BK S P BOOM RETRACT C3B 8 BK WH 6 8 8 BK WH C6 38 BK WH S P ed 1 EXTEND RETRACT FLOW CONTROL BK RD C3B 9 BK RD C6 9 9 BK RD S P WH 23A 1 SBD DESCENT ALARM 10 I 11 l PLATFORM LEVEL UP OR C4B 2 OR C6 14 14 OR S P PLATFORM LEVEL DOWN OR BK 48 3 OR BK C6 15 Die 15 OR BK S P AXLE DUMP VALVE OR RD 6 11 CR38 87A 16 DVRD 8 87 gt 4 PLATFORM ROTATE LEFT 4 5 6 17 17 GR S P PLATFORM ROTATE RIGHT GRIBK C4B 6 GRIBK C6 18 18 GR BK S P P1 TS51 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P EMERGENCY KS1 AUXILIARY 3 IGNITION POWER WH 86 WH 5 3 8 5 11 21 gt KEY SWITCH PUMP HORN BK C23 4 22 BK CR5 30 BK S KEYSWITCH PWR PWR TOPLAT 7 2 RD C6 30 23 WH ISM87 WH S P D2 FUSED 12V DC RD CR28 30 CR39430 24 RD CR2 30 RD S P CB1 1 COOLER FAN 24A RD CR17 30 RD S
142. _ 0291 0292 PRIMARY BOOM sc I FLOW CONTROL C3P 1 g 13 OUT s veL gt 5 8 SE lt 5 C3P 2 C2PBD RD BK pwr BZ 1 19 22 BaN 1 16 C3P 3 C3PBF RDWH 10 p lt 02 1 C3P 9 C9PERF BK RD g SEE g lt C3P 8 C8PBR BK WH 5 n PRIMARY BOOM EXTEND 8 CUTOUT RELAY BRN 7 5 8 C16 1 C16 2 PMFSWH syg 06 7 e PRIMARY BOOM EXTEND P24FS WH 5 1 23 8 RETRACT 17 1 I Se BOOM BER P26ESTPBK ys 8 a 6 9 02771 cere BOOM EXTEND RETRACT FLOW CONTROL 2 12 C12DRE 8 EI Tog i 06 12 C12DREBLWH _ Ex 06 29 RI6PBR BKWH z e m i 7E 58 DRIVE ENABLE LIMIT SWITCH C6 88 BKWH u lt 213 5 8 1 5 53 i 06 30 C23BAT RD 1 1 4 2 lt lt e e pow LATFORM LEVEL 1 at C4P8 g C15PLD OR BK E C20 1 C202 2 8 h ONTEM El A 4 PLATFORM LEVEL UP PLATFORM LEVEL Tost 4 l ORBKIG MH D 4 PLATFORM LEVEL DOWN C21 1 C21 2 I C4P 6 RiGHT 9 4 iiber PLATFORM ROTATE DUE 1 Bt gt C23 1 C24 2 8 GIUBICTE M RI
143. lt BOOM RETRACTED iz 9 qa i amp a C6 31 C46PWR RD YOUT 5 lt WH gt v 192 3 BL BK C6 20 C37STC WH 2 4 Pwa e lt et 5 gt C30EDC WH B i 2 lt 1 5 AXLE DUMP VALVE X e c6 11 C42AXDP WH cere 2 E 1 5 C31EDC WH BK 1 5 lt lt GES SELECT lt C1P 3 C29MS RD WH C1B 3 E I 4 BATGND2 BRN 5 2 X 8 lt BOOM EXTEND s lt 7 cag C67 C7PBE BK gt m s youl 2 8 2 ca s 2 o v RD L 2 E xour AE CL 2 NN p S BOOM RETRACT pwa e lt C6 8 C8PBR BK WH 1 2 5 zL E lt 2237 2 Q9 BATGND1 BRN 1 EA VRL t um es K BOOMEXT RET 2 9 C9PERF BK RD 9 B 06 9 C9PERF BK RD gt FLOW CONTROL VEG 6 C32BRK WH RD C1B 6 N 2 TURNTABLE ROTATE LEFT Ballet EE 4 C4TRL WH C3B 4 06 4 C4TRL WH 1 gt i Ik lt 2 2 E 5 WH BK 5 06 5 CSTRR WH BK 1 IE our sC ve 5 6 16 sis Ed t 2 PWR EK OR 6 g J TURNTABLE ROTATE 6 C6TRF W
144. o e P2aBAT WH GLOW PLUG RELAY 1 1 C7P 1 P22BAT T 1 FLAMMABLE kaa START IGNITOR 7 3 BATGND BRN Ma a DERE T l 1 7 4 50 rd o BATGND BRN _____ _ AN gl lb gl gl ou E P22BAT 7 1 C5 18 lt P23BAT WH 7 2 EE BOOM 3 RETRACT 4 C627 C27AUX RD el le AUXILIARY PUMP RELAY t C9REREBERD B AUXILIARY PUMP C4TRL WH S 6 LEFT T 4 gt TURNTABLE ROTATE C5 16 C2SPSR BL BK A 4 OIL PRESSURE SENDER g C5TRR WH BK PIL OHe 2 T 1 5 NB tpe OIL PRESSURE SWITCH 5 rr MEE C5 15 C24TSPS BL RD b 8g 59 OIL TEMPERATURE SWITCH C1PBU sur PRIMARY BOOM e o 5 DOWN C2PBD RD BK C5 14 C26TSR GR BK 4 OIL TEMBERATUREISENDER 0 1 i C14PLU OR WH 5 11 C211GN2 sur 5 HOLD e PLATFORM LEVEL BK RD a 4 C15PLD OR BK 5 PULL IN FUEL SOLENOID S Q x za C17JU GR pin C18JD GR BK EE m HOLD n 4 RIGHT e o PLATFORM ROTATE BK 5 7 R33STR PULLIN tum lt gt EF 4 eu RPM SOLENOID e C19JSV GR WH Ses 8 5 HH is pm m LOW RPM FUNCTION EN
145. 1 P23BAT RD 08 23 3 RD Ye LEVEL SENSOR lt Sa m 8 E 4 lt APS C46HRN GR GR r 4 HORN RELAY E 29 621 22 7 1 pu p 10616 4 C132PLI BLWH 0634 R2IIGN WH HYDRUALIC OIL C1B 12 SWITCH OPTION P134PWR GR BK 8 5 TEE Er C6 83 8 HYDRAULIC COOLING OPTION NBC anes RD C6 24 RD C134 E H FLASHING BEACONS OPTION n u m Lo S x a 5 ALTERNATOR 5 o 4 5 a perpe Dia 1 mio MEN cee AE AE N 8 m i 4 START BATTERY i Ei altel amp NET RD No 77832 Genie S 80 amp Genie S 85 7 46 Section 7 Schematics 2004 Electrical Schematic 5 85 GM 3 0L Models after serial number 3576 REVA C28TTA RD BK
146. 41 Nm 3 Counterbalance valve 25 30 ft Ibs 34 41 Nm 9 Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm 4 3 16 13 ft Ibs 18 6 1 4 18 ft Ibs 24 5 48 Genie 5 80 amp Genie 5 85 Part No 77832 January 2004 Section 5 Repair Procedures REV 9 5 MANIFOLDS Brake Two Speed Manifold Components The brake two speed manifold is mounted on the engine tray Index Schematic No Description Item 1 CHECK valve ae SS us 2 Solenoid valve 2 position 3 way seats 3 Solenoid valve 2 position 3 way 00 Valve Resistance Specification Solenoid valve 2 position 3 way 10V DC schematic items TT and UU Function Torque 8 10 ft Ibs 10 15 Nm 25 30 ft Ibs 34 41 Nm Brake circuit Brake release 2 Speed wheel motors energized in high range to destroke the drive motor swash plates Part No 77832 Genie S 80 amp Genie S 85 Section 5 Repair Procedures January 2004 TEE MANIFOLDS REVA 9 6 Jib Boom Select Manifold Components S 85 The jib boom platform rotate manifold is mounted on the platform end of the boom Index No 1 2 Description Item Function Torque Solenoid valve 2 position 3 way VV Platform rotate select 8 10 ft l
147. 5 Te LEFT ROTATE Y Te Lert ROTATE 5i B C6 19 L l wm DESCENT ALARM NUN C4P 7 C19JSV GRWH i MR N nnn lee 2 i 5 8 a gt 5 u n x gea JIB VALVES amp 2 JIB VALVES 2 XR tg ra Oa O a a a 7 53 Genie S 80 amp Genie S 85 Part No 77832 2004 Section 7 Schematics s Electrical Schematic S 85 Perkins 704 30 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Box Wiring Diagram S 85 Perkins 704 30 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 85 REV A1 Perkins 704 30 Models after serial number 3576 A B G H 9 K L M N
148. 5 S2 N a Q EE STARTER MOTOR ge d RD 7 2 7 2 PesBATWH 5 ES ar g WH FL 67 2 0192 D AUXILIARY POWER RELAY 9 53 AUXILIARY 18 E6 5 2m 5 OIL Lj gt e 8 C2SRSR RA p N HE VOLT METER OPTION 8 C26TSR GR BK 4 OIL TEMPERATURE 4 C133PLA 38 10 C28TTA RD BK WH d gt 10 133 C6 28 lt ALARM m C6 23 P134 RD RDI 5 IB iEVELSENSOR L lt EE e eil a T gz C2B 5 m 2 5 C46HRN GR GR HORN RELAY o 418 Grek 59 P22BAT ag CASHIN C HORN 1 g N e C132PLI BL WH ul gt 9898 IA 66 34 4 HYDRAULIC OIL TEMPERATURE 12 C1B 12 8 SWITCH OPTION P134PWR GR BK 309 E gt 5 2 6 C2B 6 I HYDRAULIC COOLING T FAN OPTION 9 e RD PAC e o C6 134 RD Y FLASHING BEACONS BK er OPTION Es N a 5 T 5 2 OR BK 2 te 9 1 gt C53 CIOZAFWH y 28 6 ALTERNATOR HE E j 5 sel el 5
149. 7514 LOW HIGH DRIVE SPEED TOGGLE SWITCH 7815 DRIVE ENABLE TOGGLE SWITCH Na NX Se E K e o 1 7516 AXLE EXTEND RETRACT TOGGLE SWITCH EE EE EE EFESE NF FF M TS47 GENERATOR TOGGLE SWITCH OPTION 548 LR SEE OGE Boe ER AE dq HE WORK TOGGLE SWITCH sr eee 93518339 8532953 29 55295 1549 DRIVE LIGHT TOGGLE SWITCH OPTION LAG 990900 eR BES PEER ER GELE 22 88883 1518 PLATFORM OVERLOAD LIMIT SWITCH EERE 55 52 235555552 832 11 DRIVE ENABLE LED 822g 99 2289025523858 93288 L4 PLATFORM OVERLOAD LED 3 v 5558 23982243 298229 2 928 190 AXEEIEXTENDED CED 79 43 gt 509850248 2982 450 f oe 99412 M DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT 2 q JC2 BOOM PROPORTIONAL JOYSTICK SECONDARY BOOM UP DOWN BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE C28TTA RD BK C1P 2 2 n 013 ALC500 D 26 AXLE CUTOUT RELAY H1 TILT ALARM BATGND 7 3 4 E r T s ie ates Le oe fee BK LS CABLE 12 7 i z 15113 E LIFT DRIVE OPTION 7 13 3 13 5 LIFT Hi
150. 80 amp Genie 5 85 7 57 2004 Section 7 Schematics pum EE EE EE Hydraulic Schematic 4WD Models California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 10 220 7911 31 10 220 6642
151. BK E 19 22 15 E ie EE c Coa RD WH 1 8 i Nr 9 C9PERF BK RD 8 BK WH 5 PRIMARY BOOM EXTEND CUTOUT RELAY BRN 1 E Rs 7 7 2 8 C16 1 C162 o 1 67 Ses e us s PRIMARY BOOM EXTEND P24FS WH ee BOOM 1 _ _ 1 24 6 6 RETRACT BKWH d c68 6171 Al s RE 26 8 B t gt C27 1 C27 2 BK RD 06 9 C9PERF BK RD BOOM EXTEND RETRACT lt FLOW CONTROL 2 C3P 12 C12DRE BLWH i 3 lt lt lt lt A i C612 CI2DREBUWH s lt CEPS TTT beep C629 RI6PBRBKWH z e 4 DRIVE ENABLE LIMIT SWITCH 6 38 C8PBRBKWH lt 1 o 5155 525 8 4 5 E 9 C630 C23BAT ME C4P 2 C14PLUOR sur 4 o 1 pown LEVEL E C4P 3 C15PLD OR BK C20 1 C20 2 2 06 14 op i I lt lt 455 PLATFORM LEVEL te PLATFORM LEVEL DOWN 6615 OR BK 15 M H t PLATFORM LEVEL DOWN 2 c21 1 21 2 I 027 6 lt i 1 8t GEB e c23 1 024 2 5 D28 C618 GRIBK 18
152. C3B 11 BL BK C6 21 MEM ZZ 7 8 5 80 amp 5 85 77832 2004 Section 7 Schematics S Platform Control Wiring Diagram 5 80 Deutz F4L 913 Models before serialnumber 3577 REV A N M L COMPONENT INDEX 2 EMERGENCY STOP BUTTON P3 HORN SWITCH TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START SWITCH TS6 GLOW PLUG OPTION TS4 HIGH RPM SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS14 LOW HIGH DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 AXLE EXTEND RETRACT TOGGLE SWITCH TS47 GENERATOR TOGGLE SWITCH OPTION TS48 WORK LIGHT TOGGLE SWITCH OPTION DRIVE ENABLE LED 140 AXLE EXTENDED LED JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE CR26 AXLE CUT OUT RELAY U13 ALC500 H1 TILTALARM 1 LIFT DRIVE REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND GND STUD CR27 WETS e WH TS1 WH RD C32BRK SPLICE C32BRK CR40 ulli OR RD R40LS2 R40LS2
153. CONTROLS 557 a dates 24 mm PLATFORM R2 5 OHM RESISTOR E 1 RD B1 20A LEVEL ROTATE UI IGNITION START MODULE WH 21B 5 Es 86 RD 24AD OR 14A I GR 17A 7 5 3 cR29 GIB 2 1 GR BK 18A 1 LLL CIRCUIT DESCRIPTION FROM u 1 GROUND STUD BEE cibi 12 DRIVE ENABLE BL WH C6 12 BL WH C3B 12 19 VALVE GRIWH 4 7 GRIWH S P RD BK 28 rer 25 OIL PRESSURE SENDER 5 16 BL BK S P i 26 WATER TEMP SENDER GR BK 05 14 GR BK S P 5 lo ALL BRN WIRES WH RD 6A CERE 1 Pe ALARM 2 gg TE 5 RD BK C1 2 RD BK C6 28 al HARNESS 29 2WD 4WD RD WH 5 24 RD WH 1 3 ago a 30 E D C REV WHC1B 4 WH 5 21 I 8 8 S CONNECTIONS 31 E D C FWD WH BK C5 20 WHIBK 1 5 S mi 36 STEER LEFT AXLE RETRACT BL 1 10 6 36 1 56 43 GR C2B 5 GR CR5 86 5 zZ 45 GEN OPTION GR WHC2B GR WH C5 12 60 AXLE EXT RET SELECT OR RD 06 39 OR RD C2B 4 61 AXLE RETRACT BL BK C3B 11 6 21 1 EE awu DER HEESE ED s S 7 30 Genie 5 80 amp Genie 5 85 PartNo 77832 Section 7 Schematics 2004 Platform Control Wiring Diagram 5 80 RE
154. ENABLE 31 BANBATGND 2 140 m 2 2 7 25 GND STUD E X cmm E 182 E CR27 WH TS7 012 j WH TS1 N TS48 TS7 WORK WH RD C32BRK PLATFORM SPLICE C32BRK L1 a DEA CR40 H HORN Q ej Ts 15 8 AUXILIARY PUMP 7514 TS3 89 ENGINE START FUEL SELECT OR RD R40LS2 DRIVE TS4 P2 PLATFORM TM SPLICE R40LS2 LEVEL ee CE Lift Dirve Option SPEED HIGH LOW RPM Mr 5 i 77832 5 80 8 5 85 7 21 2004 Section 7 Schematics Platform Control Wiring Diagram 5 80 GM 3 0L Models before serial number 3577 January 2004 Section 7 Schematics REVA Electrical Schematic S 80 GM 3 0L Models after serial number 3576 RD BK
155. IGNITION POWER WH CR17 86 21 HORN 7 1 22 CR5 30 BK S P KEY SWITCH PWR PWR TO PLAT RD C6 23 23 RD C6 24 RD S P L2 KEY SWITCH PWR PWR TO PLAT WH 7 2 RD C5 19 23A RD C6 30 RD S P D2 FUSED 12V DC 24 RD CR2 30 RD S P OIL COOLER FAN RD CR17 30 RD CR23 30 24A RD S P AUXILIARY PUMP RD C6 27 amp C1B 1 RD 27 RD 5 6 RD S P BRAKE WT RD 5 23 WH RD C1B 6 32 WH RD C6 32 ENGINE START BK C5 5 BK C1B 7 33 BK S P START RELAY 33A GLOW PLUG BK WH 5 22 BK WH 1 8 34 ENGINE RPM BK RD C1B 9 35 BK RD C5 18 BK RD S P STEER RIGHT AXLE EXTEND BL BK C6 37 BL BK C1B 11 37 BUBK C6 20 38 LP BL RD C2B 1 39 BURD C5 10 BL RD S P LIMIT SWITCH 1 WH 2 2 OR C6 40 40 OR 6 10 ENGINE RPM OR BK C2B 3 OR BK C5 2 41 LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD C6 22 D34 LIMIT SWITCH 6 31 as 08 4 1 8 BRN GND STUD m 1 9 BK22D 5 O WH 23AD RD B1 20C x 80 61 200 WH 5 11 RD B2 S P RD 248 MN N GR C2B 5 m 5 22 RD BK 6 19 m e m OR RD 16B 9 BK 7B m BL RD C6 13 o OR C6 33 l p WH 21B Be RD 24AD WH C6 34 OR RD 42C i BL RD C4B 1 l GROUND STUD BRN RD BK 2B ALL WIRES 1 1 GROUND STUD
156. M H cae i zt PLATFORM ROTATE RIGHT JIB DOWN ge PLATFORM ROTATE L 1 AR ITEM Al PLATFORM ROTATE LEFT JIB UP C22 1 C22 2 ia Y i ERS N OR NEH OE EN GEREEN C6 19 DESCENT ALARM OPTION LI i I x lt x Tiom N N SERO 6 7 11 Genie 5 80 8 Genie 5 85 77832 2004 Section 7 Schematics BEE EE EE EE Electrical Schematic 5 80 Deutz F4L 913 Models after serial number 3576 January 2004 Section 7 Schematics REV A1 Electrical Schematic S 80 with Dual Battery Option Deutz F4L 913 Models after serial number 3576 C28TTA RD BK
157. OPTION 69 9 o 9 A A Y 7549 DRIVE LIGHT RELAY OPTION 2 1 1 i L1 DRIVE ENABLE LED 1 1 14 PLATFORM OVERLOAD LED 140 AXLE EXTENDED LED l JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT En Dr uet TOT Na AT JC2 BOOM PROPORTIONAL JOYSTICK PRIMARY BOOM UP DOWN TURNTABLE ROTATE dad ej sad M Eos si uU AU 1 JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT 92892 8 848822585829 9 2585 CR26 AXLE CUTOUT RELAY 25554 DE 5555 55555 mo gosa 5 018 ALC500 Be Ban 28 09 828805 ALARM 5 DA Hi CASO io lt EX 20 gt o 2305 x Dav 29 3o aS ADR 1 1518 OVERLOAD LIMIT SWITCH 2 r9g950I2 598 5 9050r29 26 1 855 29 2 1 5 9205002259922 2 8 1 148 TILT ALARM LED SOEK 0 20828982250908887 85 85059 92055 1 552 15 Pa SI 45572053 80 00535 9599 3 599 amp 2 220985 7559 1 N bed
158. OR Y 00 PLATFORM ROTATE RIGHT JIB BOOM DOWN PLATFORM LEVEL 06 18 C18JD GR BK 1 o DOWN C4P 3 C15PLD OR BK C4B 3 el 191 10 JDALARM BL 3 2 C3B 10 5 C17JU GR C4B 5 N BATGND BRN 2 JBBOOM 027 STEER RIGHT AXLE RETRACT u DOWN gt 6 C18JD GR BK C4B 6 4 06 37 C37STC BUBK 1 gt to P 2 RIGHT ATFORM ROTATE STEER LEFT AXLE EXTEND 93 0 C6 36 BL 1 gt 2 1 i 96 13 S3LED BURD AXLE EXTENDED 4 7 lt C19JSV GR WH C4B 7 T PRESSURE SWITCH 29 OPEN WHEN AXLES ARE FULLY EXTENDED BATGND 2 N MOTOR STROKE 05 24 C29MS RD WH 1 gt JIB VALVES 2 8 DRIVE BRAKE VALVE E 5 23 C32BRK WH RD 1 2 t lt lt lt gt 9 BK RD C1B 9 HIGH RPM FS i 4 e a 5 21 WH L DRIVE EDC FORWARD 7 5 20 C31EDC WH BK D 18 NGNE SREED lt iV DRIVE EDC REVERSE i 1 HIGH RPM C6 28 C28TTA RD BK OFF T GENERATOR C6 23 P23BAT RD RD LEVEL SENSOR o eet SWITCH 1 2 7 C45GEN GR WH C2B 7 4 GND1 BRN B 75225242523 LEVEL SENSOR E 8 1 8 34 BK WH C1B 8 Qi v GLOW PLUG me 4 m i lt lt GENERATOR OPTION 5 12 C45GEN GR WH lt TETTE RM LE 1 7 C33STR C1B 7 ENGI
159. PRIMARY BOOM 6 lt FLOW CONTROL i gt C1PBU RD i s YEL 2 6 lt lt lt 8 918 lt Pun s on s 5 2 C2PBD RD BK 19 2 BRN 9510 18 C3P 3 C3PBF RDWH D 8 9 C9PERF BK RD lt S 8 C8PBR BK WH 5 4 PRIMARY BOOM EXTEND 9 CUTOUT RELAY BRN 1 Eu lt 7 gt o P24FS WH M por C PBEBK cies 5 PAAFSWH 2 43 8 a 5 g t ET E carer _ Al 972 PRIMARY BOOM RETRACT P2EESTP BK Sys gt 2 m m ee m 069 2721 4 5272 BOOM EXTEND RETRACT E FLOW CONTROL 12 C12DRE BLWH 8 C2P 3 C612 CI2DREBUWH 6 29 RI6PBRBKWH 7E 58 PRIVE ENABLE LIMIT SWITCH C6 38 C8PBRBKWH 2 eL 5 8 69 C6 30 C23BAT RD 2 C14PLUOR sup LEVEL DOWN C4P 3 C15PLD 20 1 20 2 p p 2 C6 14 8 OER PLATFORM LEVEL UP E e PLATFORM LEVEL C6 15 DOWN OR BK 15 M H 10 gt PLATFORM LEVEL DOWN 2 21 1 21 2 027 C4P 6 Hu ager PLATFORM ROTATE 5 Bt C23 1 C24 2 Gor GRIER BMH D 4 PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE q LEFT c6 17 GR 17 M H PLATFORM ROTATE LEFT JIB UP 5 C22 1 C22 2 m C6 19 DESCENT ALARM OPTION X xg x u
160. Part No 77832 Genie S 80 amp Genie S 85 7 36 Section 7 Schematics 2004 Electrical Schematic 5 85 with Dual Battery Option REV Deutz F4L 913 Models after serial number 3576 e 0 1 7 BBN GROUND amp 9 C6 13 S3LEDBL RD AXLE EXTENDED PRESSURE SWITCH n SaEEDIBURD OPEN WHEN AXLE FULLY EXTENDED an p AXLE EXTEND RELAY C6 39 C60AX OR RD 34 1 CETAK BEBK AXLE EXTEND RETRACT SELECT 4 RETRACT AXLE EXTEND C6 11 C42AXDP WH 35 1 5 AXLE DUMP VALVE Sas RETRACT AXE C2P 4 C621 C6lAXRTBL 62 1 LO 6 22 C42LS2 GR lt lt oo LS2A0 BOOM ANGLE OPERATIONAL
161. RETRACTED w As 2 OPERATIONAL 2 DRE A BL WH D36 3 BK 1 11 C37STC BUBK C1B 11 e lt gt me gt 1 1 10 7 BL C1B 10 J2 WH 1 RD m 2 2 C40LS1 C2B 2 doek c LS1RS Qq 4 BOOM 19 amp BL s SAFETY lt C46PWR RD 3 M 9 lt 8 15 4 BUBK 6 20 C37STC WH 2 BRN S es 6 m pwr EP 5 5 C1B 4 B iu C30EDC WH 5 enple lt BRN Ist lt AXLE DUMP VALVE c6 11 C42AXDP WH Lane y 1 5 C31EDC WH BK 1 5 lt lt C6 39 lt C60AX OR RD 1 y AXLE EXTEND RETRACT SELECT loa lt C1P 3 C29MS RD WH C1B 3 Ds 4 BATGND2 BRN BOOM EXTEND h s lt 7 7 F C6 7 C7PBE BK gt 2 488 D 8 2 C3B 8 5 Su xour r RD 24 m k 5 KATE TS C6 8 C8PBR BK WH 1 gt BOOM RETRACT 8 se on 4 2 lt BRN gt zL a n BATGND1 BRN SP E BOOM EXTEND RETRACT 2 eee 9 C9PERF BK RD C3B 9 B C6 9 C9PERF BK RD gt FLOW CONTROL lt DE 1 6 C32BRK WH RD C1B 6 2 61 e amp TURNTABLE ROTATE LEFT lore 4 C4TRL WH C3B 4 C64 CATRL WH 1 gt PEU NEA Ip 19 2 lt
162. SWITCH x 1777 89858552044 8 START S i y x fad Ge Col CoS cal els 406 5 5 gog 4 ES COSTSTP T OIL PRESSURE SWITCH g 5 N ENGINE ar START 2 oz 5 POWER RELAY 5 E 1 8 F 1k AUXILIARY SM tw i O wu __ 59 5 FUEL SOLENOID C14 oz 5 7 lt lt R33STR BK 5 C5 5 EK IGNITION START RELAY Eg gt M e 5 58 127 AUXILIARY 5 5 e POWER Q 95 5 MOTOR a o o e C7B 2 4 7 2 2 z 4 5 ES x xm 8 F 94 5 2 0182 ce A AUXILIARY POWER RELAY eg ole IS SY AUXILIARY PUMP a T 2a i PR 5 19 2 4 __ 25 BL BK OIL PRESSURE SENDER OPTION ME 8 4 a el 5 VOLT 8 C26TSR GR BK OIL TEMPERATURE SENDER OPTION N C3B 10 Sd hi 4 C3P 10 EL 06 28 C28TTA RD BK WH 1 T x l l P134 RD C6 23 RD s EK LEVEL SENSOR NG lt a LL ge C2B 5 ne C2P 5 C46HRN GR GR HORN R EAY GR BK C7P 1 P22BAT BK C7B 1
163. a 9 Zoos SEEN N Saa o M m 7 15 Genie 5 80 amp Genie 5 85 77832 2004 Section 7 Schematics Electrical Schematic 5 80 CE Models Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 s Ground Control Box Wiring Diagram S 80 Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Box Wiring Diagram S 80 REV A1 Deutz F4L 913 Models after serial number 3576 A B D E F G H J K L M N
164. access covers from both sides of the axle 4 5 EXTENDABLE AXLE COMPONENTS Remove the drive motor See 14 1 How to Remove a Drive Motor Remove the drive hub See 14 2 How to Remove a Drive Hub 6 Tag disconnect and plug the axle extend cylinder hydraulic hoses from RAE and Rar ports on the axle select manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying 7 8 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 Place blocks under the axle extension cylinder for support Remove the external snap rings from the axle extension cylinder pivot pins Use a soft metal drift to remove the pins 9 Carefully remove the axle extension cylinder from the machine by pulling it out the end of the inner axle AWARNING Crushing hazard The axle extension cylinder could become unbalanced and fall if not properly supported when it is removed from the axle Part No 77832 Genie S 80 and Genie S 85 5 81 Section 5 Repair Procedures January 2004 Ee SSS SSE This page intentionally left blank 5 82 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 6 Fault Codes Observe and Obey Troubleshooting andrepair procedures shallbe completed by a person trained and qualified on the repair of this machine Immediate
165. ae REPLACE WIRE WITH THIS WIRING DIAGRAM p2 BOOM UP DOWN AND 7515 DRIVE STEER TURNTABLE 3 m RETRACT 3 BRN BATGND 2 140 gt GND STUD 2 7 X 1 CR27 012 WH TS7 WH TS1 7548 57 WORKLIGHT 1 WH RD C32BRK PLATFORM TS8 SPLICE C32BRK m L1 QA GEL Ko De NO oH nn NC NC H HORN PG o TS1 Logo TS OR 8 m AUXILIARY PUMP L24 2 TS9 027 7514 GLOW PLUG LED ENGINE OR RD R40LS2 PLATFORM Lift Dirve Option DRIVE HIGH LOW SPLICE R40LS2 LEVEL SPEED STOP Less IE N I 1 77832 Genie 5 80 amp Genie 5 85 7 51 2004 Section 7 Schematics Platform Control Wiring Diagram 5 85 Perkins 704 30 Models before serialnumber 3577 C28TTA RD BK P26ESTP BK OR BK WH 21 BRN C35ESPD BK RD HOUR METE
166. gy 2 05 23 026 1 026 2 ERE ls 1 6 C32BRK WH RD i C32BRK WH RD BRAKE RELEASE VALVE 1 3 C29MS RD WH C5 24 028 1 2 po lt MOTOR STROKE D 18 6 C6TRF WH RD 59 4 Ex C3P 5 CSTRR WH BK CATRL WH z lt 4 s lt ex lt lt br C64 WH 0151 M cis SE Your 5 Sk 4 RIGHT 7 TURNTABLE ROTATE LEFT 1 9 a 5 2 TURNTABLE ROTATE T 8188 m 3 LEFT c65 C141 4 14 2 Sigs 5 81 lt lt lt V gt gt TURNTABLE ROTATE RIGHT S pur 3 lt oR gt gt x 2 lt BRN 12 E 4 gt t ose wump 6311 0912 TURNTABLE ROTATE Ex iC u FLOW CONTROL BEE 4 8 Em PRIMARY BOOM UP CUTOUT RELAY C64 C121 M 12 2 m d EIE AD PRIMARY BOOM UP PRIMARY BOOM C13 1 6 C13 2 Te DOWN 1 5 2 Kx 5 it r lt GEED HOEK lt lt PRIMARY BOOM DOWN p een n 063 _ C 91 De 29 2 PRIMARY BOOM is 6 lt i FLOW CONTROL gt i E KC C1PBU RD 8 Sig lt pwn BC on 358 5 2 C2PBD RD BK 19 2 10 18 T 18 sz C3P 3 RDWH 5 k E 1 6 Nor 9 C9PERF BK RD 1 2 EX C3P 8 C8PBR BK
167. indicate reversed connection as specified in step 6 3 Seta multimeter to read DC current The multimeter when set to read DC current should be capable of reading up to 800 mA 3 K A NS A L a V N lao EE pe J Lla fi Connect the negative lead to the other terminal on the coil Iftesting a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 are different by a minimum of 20 The coil is good Result If one or both of the current readings are mA or 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 5 60 Genie 5 80 amp Genie 5 85 Part No 77832 January 2004 Section 5 Repair Procedures Fuel and Hydraulic Tanks REV 10 1 4 Tag disconnect drain and plug the supply and return fuel hoses Cap the fittings on the fuel Fuel Tank iade How to Remove the Fuel Tank 5 Remove the fuel tank retaining fasteners 6 Remove the fuel tank from the machine
168. lbs 20 24 Nm Testing 4 Shuttle valve position way Bl 5 Diagnostic nipple Plug Torque Specifications Description Hex size Torque SAE No 4 3 16 13 ft Ibs 18 Nm SAE No 12 5 g 75 ft lbs 102 Nm 5 54 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair REV MANIFOLDS Part No 77832 Genie S 80 amp Genie S 85 5 55 Section 5 Repair Procedures January 2004 MANIFOLDS 9 9 4WD Drive Manifold Components REV The drive manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Item Relief valve 280 psi 19 3 bar BJ 2 Check valve 5 psi 0 34 bar BK Flow divider combiner valve BL Check valve 5 psi 0 34 bar Check valve 5 psi 0 34 bar BN Shuttle valve ee esse ee ee ee Re eg BO Check valve 5 psi 0 34 bar Flow divider combiner valve 9 Check valve 5 psi 0 34 BR 10 Flow regulator valve 2 GPM 7 6 5 11 Flow regulator valve 2 7 6 L MIN a BT 12 Flow regulator valve 2 7 6
169. lt gt PLATFORM ROTATE RIGHT JIB DOWN 4 PLATFORM ROTATE 156545 Grat tl PLATFORM ROTATE LEFT JIB UP C22 1 C22 2 y EE ERENS Rr I EE EL 6 19 4 DESCENT ALARM OPTION i x zou E 2995 lt SER amp gt 5 7 29 Genie 5 80 8 Genie 5 85 77832 2004 Section 7 Schematics Electrical Schematic 5 80 Perkins 704 30 Models after serial number 3576 Section 7 Schematics January 2004 E P EN Ground Control Box Wiring Diagram S 80 Perkins 704 30 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 80 REV A1 Perkins 704 30 Models after serial number 3576 A B G H 9 K L M N
170. lt gt gt AXLE EXTEND RETRACT SELECT 4 RETRACT C6 11 C42AXDP C35 1 35 2 COAX OB RD AXLE DUMP VALVE 6 21 LO 6 22 4215208 4 t LS2AO BOOM ANGLE OPERATIONAL 40 aS 2 DRIVELIMIT SWITCH e i 5 J3WH ax C4P 4 C40LS OR RD 4 deca 8 lt lt LS2AS BOOM ANGLE SAFETY 66 10 C40LS2BK 5 7 4 DRIVELIMI SWITCH EE 2 2 40151 5 0640 C40LS1 OR N m E OQ LS1RO BOOM RETRACT OPERATIONAL DRIVE ROTATE SPEED LIMIT SWITCH Pr J2WH 8 1 5 H1 RD BK 22 AR BEK a 5 LS1RS BOOM RETRACT SAFETY 6 DRIVE OT DRIVEROTATE SPEED e ss s C6 31 RD 2 LIMIT SWITCH C29MS RD WH lt lt n 5 c6 20 D LED BURD 5 06 37 25 1 25 2 1 11 C37STC C37STC STEER RIGHT 2 CDE2 BL BK 7 7 N gt e af DRIVE ENABLE s 15 10 C36STCC BL 06 36 C36STCC BL iia D 942 STEERLEFT tee lt CDE1 BLWH e EE 1 4 C30EDC WH C521 C30EDC WH A CO 15 Ne DRIVE EDC FORWARD N Rkour e E 3 E 12 B 7 C5 20 C81EDC WH BK Your s w 35 4 5 C31EDC WH BK D DRIVE EDS REVERSE 8 4 lt 5 55 MC GS AE AC CUI d z 4 PwR 3 lt OR gt gt 13 6 32 g SE 1 L1 4 TRAVEL ALARM OPTI
171. of JC1 Qo JC2 5 S BOOM 5 5 1 BOOM UP DOWN EXTEND JC3 4 4 4 AND RETRACT _ 515 DRIVE STEER 3 OS 3 DRIVE ENABLE 3 I 7 2 140 2 2 M cRas E AXLE CUTOUT 2 O Ma TS48 787 n WORK LIGHT 58 JIB BOOM T L1 SAP GT TS4 el 5 OO HIGH LOW NC HORN TSi Wwe Hodo 499 ne se AUXILIARY PUMP 56 TS2 59 Y 1914 GLOWPLUG ENGINE START PLATFORM 5 TM LEVEL 7 Lift Drive Option STOP AE EE OE EE Ua 2 2 2 225 153 Be ae RE AE EF ON NA OO IE WAN ET N ME el Re EE 525 AE SAL N SE N 3j PartNo 77832 Genie S 80 amp Genie S 85 7 33 2004 Section 7 Schematics Platform Control Wiring Diagram 5 85 Deutz F4L 913 Models before serial number 3577 January 2004 Section 7 Schematics REVA Electrical Schematic S 85 Deutz F4L 913 Models after serial number 3576 C28TTA RD BK
172. p gt 2 C9PERF BK RD C3P 9 96 J gt 5 nRpciP Ni C41RPM OR BK C2P 3 4 N lt 10 gt el C1PBU RD C3P 1 4 a C31EDC 5 GEVEK C4F 6 2 5 _ C2PBD RD BK C3P 2 4 5 WH CR26 85 Te C37STC C1P 11 U GR WH CABLE C3P 3 1 1 r a J2 DIODE WH 1 EG C36STCC 10 5 a C5TRR WHIBK C3P 5 I C3P GR BRN C32BRK WH RD C1P 6 GR i Q S C4TRL WH C3P 4 90 5 3 g L C29MS C1P 3 2 5 5 a 509 DE 59 gt 3 gt 5 z lew BL TSI6 x i 1 TS4 C35ESPD BK RD 1 9 Os s TS6 C34SA C1P 8 2 4 5 TS2 C33STR C1P 7 1 TS1 C27AUX RD EN 2 lt 9 RD BK 148 Je 5 2 u 3 D 1 5 9 d LJc1 30R 8 BLC1P 10 Te Fe JC2 4RD lt 11 LJC1 2 BRN le m 1 5 BL RD 1 E 5 2 JC2 30R 5 J
173. s GERA eu LS2AO BOOM ANGLE OPERATIONAL 28 DRIVELIMIT SWITCH 4 C40LS OR RD 6 4 o 4 T 4 59 LS2AS BOOM ANGLE SAFETY Q DRIVELIMIT SWITCH EK 2 2 d 15180 RETRACT OPERATIONAL DRIVE ROTATE SPEED LIMIT SWITCH J2WH 8 5 15 5 WIRDBK 215 58 J5BK D 9 EN DRIVE MODE LS1RS BOOM RETRACT SAFETY 6 31 RD DRIVE ROTATE SPEED GERUS BEWE 2 _5 LIMIT SWITCH 5 5 66 20 D LEDBURD 16 5 025 1 025 2 1 11 C37STC E 06 37 C37STC BL BK 3 CDE2 gt 6 lt STEER RIGHT kaar 72 P4 RIGHT 8 C24 1 C24 2 DRIVE ENABLE 1 10 06 36 BL LEFT d Hz lt lt wen A STEERLEFT CDETBUWH gt gt C5 21 C30EDC WH A x 15 DRIVE EDC FORWARD 19 x C5 20 WH BK ac 5 Og he lt lt CP Dee DRIVE EDC REVERSE 5 AE ee EN ET MET ARE T 10 C6 32 n OR 213 TRAVELALARM 12 14 g nn 8 5 B 05 23 026 1 C26 2 RR ls 6 C32BRK WH RD C32BRK WH RD BRAKE RELEASE VALVE 1 3 C29MS RD WH C5 24 CogMS 028 1 2 lt MOTOR STROKE EE e Se
174. slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray TURNTABLE ROTATION COMPONENTS 4 Remove the motor brake mounting fasteners Carefully remove the motor from the brake TE AE SS p a motor b drive hub drive hub mounting bolts 5 Clean up any oil that may have spilled Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear Perform this procedure with the boom between the non steer end tires and with the machine ona firm and level surface 1 Secure the turntable from rotating with the turntable rotation lock pin The turntable rotation lock pin is located next to the boom rest pad 2 Loosen the backlash pivot plate mounting fasteners a backlash pivot plate b adjustment bolt with lock nut backlash pivot plate mounting bolts REVA Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear 3 Loosen the lock nut on the adjustment bolt Turn the adjustment bolt clockwise until it contacts the backlash pivot plate Turn the adjustment b
175. sx DRIVELIGHT gt N LO C2P 6 E DLITE GR BK C2B 6 5 DRIVELITE 2 lt lt A p N C4B 11 DRVELTEIRD lt 5 lt ET Dolo GND WORKLITE2 BK C6 12 ZZ C12DRE BL WH 2 WH m 909 ejg ss N LE 5 GND WORKLITE1 54 5 DRIVE ENABLE LED I U 25 OFF C23BAT RD 1 7 o WORKLIGHT WORKLITE1 WH 9 en lt m 3 WORKLITE2 WH K i Val EDS VLE CRUDUBUBK BL BK C621 C61AXRT BL 1 RD 1 aA OR RD C6 22 C42L82 GR 4 7 WH 4 gt Un eN 2 lt 9 c o F 4 C60AX OR RD lt qQ4 4 8 LS2AO t E EE 3 BOOM ANGLE OPERATIONAL N 12 27 C12DRE C3B 12 2 77 BRN LLI X J3 WH 1 Q ETA gt 8401 52 OR RD C4B 4 l eet lt lt lt BK 4 Z7 LS2AS ol 2 BOOM ANGLE 2 DRIVE MODE 57 i C40LS2BK 3 2 BK SAFETY 29 5 RD WH 1 12 C38ESL BL WH C1B 12 lt lt lt En DRELED BURD 2291 Be J1 WH 1 lt RD 9 C6 40 4 Z WH DRE B y 2 0401 51 2 LS1RO 19 BOOM RETRACTED 1 VV sj 5 2 OPERATIONAL p DRE A BL WH D
176. the fitting on the hydraulic tank Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank 5 62 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine AWARNING Crushing hazard The hydraulic tank could become unbalanced and fall if not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using pipe thread sealant on the threads 14 Install the drain plug using pipe thread sealant on the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have spilled 19 Open the hydraulic tank shutoff valves if equipped Component damage hazard CAUTION Be sure to open the two hydraulic tank shutoff valves if equipped and prime the pump after installing the hydraulic tank Always use pipe th
177. ur Ut CIRCUIT BREAKER OIL COOLER OPTION 15A 4 3 5 8 BKC23 5 BRNGND i 5 GROUND IGNITION VOLT METER GAUGE OPTIONAL 2 lt RD CR1 30 e BATTERY START 2 OIL PRESSURE GAUGE OPTIONAL mE 7 KEY PWR MODULE 63 TEMPERATURE GAUGE OPTIONAL KEY BYPASS I WH CR2 86 BK 33 TS52 06 HOURMETER 90 81 2005 BL RD 12 2 IGN FUEL ON OIL COOLER BURD L2 C 10 ENG FAULT START OPTION 12 CHECK ENGINE LED 128 GLOW PLUG LED I BK RD 35B f H 145 PLATFORM OVERLOAD LED I 128 IGNITION START RELAY 8 CRT CR2 GLOW PLUG 1562 CR2 IGNITION POWER RELAY I e RD 24AA CR3 HIGH IDLE CUTOUT RELAY 86 86 86 OR BK 15A ROTATE l 6 CR5 HORN RELAY e MET 6 BK C6 16 GEED CR17 HYDRAULIC COOLER FAN RELAY BIRD C5 18 I CR23 DRIVE LIGHT RELAY OPTION a OR RD 168 1 1 CR25 AXLE RELAY AX N 1 6 BK7B Hanow 4 CR29 AXLE EXTEND LED RELAY i BL RD C6 13 Q J CR38 EXTEND FUNCTION CUTOUT RELAY e 1 CR39 AUXILIARY PUMP RELAY pe ENGINE
178. vx ENA E amp 4 e _ 06 24 P23FB RD O 4 5 4 EER FLASHING BEACON m AUXILIARY PUMP UK ED lt 2 N c6 32 2 WH RD 2 5 NE 2 m B TRAVEL ALARM o e A zi 4 2 g 6 19 C2DA RD BK 8 LJ DESCENT ALARM uj a a 4 1 2 C28TTA RD BK 2 C6 16 C43HRN BK L n HORN d l BATGND 5 24 1 2 o no C2P 5 C43HRN GR C2B 5 P23BAT WH C7P 1 P22BAT BK 3 BATGND BRN C7B 3 P22BAT BK C7B 1 P23BAT WH Emm ae ee RETRACT C8PBR BK WH 6 27 C27AUX RD Je 4 RELAY e e _ C9PERF BK RD ee le B AUXILIARY PUMP 22 5 C4TRL WH N LEFT TURNTABLE ROTATE 55 16 4 OIL PRESSURE g RIGHT C5TRR WH BK OPTIONAL h TAH S n _ _ mo WH RD 5 Te a i 1 1 m C1PBU 5 DOWN C2PBD RD BK C5 14 EET GED 4 WATER i 4 C14PLU OR 2 PLATFORM LEVEL C8 9 lt YEBK o DOWN C15PLD OR BK 5 2 C41RPM OR BK C8 8 DK BL 8 RD 5 6 C27AUX C8 5 lt GR BK BK C55 C33STR BK C8 3 RD BL d RD 5 19 P23BATSA RD C8 4 lt 2 5 C17JU GR BURD C5 13 C38ESL BL RD C87 WH BL
179. x Zoos EBE amp Saa o a 7 13 Genie S 80 amp Genie S 85 PartNo 77832 2004 Section 7 Schematics E au Electrical Schematic 5 80 with Dual Battery Option Deutz F4L 913 Models after serial number 3576 January 2004 Section 7 Schematics REVA Electrical Schematic S 80 CE Models Deutz F4L 913 Models after serial number 3576 C28TTA RD BK x mE HOUR METER t5 8 5 C1 9 BK RD RPM HIGH FS 8 I 7 ENGINE SPEED S 2 norm 5 WH RPM SOLENOID 5 PULLIN a E lt lt wx 4 a 593 8 5
180. 0 Models after serial number 3576 LO E 5 gt aa 2 lt 5 zu I x m lt m lt 2 lt 8 2 Oo ES 2 lt EB Os u 5 e gt 5 1511 1 2r ugs ZE lt 6 5 5 000 ale T 2 6 gt SP 6 GEEEIS 5 5 5 ss S S S 51815 Sc 519
181. 05 LT GREEN J e CAVITY B SIGNAL L CAVITY FROM ALTERNATOR ALT CONNECTOR 100 BLACK FOR MODEL 751 2 COOLANT TEMPERATURE SENSOR Ge N CAVITY B CAVITY A COIL POWER CONNECTOR 106 DK BLUE _ AIR TEMPERATURE SENSOR 105 GREEN 1 CABLE a ALT SENSE 2 103 ORANGE WIRE 3 12VDC S 5007 PURPLE COIL WIRE GRAY E 2009 WHITE BLUE HI 1006 LT BLUE L P G LOCK OFF 2 e 2002 RED CAVITY B GER CAVITY A GROUND CONNECTOR L P G LOCK OFF m ALT WIRE L P G INJECTOR CONNECTOR TO STARTER POSITIVE CONNECTOR 1 12 4 SOLENOID i 1 8 A I EE s i 10 1001 BROWN WHITE i 2007 GOVERNOR x e L ACTUATOR CAVITY B CONNECTOR 8 9 5 12 8 5 2001 BROWN 5 2 1 L P FUEL REQUEST 12VDC ENABLES 5 8 x 5 2 HI SPEED REQUEST 12VDC ENABLES 1008 N x 5 lt lt 5 3 12VDC STARTER INPUT 8 D a 5 a 8 gt w 3 DIODE 4 12VDC IGN COIL POWER RELAY WHITE 8 8 g 1000 5 AUX INPUT SHUTDOWN x 5 6 ENGINE SIGNAL 12 2002 RED a
182. 1 E C3P 11 a 01 2 BRN 4 1 1 2 5 1 3 8 rx 5 12 01 5 YEL JOR 1 11 2 2 5 DRS 1 h 8 CHE 8 J1 2 i 03 6 BL 8 E sola JC3 2 BRN 1 TS15 DRE ABUWH Ai o I O lt Qu TS15 DRE BUBK Ee lt gt lt 1 1 1 S EIE z 814 29 5 ut i L 8 2 9 5 8 TES GN BK C3P 10 lt 2 2 i GN BK L4 OR BK C4P 3 RD C2P 6 2 5 1 1518 AE ED EE EEN EE eres sd REVA 77832 MODELS SEE DETAIL 2004 Section 7 Schematics EES EE Platform Control Wiring Diagram 5 85 Models Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 Ground Control Box Wiring Diagram S 85 GM 3 0L Models before serial number 3577 Section 7 Schematics January 2004 LSS SSS Ground Control Box Wiring Diagram S 85 GM 3 0L Models before serial number 3577
183. 1 J2 om 1 TS16 AXLE EXTEND RETRACT TOGGLE SWITCH 1 111 7547 GENERATOR TOGGLE SWITCH OPTION 9 Y 8 7548 WORK LIGHT RELAY OPTION 2 1 1 7549 DRIVE LIGHT RELAY OPTION e 4 1 L1 DRIVE ENABLE LED i 14 PLATFORM OVERLOAD LED 1 140 AXLE EXTENDED LED ee a ee a ie Fr JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT di d a 4 9 Q 9 9 9 9 9 9999 9 2 9909 9 9 d d 2 I EINE di 5 JC2 BOOM PROPORTIONAL JOYSTICK PRIMARY BOOM UP DOWN TURNTABLE ROTATE Sz Bar ms ge e 59256659599 055 1 JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT AR BBR m9 13 BOOM CUTOUT RELAY 52868 as2s82g2P zo 288 FF 2338 52658 eon3323 26 AXLE RELAY x DOV SS REO 5 2 420 1 013 ALC500 950 985 0 52 6 851 5 ON 000 Hi oz 9 28 289825500 805 ge 1 1818 PLATFORM OVERLOAD LIMIT SWITCH 5 52 92315088522965 99 68 148 TILTALARM LED 3 2520 S ee g 32 2
184. 2522260 52 522 3 3 2 59 182 01 552 242818 ON 98 9 7 o z9 o 59 999 2 2509o0955 92 0988500867290059 51 10 9 2225 98 2 5 972868 5 8 IN 959 255092532 299 2399 2 pa eang dotes Q FAN Gee 65 P 8 25 S 5 3 5 C28TTA RD BK 2 Lt EE EE L Pee _ 4 BATGND 7 3 2 GRMH 7 CR13 BRN _ 2 9 amp 10 GND a GR WH 57 9 fe RED BLK CABLE gt N 512 m 5 15 18 qu m 515 2 2 TILT ALARM GND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH 5 Poo Pirna epee CE mM ee RM dC RR EE _____ _ _ _ ___ ____ __ ____ _ __ _ __ _ ___ _ M 75551 gm oo 6 lt 2 2171 9 ASBES 9 59991295 59909 CIO Raz 98 5 CR13 5 z 9 EEE 1516 9 JIB S 9 5 ER sell 0825 Fis 58080 519 S lar N amp e 583 AxE CUTOUT MIS io lajt 2 a f 8 e in bal 8 515 EXTEND b 5 6 1 eo N TS47 1 7 7 LE 1 6 6 6
185. 2BL BK 2 9 2 8 024 1 024 2 e DRIVE ENABLE 1 10 C36STCC BL C636 C36STCC BL LEFT I 7 lt STEERLEFT CDE1 BLWH C521 WH A B UC hs lt CIE CS0EDCKWH DRIVE EDC FORWARD RKOUT 6 gt x i gt vour z GRS C31EDC WH BK 05 20 C31EDC WH BK Be p me REVERSE 4C BL 5 5 C Ra 30 08 gt 13 1 6 32 e TRAVEL ALARM OPTION 2 lt BRN gt gt 14 1 5 23 26 1 IS C26 2 C32BRK WH RD 2BRK WH RD e CIPS lt 42 63 lt gt gt BRAKE RELEASE VALVE po lt CIP 3 C29MS RD WH C524 0251 ti S7 4 smore EF 1o 8 6 C6TRF WH RD 25 of 2 sz 5 C5TRR WH BK gt 5 4 C4TRL WH az 664 C4TRL WH 4 RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE oy 1 LEFT u C65 C5TRR WH BK 8 TURNTABLE ROTATE RIGHT a 5 8 t C6 6 C311 C312 TURNTABLE ROTATE FLOW CONTROL oo R2 PRIMARY BOOM UP CUTOUT RELAY C64 C121 Ie 12 2 vor id lt lt PRIMARY BOOM UP e PRIMARY BOOM C13 1 C13 2 DOWN 62 IS s 5 a C2PBDRD BK PRIMARY BOOM DOWN 1 ee a 7 C63 6297 n 0292 PRIMARY
186. 32 January 2004 Section 5 Repair REV MANIFOLDS Pk cx lt e BR N Pad 53 p 8 NON STEER END Part No 77832 Genie S 80 amp Genie S 85 5 57 Section 5 Repair Procedures January 2004 MANIFOLDS 9 10 Valve Adjustments Drive Manifold How to Adjust the Hot Oil Shuttle Relief Valve The pressure differential between the charge pump relief valve located in the drive pump and the hot oil shuttle relief valve located in the drive manifold is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for cooling This pressure differential must be maintained at 40 psi 14 5 bar The following procedure will require two people 1 Open the engine side turntable cover and connect 0 to 600 psi 0 to 41 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 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold REV Start the engine from the platform controls and drive the machine slowly in the forward direction Note the pressure reading on the pressure gauge Turn the engine off and remove the hot oil shuttle relief valve cap item BJ Adjust the internal hex socket
187. 36 3 BK aK 1 11 C37STC BUBK 1 11 lt gt i 1 10 BL g C1B 10 J2 WH 1 RD C2P 2 C40LS1 OR C2B 2 DEK 4 Due lt lt lt 16 9 22 sj c6 31 C46PWR RD 4 BK Your s WH v lt 3 15 1 BL BK c6 20 ZZ CSTSTC WH 2 Z BRN 5 PWR ejs s lt S 1 4 7 WH 1 4 m GND Z amp san 1 lt AXLE DUMP VALVE lt e C6 11 C42AXDP WH l EMEN 2 1 5 Z C31EDC WH BK Z 1 5 m Gus lt GEMORS p AXLE EXTEND RETRACT SELECT raten 1 3 Z C29MS RD WH Z 057 BATGND2 BRN lt 4 BOOM EXTEND 7 7 F C6 7 gt amp m St 8 BK WH C3B 8 N OO u BOOM RETRACT Em C6 8 BK WH 1 gt 105 XN iQ 165 BATGND1 DE m BOOM EXTEND RETRACT ENE il 9 C9PERF BK RD C3B 9 C6 9 C9PERF BK RD gt FLOW CONTROL 1 6 C32BRK WH RD 1 6 4 2 oe e amp TURNTABLE ROTATE LEFT C3P 4 C4TRL WH C3B 4 C64 CATRL WH 1 gt 2 1 x amp TURNTABLE ROTATE RIGHT 5 5 WH BK 5 C6 5 CBTRR WH BK 1 gt 51 5 2 PWR e OR 6 L TURNTABLE ROTATE BEN TI 6 C6TR
188. 4 ENGINE RPM BK RD C1B 9 35 CR3 30 BK RD S P En I STEER RT AXLE EXT BL BK 6 37 BUBK 1 11 37 6 20 RD WH 3A 1 38 RD BK 2A 39 BL RD TS53 EI LABEL DESCRIPTION LIMIT SWITCH 1 WH 2 2 06 40 40 OR C6 10 EMERGENCY STOP BUTTON ENGINE RPM ORIBK C2B 3 OR BK C5 2 41 LIMIT SWITCH 2 OR RD C4B 4 OR RD 29 86 42 OR RD C6 22 BI RD 9A 1 KS1 KEY SWITCH 4 Buc SWITCH POWER RD C6 31 46 Drei 2 34 TS51 AUXILIARY POWER TOGGLE SWITCH RD C6 23 134 RD H6 KS I 12 1 1 KEY SWITCH POWER RD 6 24 ET CHECK LED 1552 ENGINE START TOGGLE SWITCH TS53 LP GAS SELECT TOGGLE SWITCH TERMINATION BLOCK BL RD 39A 7554 FUNCTION ENABLE RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH 1 WH 21A 1 G6 O GO 1 7559 PLATFORM LEVEL TOGGLE SWITCH 1 HOURMETER Booms TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH BRN GND UPIDOWN 7562 TOGGLE SWITCH 56 2 s k an O O TS63 TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH BL GO _ WH 28AB I FEN RETRACT CIRCUIT ENGINE 15 5 2 CB2 CIRCUIT BREAKER CONTROLS 15A UM e CIRCUIT BREAKER OIL COOLER OPTION 20A EE ENG
189. 4 RD JC1 2 BRN Lucas BK P JC2 3 OR e 5 HJCt 5 YEL CJC22BRN 1e 2 JC3 5 WH lt JC330R J03 6 BL 1003 2 BRN TS15 DRE t 9 TA i a TS15 DRE BUBK L1 C13LED 1 614 029 8 DA 8 TES GNIBK 10 GN BK 14 2 6 RD 1518 BATGND GND STUD WH TS1 CR30 T WH RD C32BRK SPLICE TO C32BRK WH TS7 OR RD R40LS2 SPLICE TO R40LS2 7 GRANH 2 7 DETAIL B GENERATOR OPTION DETAIL C WORKLIGHT DRIVELIGHT OPTION RD WL1 TS48 TS49 RD LS18 BK C7P 1 WH C7P 2 RD O BK C9 1 STOP BK J3 3 P2 EMERGENCY GN BK H1 D39 BK BRN J1 14 OR J1 13 WH 1 5 BL J1 4 WH 43 2 m OO st TEE u DRIVE TS4 HIGH LOW RPM RD BK H1 BK RD C1P 9 L48 990 d 14 012 1 7 9 3 TS2 BL RD J1 16 ENGINE START BRN GND BL WH 1 6 BUBK J1 7 BK WH C1P 8 Gd 815 ENABLE id L1 124 G
190. 4 WATER O pi OPTIONAL C14PLU OR 5 11 a UP lt LEVEL BK lt WH 5 C15PLD OR BK a FUEL SOLENOID 8 lt o BL 9 9 C17JU GR E s o JIB BOOM D28 DOWN gt C18JD GR BK RIGHT EE N 1 PLATFORM ROTATE LEFT Bi e Fi C19JSV GR WH LOW RPM FUNCTION ENABLE HIGH RPM 2 e e D m C34SA 1 BATGND BRN Muro 056 dd le STARTER RELAY C25PSR 8 1 m STARTER MOTOR C26TSR GR BK Ps E d BOE u a R21IGN WH C63 pd Es HYDRAULIC OIL TEMPERATURE SWITCH R116HYD OR 2 4 HYDRAULIC OIL COOLING FAN C21IGN WH 25 cd N N or C5 3 C107AF WH F 5 13N4 Nel 6 lt gt ssvdAg A34 8 O lt 05 2 1 OR BK 8 Eu H3MOd 213 E iz ee lt 9 START C33STR BK E gt t 3 zg B indNiiHvis 9 H313WOHOVL AE gt er Lavis ALTERNATOR 4 1 AQ 1 a O AUXILIARY POWER 2 z 2 1 2 g lt LA VEE
191. 5 74 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Non steer Axle Components REVA 14 1 Drive Motor How to Remove a Drive Motor This procedure is the same as the steer axle procedure See 13 2 How to Remove a Drive Motor 14 2 Drive Hub How to Remove a Drive Hub This procedure is the same as the steer axle procedure See 13 3 How to Remove a Drive Hub Part No 77832 Genie S 80 and Genie S 85 5 75 Section 5 Repair Procedures January 2004 Oscillating Axle Components REVA 15 1 3 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the Oscillate Axle Cylinders 2 cylinder The oscillating axle cylinders extend and retract AWARNING P 4dily injury hazard Spraying between the drive chassis and the axle to maintain hydraulic oil can penetrate and a level chassis while driving over uneven terrain burn skin Loosen hydraulic The cylinders are equipped with counterbalance connections very slowly to allow valves to prevent movement in the event of a the oil pressure to dissipate hydraulic hose failure gradually Do not allow oil to squirt or spray How to Remove an Oscillate Axle 4 Remove the pin retaining fasteners from the Cylinder rod end pivot pin Use a soft metal drift to remove the Perform this procedure on firm level surface with the boom in the 5 Attach a lifting strap from an over
192. 562 IGNITION START RELAY 5 8 BK C6 16 SIBBOOM TURNTABLE CR2 IGNITION POWER RELAY 6 2 BK RD C5 18 RD B2 H1 ROTATE CR3 HIGH IDLE CUTOUT RELAY m OR RD 16B BK RD 35A 5 a Fe CR5 HORN RELAY 2 BK 7B BOOM FUNCTION CUTOUT C6 13 554 Dod N E CR17 HYDRAULIC COOLER FAN RELAY 5 HIGH LOW 2 U 19 TURNTABLE ROTATE LIMITING RELAY 1 7 ones RPM CB1 2 CR23 DRIVE LIGHT RELAY OPTION 1 2 l RD 24A ENGINE 15A CONTROLS 15A TS59 TS57 CR29 AXLE EXTEND LED RELAY 2 WH 21B PLATFORM PLATFORM R2 TURNTABLE ROTATE LIMITING RESISTOR 10 OHMS RD 24AD LEVEL ROTATE R3 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS APU 5 8 WH C6 34 OR 14A ut IGNITION START MODULE z GR 17A 7 2 CREDAL GR WH 4 7 GR BK 18A 1 1 GROUND SENS BL RD C4B 1 BRN G6 RD BK 28 BRN GND CIRCUIT DESCRIPTION FROM TO WH 4A 12 DRIVE ENABLE BLMH C6 12 BL WH C3B 12 ALL BRN WIRES I WH BK 5A 19 VALVE GR WH C4B 7 GR WH S P B WH RD 6A 25 OIL PRESSEURE SENDER BL BK C5 16 BL BK S P gt I 1 i HARNESS E 26 WATER TEMP SENDER GR BK C5 14 GR BK S P 1 28 ALARM RD BK C1B 2 RD BK C6 28 zl 29 2WD 4WD RD WH 5 24 RD WH C1B 3 1 1 1 8 1 30 E D C REV WH C1B 4 WH 5 21 CR19 31 E D C FWD 1 1 D C WH BK
193. 6 RD WL1 4 4 4 1 I N 2 Y RDWL2 3 3 TS15 3 N 148 i i r 7815 I 140 2 M D 2 es ENABLE 012 iG 2 S 7 PRIMARY BOOM L CR26 11 DRIVE 11 A P 7 UP DOWN AND AXLE CUTOUT ANDSIEER TS48 TS49 TURNTABLE E TS7 D 1 1 m As 012 ROTATE mU FO Qc 5 x D10 Ro 1 HORN Lo 290 151 NC AUXILIARY PUMP TS2 TS9 1514 FUEL SELECT R 8 DRIVE START HIGH LOW PLATFORM RPM i LEVEL SPEED i P2 i STOP i TE E N EE A AE MODELS SEE DETAIL PartNo 77832 Genie S 80 amp Genie S 85 7 25 2004 Section 7 Schematics Platform Control Box Wiring Diagram S 80 GM 3 0L Models after serial number 3576 Section 7 Schematics January 2004 EZ SSS Ground Control Box Wiring Diagram S 80 Perkins 704 30 Models before serial number 3577 Section 7 Schematics January 2004 Ground Control Wiring Diagram 5 80 REV Perkins 704 30 Models before serialnumber 3577
194. 6 12 BL WH C3B 12 BRN WH 4A 19 VALVE GR WH 7 GR WH S P RD BK 2B I WHEKEA i 25 PRESSURE 5 16 BL BK S P 1 5 Q ALL BAN WIRES 26 OIL TEMP SENDER GR BK C5 14 GR BK S P 9 775 u 1 28 ALARM RD BK C1 2 RD BK C6 28 amp sl 9 S I WIRING 1 5258 IS HARNESS 29 2WD AWD RD WH 5 24 C1B 3 g 7 z ol e TO BASE 30 E D C REV 1 4 5 21 8 b I T CONTROL BOX ns CONNECTIONS 31 E D C FWD WH BK 5 20 WH BK C1B 5 Ti 36 STEER LEFT AXLE RETRACT 1 10 BL C6 36 J t 43 HORN GR C2B 5 GR CR5 86 5 45 GEN OPTION GR WH C2B7 GR WH C5 12 60 AXLE EXT RET SELECT OR RD C6 39 OR RD C2B 4 61 AXLE RETRACT BL BK C3B 11 BL BK C6 21 1 De EN SE RE es Ee EE SE 7 40 5 80 8 5 85 77832 2004 Section 7 Schematics
195. 832 Genie S 80 amp Genie S 85 7 56 2004 Section 7 Schematics EE Hydraulic Schematic 2WD Models 2004 Section 7 Schematics p re u u REVA Schematic 4WD Models
196. 9 Nm during installation Refer to Drive motor mounting bolts lubricated 94 ft lbs Section Two Hydraulic Hose and 127 Nm Fitting Torque Specifications 1 Extend the axles 2 Remove the drive motor access covers from both sides of the inner axle 5 72 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REVA 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor AWARNING 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 drive motor mounting fasteners 5 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine Torque specifications Drive motor mounting bolts dry 125 ft lbs 169 Nm Drive motor mounting bolts lubricated 94 ft lbs 127 Nm 4WD STEER AXLE COMPONENTS 13 3 Drive Hub How to Remove a Drive Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 13 2 How to Remove a Drive Motor 2 Loosen the wheel lug nuts Do not remove them 3 Center a lifting jack of ample capacity under the non steer axl
197. A RD BK WH 0285 6 23 134 GR SENDER OPTION TILT ALARM LEVEL SENSOR HORN RELAY q HORN C7P 1 P22BAT BK C7B 1 GR BK lt C132PLI BLWH P134PWR GR BK MC C32 8 C43HRN BK H2 R21IGN WH HORN R116HYD OR TB24A HYDRAULIC OIL TEMPERATURE SWITCH OPTION RD RD 134 22 WH hd t 1 81 PLAT GRD 6 134 FLASHING 5 2 C41RPM 1 l T i CB3 204 m TB20 C5 3 C107AF WH y 02 ALTERNATOR LET gta 20 OPTION ALTERNATOR IF 4 STAAT BATTERY No 77832 Genie 5 80 amp Genie 5 85 7 28 Section 7 Schematics Electrical Schematic 5 80 Perkins 704 30 Models after serial number 3576 January2004
198. ABLE 5 3 5 lehren C35RPM BK RD 4 BK RD 8 i Q C34SA BK WH 1 R33STR 4 e 65 5 STARTER RELAY C25PSR BL BK 5 m C26TSR GR BK 5 in 2 n 4 06 34 R21IGN WH we HYDRAULIC OIL TEMPERATURE SWITCH gt P R116HYD OR _ 56 33 lt HYDRAULIC OIL COOLING FAN C21IGN WH 45 S 0 2 1 9 CES CASTA a 6 O lt gt D lt 8 8 05 2 C41RPM OR BK wo ja A34 210 F ENGINE 25 Aual va 9 t START 52 B C33STR 8 4 EF NO FO INdNi Luvis H313WOHOVL or Avi3H Lavis 110 ALTERNATOR 49 P AUXILIARY POWER 4 8 55 veel 9 4 6 m e 5 E S R C27AUX GR WH gt 4 2281 5 4 P23BAT RD e gt 5 5 n 5 1 B lt tw I a DY 1 a lt as o5 OR 4 ENGINE STARTING BATTERY 5 a C21IGN WH RD 5 1 a 9 e Ne ee Ne e 116 RD 8 a m 9 EN 15 2 RD gt N APU BATTERY OPTION e 2
199. AN OPTION di EE 5 RD E sic C6 134 RD FLASHING BEACONS OPTION N z c 5 2 C41RPM lt 1 26 Le 0 0 0 0 0 0 0 jJ dd o fff p 2 4 b 4 SC Pele 5 3__ 107 y gig REIS lt 5 E 5 ALTERNATOR Spey i P8 ETVYY t c 1 1 1 1 4 1 _ Lud ad i P20BAT RD 88 4 l v LO amp GRAY 2 4 BLACK 8 GREEN 4 BROWN 3 ROCKER STEER OPTION ONLY gt ADD 040 ONLY IF UNIT HAS L4 AND 148 Part No 77832 Genie S 80 amp Genie S 85 7 10 Section 7 Schematics 2004 Electrical Schematic 5 80 Deutz F4L 913 Models after serial number 3576 REVA 28 RD BK
200. ARY BOOM RD WH 3 RD WH 6 3 3 RD WH S P 4 4 TURNTABLE ROTATE RIGHT WH C3B 4 WH C6 4 4 WH S P 5 r EE TURNTABLE ROTATE LEFT WH BK C3B 5 WH BK 6 5 5 WH BK S P TURNTABLE ROTATE WH RD C3B 6 WH RD C6 6 6 WH RD S P DRIVE LIGHT OPTION RELAY BOOM EXTEND BK C3B 7 66 7 7 stud BK S P G1 G2 BOOM RETRACT BK WH C3B 8 BK WH C6 8 8 057 BKIWH S P H EXTEND RETRACT BK RD C3B 9 BK RD C6 9 9 BK RD S P 0 24 SBD DESCENT ALARM BL C3B 10 10 BL S P gt 15 AMP FUSE 11 BL BK C5 16 ie 2 PLATFORM LEVEL UP 4 2 OR 66 14 14 OR S P CR23 PLATFORM LEVEL DOWN OR BK C4B 3 OR BK C6 15 15 OR BK S P 30 AXLE DUMP VALVE OR RD C6 11 16 OR RD CR8 87A P1 1 sel GR BK C2B 6 PLATFORM ROTATE LEFT 4 5 GR C6 17 17 GRSP TS51 MAR PLATFORM ROTATE RIGHT GRIBK C4B 6 GRIBK C6 18 18 GRIBK S P EMERGENCY 1 RD C4B 11 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P STOP AUXILIARY PUMP IGNITION POWER WH CR17 86 WH C5 3 amp C5 T1 21 652 wnsp i i HORN 7 1 22 CR5 30 BK S P i So RD C4B 12 KEY SWITCH PWR PWR TO PLAT RD C6 23 RD C6 24 23 RD ISM 7 RD S P L2 KS1 BRN GND KEY SWITCH PWR PWR TO PLAT W
201. AUXILIARY POWER RELAY ale AUXILIARY PUMP 5 gt o z Ny 4 5 C25PSR BL BK 4 OIL PRESSURE SENDER OPTION 9 8 VOLT METER OPTION C26TSR GR BK 3 OIL TEMPERATURE SENDER OPTION AA C3B 10 a C28TTA n C3P 10 gg C628 Z FUTALARM m 66 23 Fist LEVEL SENSOR L m 2 C2B 5 1 C2P5 C46HRN GR GR HORN RELAY OREK 59 5 21 0646 C43HRN HORN z 8 n A e lt lt 1 2 gt 4 C6 34 R21IGN WH HYDRAULIC OIL TEMPERATURE 12 C1B 12 m SWITCH OPTION P134PWR GR BK C2P 6 C2B 6 52 06 33 RII6HYD OR HYDRAULIC COOLING FAN OPTION 3 BD Be 6 134 RD FLASHING BEACONS OPTION el 052 _CA1RPMORBK pee Tu E lt i C53 CIOTAFWH y 19 jg 8 S g ALTERNATOR gt E n 2 Eu 5 EIN T Ia TEE Bey ILE i 1 1 an 1 as 85 a a j DE HEESE ol NEN N N ect BATTERY SEPARATOR OPTION 8 B 1 ER START BATTERY N lt 8 2 LO amp ADD 040 ONLY IF UNIT HAS L4 AND 148
202. B 6 WH RD 6 6 6 D57 WH RD S P 10 AMP FUSE GR BK 5 14 BOOM EXTEND C3B 7 C6 7 7 stud BK S P 2 BOOM RETRACT BK WH C3B 8 BKWH 06 8 8 BK WH C6 38 BKWH S P CR23 EXTEND RETRACT BK RD C3B 9 BK RD 66 9 9 5 WH 23A SBD DESCENT ALARM 10 22 1 __ PLATFORM LEVEL UP C4B 2 OR C6 14 14 OR S P 1 PLATFORM LEVEL DOWN OR BK C4B 3 OR BK C6 15 15 OR BK S P 11 AXLE DUMP VALVE OR RD C6 11 OR RD CR38 87A 16 OR RD CR8 87A TT PLATFORM ROTATE LEFT GR C4B 5 GR C6 17 17 GR S P C4B 12 PLATFORM ROTATE RIGHT GRIBK C4B 6 GRIBK C6 18 18 GR BK S P Pi TS51 RD 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P EMERGENCY AUXILIARY i BRN GND IGNITION POWER WH 17 86 WH 5 3 amp 05 11 21 4 wHdsP KEY SWITCH HORN BK C23 4 22 BK CR5 30 5 I KEY SWITCH PWR PWR TO PLAT WH 7 2 RD C6 30 23 RD C5 19 WH S P D2 Gu FUSED 12V DC CR39 30 24 RD CR2 30 RD S P CB1 m ed ee eg es 3 OIL COOLER FAN 24 RD CR17 30 RD S P CB3 NC I 1 AUXILIARY PUMP RD CR39 868C1B 1 RD C5 6 27 RD e 4 RD SP BRAKE WT RD 5 23 WH RD CT8 6 32 WH RD C6 32 ENGINE START 5 5 1 7 33 BK S P I tef START RELAY GLOW PLUG BK WH 05 22 BK WH 1 8 3
203. B VALVE GR WH C4B 7 GR WH S P m 25 OIL PRESSURE SENDER BUBK 05 16 BL BK S P 5 8 WH RD 6A 26 WATER GR BK 5 14 GRIBICSP 4 28 ALARM RD BK 1 2 RD BK 6 28 7 WIRING I HARNESS 29 2WD 4WD RD WH 5 24 8 30 E D C REVERSE WHC1B 4 WH C5 21 CONTROL BOX 8 mmt CONNECTIONS 31 E D C FORWARD WH BK 05 20 WH BK C1B 5 5 1 36 STEER LEFT AXLE RETRACT BL CB1 10 BL 06 36 1 8 43 GR C2B 5 GR CR5 86 1 45 GENERATOR OPTION GR WH C2B 7 GR WH C5 12 1 60 AXLE EXTEND RETRACT SELECT OR RD C6 39 OR RD 2 4 Oi 61 AXLE RETRACT BL BK C3B 11 C6 21 M q J pe EE 7 48 5 80 amp 5 85 77832 2004 Section 7 Schematics Platform Control Wiring Diagram 5 85 GM 3 01 Models after serial number 3576 N M L K J H G F E D G B A
204. BL WH C3B 12 19 JIB VALVE GR WH C4B 7 GR WH S P 25 OIL PRESSURE SENDER BL BK C5 16 BL BK S P 26 WATER TEMP SENDER GR BK C5 14 GR BK S P 28 TILT ALARM RD BK C1B 2 RD BK C6 28 29 2WD 4WD RD WH 5 24 RD WH 1 3 30 E D C REVERSE C1B 4 WH C5 21 31 E D C FORWARD C5 20 WH BK C1B 5 36 STEER LEFT AXLE RETRACT BL CB1 10 BL C6 36 43 HORN GR C2B 5 GR CR5 86 45 GENERATOR OPTION GR WH C2B 7 GR WH C5 12 60 AXLE EXTEND RETRACT SELECT OR RD C6 39 OR RD C2B 4 61 AXLE RETRACT BL BK C3B 11 BL BK C6 21 REVA 2004 Section 7 Schematics Platform Control Wiring Diagram 5 85 GM 3 0L Models before serial number 3577 REVA N M L COMPONENT INDEX 2 EMERGENCY STOP BUTTON P3 HORN SWITCH TS1 AUXILIARY TOGGLE SWITCH 82 ENGINE START TOGGLE SWITCH TS3_ FUEL SELECT TOGGLE SWITCH 784 HIGH RPM TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH 89 PLATFORM LEVEL TOGGLE SWITCH TS14 LOW HIGH DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 AXLE EXTEND RETRACT TOGGLE SWITCH TS47 GENERATOR TOGGLE SWITCH OPTION TS48 WORK LIGHT TOGGLE SWITCH OPTION L1 DRIVE ENABLE LED 140 AXLE EXTENDED LED JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT JC1 BOOM PROPORTIONAL JOYS
205. BOOM FLOW CONTROL lt gt 2 9 1 our C3P 1 RD g Ed pwr s 9 7 C3P 2 C2PBD RD BK GND 2 lt gt gt 10 C3P 3 RD WH 8 lt 1 1 E __ Y 5 9 C9PERF BK RD ge lt 5 5 PRIMARY BOOM 8 EK 8 C8PBR BK WH 4 BRN E fz C3P 7 C7PBBE BK 2 8 C16 1 C16 2 PAFSWH x BK p 067 CIPBEBK PRIMARY BOOM EXTEND EE P24FS WH I 17 1 17 2 5 8 put CAPERE PRIMARY BOOM RETRACT P2EESTP BK 8 027 1 027 2 BK RD i 69 C9PERF BK RD BOOM EXTEND RETRACT a n FLOW CONTROL 5 12 C12DRE 8 lt CUPS 6 12 CI2DREBLWH lt C629 R16PBR BK WH z lt lt XM T o A 58 DRIVE ENABLE LIMIT SWITCH 638 BKWH e 2 E 9 5 62 6 30 2 RD o La 1 C4P 2 C14PLU OR 4 UP 1 1 eoe PLATFORM LEVEL 2 7 DOWN C4P 3 C15PLD OR BK C20 1 C20 2 2 2 06 14 14 1 E ORM PLATFORM LEVELUP UP e PLATFORM LEVEL Tan I E Inl PLATFORM LEVELDOWN 2 C21 1 C21 2 i i E 2 Der 4 6 C18JD PRR GR BK DOWN kama en C17JU PRL GR
206. BOOM RETRACT 6 lt OR DD M N C6 8 C8PBR BK WH 1 2 lt BRN gt zL a n BATGND1 BRN SP E BOOM EXTEND RETRACT 2 eee 9 C9PERF BK RD C3B 9 B C6 9 C9PERF BK RD gt FLOW CONTROL lt DE 1 6 C32BRK WH RD C1B 6 2 61 e amp TURNTABLE ROTATE LEFT ore 4 C4TRL WH C3B 4 C64 CATRL WH 1 gt PEU NEA Ip E lt N 2 n ES 5 C5TRR WH BK C3B 5 C6 5 CSTRR WH BK 1 F 9 E out 9 lt vi 6 2 a e i 8 lt 5 2 15 PWR EK on 6 TURNTABLE ROTATE GND BRN T 6 C6TRF WH RD C3B 6 C6 6 C6TTRF WH RD 1 gt FLOW CONTROL 2 em 2 lt An ae E PRIMARY BOOM UP 1 1 1 RUAN gt 9 2 M E 1 1 C3B 1 1 P24FS WH amp CO PRIMARY BOOM DOWN z 9 C62 C2PBD RD BK 1 gt 9 2 C2PBD RD BK C3B 2 E 5 4 P22ESTOP 5 C2P 3 C41RPM OR BK C2B 3 PRIMARY BOOM 5 6 3 RD WH gt FLOW CONTROL C3P 3 RD WH C3B 3 2 d v S PLATFORM LEVEL UP l 1 S3LED BL RD C4B 1 C6 14 C14PLU OR 1 2 Y PLATFORM LEVEL DOWN C6 15 C15PLD OR BK 1 gt u PLATFORM ROTATE LEFT JIB BOOM UP L 06 17 C17JU GR 1 z 2 m d m CUPLU
207. BRN lt 22 7 1 P23BAT WH EXTEND PES g RETRACT BK WH C6 27 C27AUX RD ie Fl E C9PERF BK RD Feng G C4TRL WH C5 16 C25PSR BL BK 4 CSTRR WH BK DAE C6TRF WH RD C1PBU RD C2PBD RD BK C5 14 C26TSR GR BK 4 l C14PLU OR 5 PLATFORM LEVEL c8 9 lt YEIBK 9 DOWN C15PLD 5 2 41 8 8 DK BL o 9 RD C56 C27AUX RD C85 lt GR BK 9 5 5 C33STR BK 08 3 2 RD 5 19 P23BATSA C8 4 PU lt 17 GR BL RD 05 13 C38ESL BURD 08 7 WH BL WHT 5 11 2 C21IGN WH 6 C18JD BK WH 5 10 C39LP BL RD C8 1 YE lt BK RD 518 7 C35RPM BK RD 2 LTBL 2 RIGHT re PLATFORM ROTATE lt PLEK gt nI 08 12 BK 6 pi F e C19JSV GR WH amp drs Low RPM 2 ee FUNCTION ENABLE HIGH RPM C85RPM BK RD 5 m BATGND BRN C25PSR m a C26TSR GR BK P d G e ud 6 34 R21IGN WH 2 i 1 R116HYD C6 33 lt 5 C21IGN WH 8 C39LP 5 FUEL E GAS P 5 E T START C33STR a Je tr x se zj 0 1 x T 5 AUX
208. C29MS RD WH 0524 025 I EEN 5 6 WH RD 25 ode 3 5 WH BK 215 ISE C3P 4 C4TRL WH 5 aE igs o C64 GEBEWE 15 1 15 2 Ht TURNTABLE ROTATE LEFT gt 4 ex 2 Et TURNTABLE ROTATE 2 gt 8188 RD gt 1 LEFT ces CSTRRWHIBK 141 M 14 2 Sigs 5 174 TURNTABLE ROTATE RIGHT SE n 2 C6 6 C3l 1 C31 2 TURNTABLE ROTATE FLOW CONTROL EZ 5 Tl elle TER 2 pee ear see BOOM af CUTOUT RELAY C64 C12 1 4 C122 far C SETPPU RD lt lt gt PRIMARY BOOM UP m PRIMARY BOOM 1 HE 2 DOWN 062 TN C2PBD RD EK 74 BOOM DOWN Di a E C29 1 C29 2 u i lt lt lt 4 PRIMARY BOOM FLOW CONTROL 9 1 1 C1PBU RD 8 5 9 1 5 2 C2PBD RD BK i lex C3P 3 x 9 C9PERF BK RD e lt t 2 5 PRIMARY BOOM EXTEND 8 BK WH 5 3 lt t JA CUTOUT RELAY BRN 2 7 7 2 C16 1 C16 2 P24FS WH 5 6 7 C7PBE gt gt 2 5 EXTEND 3 PRIMARY BOOM EXTEND 24 WH BOOM
209. C6 37 BL BK 1 11 37 C6 20 i RD WH 3A 1 1 RED STOP BUTTON E RD BIGOA KS1 KEY SWITCH LP 4 LIMIT SWITCH 1 WH C2B 2 06 40 40 6 10 BETA 1 TS51 AUXILIARY TOGGLE SWITCH ENGINE RPM OR BK 2 3 ORIBK 5 2 41 OR BK ISM 2 a 145 1852 ENGINE START TOGGLE SWITCH LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD C6 22 BK RD 9A PLATFORM 7556 GLOW PLUG TOGGLE SWITCH LIMIT SWITCH POWER RD 6 31 46 074 ps gt lt CHECK ERA 22 7554 FUNCTION ENABLE TOGGLE SWITCH KEY SWITCH POWER RD C6 23 C26 134 RD H6 RD KSI SP BL RD ISM 10 KEY SWITCH POWER TS57 PLATFORM ROTATE TOGGLE SWITCH r1 7558 JIB BOOM UP DOWN TOGGLE SWITCH TERMINATION BLOCK GR BK H6 7559 PLATFORM LEVEL TOGGLE SWITCH 7561 PRIMARY BOOM UP DOWN TOGGLE SWITCH mE G6 7662 TURNTABLE ROTATE TOGGLE SWITCH AIE 1 START RELAY HOUR METER 7563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH oz i BK 33B 9 2 METER BRN CR19485 gt OO UP DOWN 1 CIRCUIT BREAKER ENGINE 15 5 5 8NGND STUD BD 278 AUX ON U1 TS63 CIRCUIT BREAKER CONTROLS 15 BE 8 23 5 BRNGND S 5 GROUND IGNITION BOOM X TEND CIRCUIT BREAKER OIL COOLER OPTION 15 as g WHEMAB 6 BATTERY START RD 1A Gi VOLT METER GAUGE OPTIONAL
210. CASHHN BK 4 HORN Es 8 i M e CI32PLI BUWH gt 4 R21IGN WH 4 HYDRAULIC OIL TEMPERATURE 12 C1B 12 md SWITCH OPTION P134PWR GR BK yd lt 5 N 2 6 C2B 6 EE R116HYD OR 6HYDOR 5 HYDRAULIC COOLING FAN OPTION T LE d m EK C6 134 RD FLASHING BEACONS OPTION N z lt 5 2 41 1 1 9 5 3 CIOTAFWH y qd 5 ALTERNATOR 5 Pig 55 sb aS i 41 cf OCA Es Han 9 bsepe lese E BATTERY SEPARATOR OPTION 8 C K ET START BATTERY N Or 4 CONTROL v LO gt ADD 040 ONLY IF UNIT HAS L4 148 No 77832 Genie S 80 amp Genie S 85 7 12 Section 7 Schematics Deutz F4L 913 Models after serial number 3576 Electrical Schematic S 80 with Dual Battery Option January2004
211. CH39887 amp C1B1 RD C5 6 27 RDISM 4 RD S P BRAKE WT RD C5 23 WH RD C1B 6 32 WH RD 6 32 06 RD 134A ENGINE START 1 7 BK ISM 3 BK S P START RELAY qos 5 5 33A BK CR28 86 BK ISM 1 GLOW PLUG BK WH C5 22 BK WH C1B 8 34 BKIWH S P I LABEL DESCRIPTION ENGINE RPM BK RD 1 9 35 CR3 30 BK RD S P RD 27A STEER RT AXLE EXT BL BK C6 37 C1B 11 37 C6 20 EET Fi REDIEMERGENCY STORBUET 38 I RD BK 2A KEY SWITCH I z 4 SWITCH 1 WH 2 2 OR 6 40 40 BICTA i Re ENGINE RPM ORIBK C2B 3 OR BK 5 2 41 OFK mE L45 TSs2 ENGINE START TOGGLE SWITGH z 1 LIMIT SWITCH 2 GEED ABA ORD ac ORRD GS BK RD 9A PLATFORM 7556 GLOW PLUG TOGGLE SWITCH LIMIT SWITCH POWER RD C6 31 46 07 14 lt 1 CHECK ENG LED LED TS54 FUNCTION ENABLE TOGGLE SWITCH KEY SWITCH POWER RD C6 23 2 6 134 RD H6 RD KSI SP BL RD 15 10 1 TS57 PLATFORM ROTATE TOGGLE SWITCH I KEY SWITCH POWER RD 6 24 Thad TS59 PLATFORM LEVEL TOGGLE SWITCH I BASE TERMINATION BLOCK 7561 PRIMARY BOOM UP DOWN TOGGLE SWITCH 7562 TURNTABLE ROTATE TOGGLE SWITCH WHITE G6 7563 PRIMARY BOOM TOGGLE SWITCH 7561 IRCUIT BREAKER ENGINE 15A omera START RELAY Boom 3
212. CIRCUIT CONTROLS 15 8 9 m 23 5 GND 5 GROUND IGNITION i CIRCUIT BREAKER OIL COOLER OPTION 15 s WH asAB __________ 2 BATTERY START RD IA RETRACT 1 Gi VOLT METER GAUGE OPTIONAL c WH 23B OT 7 KEY PWR MODULE ER 62 PRESSURE GAUGE OPTIONAL 8 KEY BYPASS 1 i _RD B1 20C eee 1852 TEMPERATURE GAUGE OPTIONAL zu RD B1 20D BURDL2 10 ENG FAULT G6 HOUR METER EES START I L RD 248 oo TS58 L2 CHECK ENGINE LED BK RD 35B f SQO a mc 128 GLOW PLUG LED GR C2B 5 128 e 145 PLATFORM OVERLOAD LED g CRS BEER GLOW PLUG 1362 CR IGNITION START RELAY o 1 RD 24AA TURNTABLE I CR2 IGNITION POWER RELAY 86 86 1 ORBIGIEA ROTATE 1 6 2 Ta CR3 HIGH IDLE CUTOUT RELAY a 6 16 BKADASA Dis CR5 RELAY lt BK RD 5 18 1 I HYDRAULIC COOLER FAN RELAY e OR RD 168 2 8 4 CR23 DRIVE LIGHT RELAY OPTION 7B CR25 AXLE RET L O RELAY a C6 13 RPM GE 19 29 AXLE EXTEND LED m CB1 2 ENGINE CONTROLS Teer CR38 EXTEND FUNCTION CUTOUT RELAY RD 24A PLATEORM
213. CR5 30 x sD 4 12 KEYS WITCH PWR PWR TO PLAT RD C6 23 RD 06 24 23 RD ISM 7 I 1 9 KEYS WITCH PWR PWR TO WH 7 2 RD 6 38 23A RD C6 30 1 NC n 1 J FUSED 12V DC RD CR28 30 RD ISM 6 24 RD CR2 30 RD S P CB1 Q 3 OIL COOLER FAN 24 RD CR17 30 RD S P CB3 9 91 AUXILIARY PUMP RD 6 278 1 1 RD 27 RDISMA4 80 5 3 D2 i en Zn BRAKE WT RD C5 23 WH RD 1 6 32 WH RD C6 32 1 RD 23A i ENGINE START 1 7 33 BK ISM 3 BK S P STARTRELAY pes 5 5 33A BK CR28 86 BK ISM 1 1 22 GLOW PLUG BK WH C5 22 BK WH C1B 8 34 BK WH S P k s ENGINE RPM BK RD C1B 9 35 BK RD CR3 30 BK RD S P RD 27A i STEER RIGHT AXLE EXTEND C6 37 1 11 37 6 20 RD WH 3A 38 RD BK 2A LP 39 7 LABEL DESCRIPTION LIMIT SWITCH 1 WH 2 2 OR 66 40 40 6 10 ENGINE OR BK 2 3 5 2 41 OR BK ISM 2 EED ER RED EMERGENCY STOP BUTTON 4 LIMIT SWITCH 2 OR RD 4 OR RD CR29 86 42 OR RD 6 22 034 e pr KS1 KEY SWITCH LIMIT SWITCH POWER RD C6 31 0742 46 TS51 AUXILIARY TOGGLE SWITCH BOWITSAR TS52 ENGINE START TOGGLE SWITCH TERMINATION BLOCK TS56 GLOW PLUG TOGGLE SWITCH 7 START RELAY
214. CUIT DESCRIPTION FROM TO 12 DRIVE ENABLE BL WH 6 12 BL WH C3B 12 19 JIB VALVE GR WH 4 7 GR WH S P 25 OIL PRESSURE SENDER BUBK C5 16 BL BK S P 26 WATER TEMP SENDER GR BK 05 14 GR BK S P 28 TILT ALARM RD BK C1B 2 RD BK C6 28 29 2WD 4WD RD WH C5 24 RD WHC1B 3 30 E D C REVERSE WH 1 4 WH 5 21 31 E D C FORWARD WH BK C5 20 WHIBK C1B 5 36 STEER LEFT AXLE RETRACT BL CB1 10 BL 6 36 43 GR C2B 5 GR CR5 86 45 GENERATOR OPTION GR WH 2 7 GR WH 5 12 60 AXLE EXTEND RETRACT SELECT OR RD 6 39 OR RD C2B 4 61 AXLE RETRACT BL BK C3B 11 6 21 REVA 2004 Section 7 Schematics REV A Platform Control Box Wiring Diagram S 80 GM 3 0L Models before serial number 3577
215. Ct 5 YEL Lone JC2 2 BRN 8 OO 13 5 WH e 00211 lt uj 1 1 1 JC3 3 OR 1 tr 1 2 a JC3 6 BL sola BLWH ee 5 ee 5 924 1 T TS15 DRE Te lt 3 z k T L1 C13LED BL RD e s St 25 914 29 5 RD WH 5 9 2 1 1 EO ae PE 8 5 GN BK C3P 10 lt x GN BK L4 3 RD C2P 6 2 5 1 RDLS18 zi CE MODELS SEE DETAIL A 7 55 Genie S 80 amp Genie S 85 Part No 77832 2004 Section 7 Schematics Platform Control Box Wiring Diagram S 85 Perkins 704 30 Models after serial number 3576 2004 Section 7 Schematics EI Hydraulic Schematic 2WD Models
216. Do not remove them 4 Block the steer tires and center a lifting jack under the outer axle 5 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 EXTENDABLE AXLE COMPONENTS REVA Remove the lug nuts Remove the tire and wheel assembly Remove the drive motor covers from both sides of the inner axle Tag disconnect and plug the hydraulic hoses at the drive motor Cap the fittings on the drive motor AWARNING 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 9 Place blocks under the axle extension cylinder for support 10 Remove the external snap rings from the axle extension cylinder pivot pin of the inner axle to be removed Use a soft metal drift to remove the pin 11 Attach a strap from a lifting device through the inner axle close to the drive hub for support 12 Remove all wear pads from the outer axle Pay careful attention to the location and number of shims used when removing the wear pads 13 Carefully remove the inner axle from the outer axle Crushing hazard The inner axle AWARNING could become unbalanced and fall if not properly supported when it is removed from the outer axle Component dama
217. E BL WH CaB 12 2 Z J8 WH 1 RD Q ETA gt 8401 52 OR RD C4B 4 l lt lt lt BK 4 WH LS2AS 4 of BOOM ANGLE DRIVE MODE Sa 2 OR c6 10 C40LS2 3 BK SAFETY 29 5 RD WH 1 12 C38ESL BL WH C1B 12 lt lt lt En DRELED BURD 2291 HERE J1 WH 1 lt DRE B BL BK gt 2 8 C6 40 C40LS1 OR 4 WH gt 4 m 9 LS1RO 9 BOOM RETRACTED o 3 em 2 OPERATIONAL p DRE A BL WH D36 3 BK 1 11 C37STC BL BK 1 11 81 EX gt Farm lt gt i 1 10 BL g C1B 10 J2 WH 1 RD C2P 2 C40LS1 OR C2B 2 DEK 4 Due lt lt lt 16 9 22 sj c6 31 C46PWR RD 4 BK Your s WH v lt 3 15 1 BL BK c6 20 ZZ CSTSTC WH 2 Z BRN 5 PWR ejs s lt S 1 4 7 WH 1 4 m GND ZK lt AXLE DUMP VALVE lt e C6 11 C42AXDP WH l EMEN 2 Z WH BK Z 185 m lt 2 AXLE EXTEND RETRACT SELECT C1P 3 4 C29MS RD WH Z CIB3 D57 Beten BATGND2 BRN BOOM EXTEND 7 7 CaB7 67 _ gt lap 8 St 8
218. ES FULLY BATGND 2 MOTOR STROKE 5 24 RD WH 1 gt 2 8 DRIVE BRAKE VALVE A C5 23 C32BRK WH RD 1 1 9 BK RD C1B 9 HIGH RPM FS gt 65 21 CS0EDC WH DRIVE EDC FORWARD f C5 20 C31EDC WH BK D 3 5 E DRIVE EDC REVERSE ENGINE SPEED La HIGH RPM c6 28 CDBTTARD BK C WH poo 2 In OFF 5 6 23 P23BAT zo RD p LEVEL SENSOR 2 2 2 ee I SWITCH De LEVEL SENSOR C2P 7 GRWH l GND1 BRN B BK 3 4 1 8 C34SA BK WH C1B 8 RD e lt C512 C45GEN GR WH 4 E a I 8 C33STR BK C1B 7 RE TEER pn ENGINE START a b Y LAFA a C6 24 P23FB RD eo 6 A FLASHING BEACON a AUXILIARY PUMP cipi BD lt 2 S C6 32 C32TA WH RD 5 TRAVEL ALARM o a NM 8 4 C6 19 C2DA RD BK DESCENT ALARM c amp 2 1 2 C28TTA RD BK C1B 2 N c6 16 ZZ C43HRNBK lt z HORN V 5 1 BATGND ral 25 o EG 2 5 C43HRN GR 2 5 C522 C34SA BK WH 5 5 o 7 P23BAT WH m 1 65 19 Z P23BAT RD 55 GLOW PLUG RELAY 7 1 47 2 Ot 7 3 7 BRN ON
219. ETER OIL PRESSURE OIL TEMPERATURE PRIMARY BOOM DOWN 029 RD BK C3B 2 amp C6 2 2 015 DH RD BK S P i PRIMARY BOOM RD WH 3 RD WH 6 3 RD WH S P TURNTABLE ROTATE RIGHT WH C3B 4 WH 6 4 4 WH S P TURNTABLE ROTATE LEFT WH BK C3B 5 WH BK C6 5 5 WH BK S P gt WH RD C3B 6 WH RD C6 6 6 WH RD S P C3B 7 C67 7 stud BK S P G2 G3 DRIVE LIGHT OPTION RELAY BOOM C3B 8 BKIWH 6 8 8 057 BK WH S P 4 EXTEND RETRACT BK RD C3B 9 BK RD C6 9 9 BK RD S P SBD DESCENT ALARM BL C3B 10 10 BL S P 24 1 11 1 BL BK 5 16 15 FUSE 2 PLATFORM LEVEL UP OR 4 2 6 14 14 OR S P PLATFORM LEVEL DOWN C4B 3 OR BK 6 15 15 OR BK S P CR23 AXLE DUMP VALVE OR RD C6 11 16 OR RD CR8 87A EES PLATFORM ROTATE LEFT GR C4B 5 GR C6 17 17 GR S P 1 d 1551 85 ___ 6 GR BK C2B 6 PLATFORM ROTATE RIGHT 4 6 GRIBK 6 18 18 GR BK S P EE ETOE ee 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P gt 12 AUXILIAHY PUMP RDC4B 11 IGNITION POWER WH 17886 WH C5 38C5 11 21 652 stun WHSP m HORN C7B 1 22
220. Error Source Error Type Condition Solution ID Name ID Name 33 Boom 2 flow Limited speed and control valve 12 Value too high direction frozen 4 15 Value too low zero and neutral controller wit Alarm sounds problem corrected indicating fault Normal function except threshold for Calibrate valve 17 Not calibrated one or both directions thresholds is zero 18 Just calibrated Self clearing transient 41 Turntable rotate 11 Value at 5V Limited speed and joystick 12 Value too high direction frozen at Power up 15 Value too low zero and neutral controller with 16 Value at 0V Alarm sounds problem corrected indicating fault Joystick speed and 17 Not calibrated direction frozen at Calibrate joystick zero and neutral 18 Justcalibrated Initiate 1 second beep Self clearing of alarm transient 42 Turntable rotate Limited speed and directional valves direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault 43 Turntable rotate Limited speed and flow control valve 12 Value too high direction frozen 15 Value too low zero and neutral controller wit Alarm sounds problem corrected indicating fault Normal function Calibrate valve bu except threshold for thresholds both directions Self clearing 18 Just calibrated ie sao transient 44 Drive enable Enable override Power up override switches 21 Faul
221. F WH RD C3B 6 6 6 C6TTRF WH RD 1 gt FLOW CONTROL jg og am 19 2 im An ben neil PRIMARY BOOM UP 2 C6 1 FA C1PBU RD 1 gt lt x 9 2 m 9 CaP CIPBUIRD Ser 4 PRIMARY BOOM DOWN l 4 P24FS WH z amp 6 2 C2PBD 1 7 2 C2PBD RD BK C3B 2 E S 4 e P22ESTOP BK 578 Exe C2P 3 C41RPM OR BK C2B 3 PRIMARY BOOM 5 2 C6 3 RD WH EUCH FLOW CONTROL C3P 3 C3PBF RDWH C3B 3 2 amp PLATFORM LEVEL UP 4 S3LED C4B 1 C6 14 C14PLU OR 1 I N 2 5 2 PLATFORM LEVEL DOWN C6 15 C15PLD OR BK 1 1 gt gt 3 2 ES PLATFORM ROTATE LEFT L C6 17 C17JU GR 1 gt NS 2 m e lt CAD bo Y PLATFORM ROTATE RIGHT PLATFORM LEVEE E C6 18 C18JD GR BK 1 00WN C4P 3 C15PLD OR BK C4B 3 eo 10 lt JDALARM BL 3 lt C3B 10 5 C17JU GR C4B 5 13 BATGND 2 Cu STEER RIGHT AXLE RETRACT 6 C18JD GRIBK C4B 6 6 37 C37STC 1 gt i 2 RIGHT PLATFORM ROTATE m C STEER LEFT AXLE EXTEND 6 36 BL 1 gt i SM boog S3LED BURD t lt lt AXLE NOT EXTENDED 7 lt C19JSV GR WH 4 7 PRESSURE SWITCH 39 AXL
222. G 8 000 lt 7 gt GLOW PLUG FUEL VALVE OIL TEMPERATURE AND OIL PRESSURE LED a 55 3 SES ee 52 1 7 C33STR amp 08 03 4 ENGINE OIL TEMPERATURE SWITCH ee OE gt 2 6 d x START 95582688206 3 4064 3 6 05 15 ao OIL PRESSURE SWITCH F ENGINE RBS n START ef Es POWER RELAY 5 8 B 1 4 gt AUXILIARY o POWER od SM CEIGNWH 80 ASA 9 n m M TiNd C27AUX FUEL SOLENOID 27 gt 57 R33STR BK C5 5 C33STR IGNITIOIN START RELAY ale a io E git 59 AUXILIARY A 5 u POWER EF STARTER MOTOR al a LES 7 2 2 PesBATWH 5 9 um I Iy 4 5 WH 3 9 g C1B 2 Ep C6 27 C27AUX RD AUXILIARY POWER RELAY 1 2 2 RD BK 4 gt 55 _ E 35 AUXILIARY 4 0 nn C25PSR BL BK oom OIL PRESSURE gt ey SENDER OPTION Ne 4 VOLT METER OPTION C26TSR GR BK FAAAL OIL TEMPERATURE a SENDER OPTION C28TTA RD BK WHI 1 C3P 10 g C133PLABL 421 06 28 an ETER l 1 134 RD 06 23 BK 4 LEVEL SENSOR M NZ
223. GLE SWITCH 2 TACHOMETER 7556 TS57 PLATFORM ROTATE TOGGLE SWITCH LO START INPUT 7559 PLATFORM LEVEL TOGGLE SWITCH WH 21A 5 5 E BRN GND STUD 122 9 4 AUX ON U1 G6 7561 PRIMARY BOOM UP DOWN TOGGLE SWITCH 5 _ RD CRi4g0 6 5 GROUND IGNITIONSTART HOUR METER 7561 7562 TURNTABLE ROTATE TOGGLE SWITCH gt lt WH 23AB Wiese 6 BATTERY MODULE BOOM 7563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 7 KEY PWR CIRCUIT BREAKER ENGINE 15 8 KEY BYPASS _ 1 1 20 WH CR2 86 S 9 IGN FUELON CIRCUIT BREAKER CONTROLS 15A 5 RD B1 20D BL RD L5 10 ENG FAULT RD 1A BOOM EXTEND CIRCUIT BREAKER COOLER OPTION 20A T 2 5 248 BK 33A Gi VOLTMETER GAUGE OPTIONAL Pp G2 OIL PRESSURE GAUGE OPTIONAL BK RD 35B CHECK ENGINE LED G3 TEMPERATURE en Pa GR C2B 5 ne Hj G6 HOUR METER x 5 7 CR2 CRS BLBDISMEO N CB3 QG 12 CHECK ENGINE LED g RD BK C6 19 BURD C5 15 7952 7562 CR2 IGNITION POWER RELAY 18 RD 24AA ENGINE START CR3 HIGH IDLE CUTOUT RELAY 5 6 16 OR BK 15A ROTATE HORN RELAY 5 BK RD 5 18 RD B2 H1 1 CR17 HYDRAULIC COOLER FAN RELAY 5 5 OR RD 168 T
224. GR WH S P u ALL WIRES 25 PRESSURE SENDER BUBKC5 16 BUBK S P 5 WH RD 6A 5 26 GRIBK C5 14 5 fm R2 28 ALARM RD BK 1 2 RD BK 6 28 WIRING HARNESS 29 2WD AWD RD WH C5 24 RD WH C1B 3 3 30 E D C REVERSE WH 4 WH 5 21 CONTROL BOX 8 8 1 CONNECTIONS 1 31 E D C FORWARD WH BKC5 20 WH BKCIB 5 8 I 36 STEER LEFT AXLE RETRACT BL CB1 10 BL C6 36 8 I 1 5 1 43 GR 2 5 GR CR5 86 45 GENERATOR OPTION GRIWH C2B 7 GRIWH C5 12 I 1 60 AXLE EXTEND RETRACT SELECT OR RD 6 39 OR RD 2 4 O 61 AXLE RETRACT C3B 11 C6 21 1 EE EHE 1 MAREE hee el EL SALE LS 1 7 24 5 80 amp 5 85 77832 REV A January 2004 Section 7 Schematics ne Ie Platform Control Wiring Diagram 5 80 GM 3 0L Models after serial number 3576 D C B A
225. H 7 2 RD 06 38 aaa RD 6 30 RD S P Nc T m FUSED 12V DC RD ISM 6 24 CR2 30 RD S P CB1 9 OIL COOLER FAN 24A RD CR17 30 RD S P CB3 8 8 3 AUXILIARY PUMP RD C6 278C1B 1 RDe 27 RDISM 4 AD S P 5 Si BRAKE WT RD C5 23 WH RD C1B 6 32 WH RD C6 32 RD 23A gt 9 ENGIEN START BK 1 7 BK ISM 3 BK S P d START RELAY 5 5 1 22 1 GLOW PLUG BK WH 5 22 BK WH C1B 8 34 BK WH S P EE BK RD C1B 9 35 BK RD CR3 30 BK RD S P RD 27A STEER RIGHT AXLE EXTEND BL BK C6 37 BL BK 1 11 37 C6 20 RD WH 3A LABEL DESCRIPTION 38 RD BK 2A P1 EMERGENCY STOP BUTTON 39 7 LIMIT SWITCH 1 WH 2 2 OR 66 40 40 OR C6 10 ERWHER KS1 KEY SWITCH ENGINE RPM OR BK C2B 3 OR BK C5 2 41 OR BK ISM 2 EKRIR 1551 AUXILIARY POWER TOGGLE SWITCH LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD 06 22 D34 TS52 ENGINE START SWITCH 4 LIMIT SWITCH POWER RD C6 31 pr 46 7554 FUNCTION ENABLE RPM SELECT TOGGLE SWITCH BK WH 34A 7557 PLATFORM ROTATE TOGGLE SWITCH BK CR1486 959 PLATFORM LEVEL TOGGLE SWITCH 1 START RELAY TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH 162 128 BK 33B 3 START IN
226. H RD 6 C6 6 WH RD 1 FLOW CONTROL gt 2 lt BRN gt gt ob n 16 18 lt 2 2 PRIMARY BOOM UP 1 C1PBU RD 1 gt ss lt lt lt L gt gt 1 C1PBU RD CaB 1 4 P24FS WH z PRIMARY BOOM DOWN l 4 24 6 06 2 C2PBD RD BK 1 2 C2PBD RD BK C3B 2 5 x 4 P22ESTOP Ek C2P 3 C41RPM OR BK C2B 3 PRIMARY BOOM 5 6 3 RD WH FLOW CONTROL dr 3 C3B 3 8 2 LA eo amp 2 PLATFORM LEVEL UP j 1 lt S3LED C4B 1 C6 14 C14PLU OR 1 N df 2 59 2 2 PLATFORM LEVEL DOWN o 06 15 C15PLD OR BK 1 A ie MEN SINIT 2 L D OER 550 PLATFORM ROTATE LEFT C6 17 C17JU GR 1 gt lt E 2 CI4PLUOR 48 2 62 5 S PLATFORM ROTATE RIGHT 4 lt PLATFORM LEVEL C6 18 C18JD GR BK 1 i DONN C4P 3 C15PLD OR BK C4B 3 o 10 lt JDALARM BL 3 lt C3B 10 4 5 C17JU GR C4B 5 l BATGND BRN 2 STEER RIGHT AXLE RETRACT 4 6 C18JD GR BK C4B 6 T C6 37 C37STC BL BK 1 I 2 RIGHT PLATFORM ROTATE C STEER LEFT AXLE EXTEND C6 36 C36STCC BL 1 gt o amp po lt SSEED BURD AXLE NOT EXTENDED C4P 7 lt C19JSV GR WH C4B 7 A PRESSURE SWITCH 39 AXLES
227. ILIARY POWER 8 EI 9 5 O 990 m C27AUX GR WH 1 gt 1 TA 2 2281 5 P23BAT RD e x lt a lt 1 2 22 i EGS m N 1 awn 1 N 1 1 m 1 1 1 1 P43HRN 5 e 55 SE N X i 1 E DE 8 S C21IGNWH I RD el le 5 on Ne e i amp i 1 IE gl 1 OAR EK eR 19 1 aos 1 1 i 2 oe e EN 8 i i BATGND BRN BATGND BRN 1 1 e N u gt 5 gt 3 01 Models before serial number 3577 AUXILIARY RELAY AUXILIARY PUMP OIL PRESSURE SENDER OPTIONAL WATER TEMPERATURE SENDER OPTIONAL STARTER RELAY STARTER MOTOR HYD OIL TEMP SWITCH COOLING FAN ALTERNATOR ENGINE STARTING BATTERY APU BATTERY OPTION
228. INE G1 VOLT METER GAUGE OPTIONAL EE START OIL PRESSURE GAUGE OPTIONAL RD CR38 30 9 G2 MIX ES WATER GAUGE OPTIONAL BK WH 06 29 GES QG G6 HOUR METER I Q OIL COOLER TS62 12 CR38 RD 24AA OPTION TURNTABLE i R2 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS I ROTATE Er CR2 IGNITION POWER RELAY a e z 6 a 6 BK C6 16 m CR3 HIGH IDLE CUTOUT RELAY 5 OR RD 16 Pers CR5 HORN RELAY o m OR RD 168 1 1 9 1554 CR8 BOOM FUNCTION CUTOUT 2 BK 7B 1 HIGHLOW Q CR17 HYDRAULIC COOLER FAN RELAY BL RD C6 13 mm CR23 DRIVE LIGHT RELAY OPTIONAL a 5 5 RD 6 27 RD 27D 42 CONTROLS 1357 CR25 AXLE RELAY RD 24A ENGINE Jes 06 33 PLATFORM DE CR29 AXLE EXTEND LED RELAY 1 1 POBILA LEVEL CR38 EXTEND FUNCTION CUTOUT RELAY i WH 21B 2 CR39 AUXILIARY 2 86 leeren 17 u1 IGNITION START MODULE creo crag IcR17 g WH C6 34 GR WH C4B 7 7 5 OR RD 42 GR BK 18A GROUND STUD e CIRCUIT DESCRIPTION FROM TO BRN WH 4A 12 DRIVE ENABLE BL WH 06 12 C3B 12 RD BK 28 WH BK 5A E RD 24B 19 VALVE GR WH C4B 7
229. ISM 3 BK S P 134 START RELAY pos BK C5 5 i GLowPLuG BK WH C5 22 BK WH 1 8 34 BK WH S P ENGINE RPM BK RD 1 9 35 BK RD CR3 30 BK RD S P RD 27A LABEL DESCRIPTION STEER RT AXLE EXT 06 37 1 11 37 C6 20 RD WH 3A I 38 EES 1 RED STOP BUTTON 2 39 ER KS1 KEY SWITCH LIMIT SWITCH 1 WH C2B 2 C6 40 40 OR 6 10 GOUER TOGGLE SWITCH 1 BK WH 8A ENGINE RPM OR BK C2B 3 5 2 41 OR BK ISM 2 145 LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR AD C6 22 I BK RD 9A PLATFORM 7552 ENGINE 8 TOGGLE SWITCH LIMIT SWITCH POWER RD C6 31 46 07 lt lt CHECK ENG LED en 1554 FUNCTION ENABLE TOGGLE SWITCH KEY SWITCH POWER RD C6 23 2 6 4 134 RD H6 RD KSI SP BL RD ISM 10 7557 PLATFORM ROTATE TOGGLE SWITCH KEY SWITCH POWER RD 06 24 1 859 PLATFORM LEVEL TOGGLE SWITCH li 1 GR BK H6 TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH I I 562 TURNTABLE ROTATE TOGGLE SWITCH WH 21A G6 TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH BK CR1 86 OR BK 41B 1 START RELAY HOURMETER CIRCUIT BREAKER ENGINE 15A m I 1 LO 2 TACHOMETER BRN GND _ ao UPDOWN CIRCUIT BREAKER CONTROLS 15 BRN GND STUD RD 27B 9 3 STRAT NP
230. ITCH C29MS RD WH 5 66 20 LED 16 e 6 37 5 216 8 8 C25 1 C25 2 1 11 C37STC BUBK 6375 STEER RIGHT CDE2 BL BK 7 gt RIGHT 8 E 8 C6 36 C24 1 C24 2 DRIVE 7 lt 40 1 10 C36STCC C36STCC BL STEERLEFT 6 CDE1 BL WH 1 05 21 C30EDC WH A UC A hs lt GIRA ESOF DEL DRIVE EDC FORWARD lt 1 12 05 20 C81EDC WH BK C aif TES 4 16 GIRS CS1EDG WHIBK Re He DRIVE EDC REVERSE 915 4 lt 5 gt 5 5 RUP e pue OE So Pes EE S Q C SA 1 pwr 3 lt on 25 1s TRAVEL ALARM OPTION 2 lt 14 EE EE NE AE EE EE N m suum 1 8 lt 05 23 026 1 I C26 2 C32BRK WH RD 2 WH RD E d fa CIPE cc OS d lt C gt gt BRAKE RELEASE VALVE C29MS RDWH C524 RDAWH C28 1 C28 2 20 lt 1 3 MOTOR STROKE 5 8 6 6 WH RD 25 97 2 mS E 7 C3P 5 WH BK 215 2 igu C3P 4 C4TRL WH 5 igs lt C64 C15 1 15 2 18 4 TURNTABLE ROTATE LEFT 5 2 RIGHT u 8 8 ii 20 g euer meee n 8 cere wiek 6144 ti Se TURNTABLE ROTATE RIGHT gt on BRN gt gt 12 6 6 31 1 31 2 TURNTABLE ROTATE FLOW CONTROL ES lt 5 Y
231. IVE SPEED TOGGLE SWITCH 1 TS15 DRIVE ENABLE TOGGLE SWITCH crime SET TS16 AXLE EXTEND RETRACT TOGGLE SWITCH TS47 GENERATOR TOGGLE SWITCH OPTION VA AA AA D Er AAAASYYSAY 5 435524650944 545564 548 WORK LIGHT TOGGLE SWITCH OPTION 35529 Besse 25888 DA 98895 9 5232802594 7549 DRIVE LIGHT TOGGLE SWITCH OPTION s 350 9 2 ss 355 ee 2 289855 295 450 1518 PLATFORM OVERLOAD LIMIT SWITCH FEF TEELS EER EER 88 98225060 25099 922 4246 L1 DRIVE ENABLE LED uo 2328 2 52 gt 29 ENS PES 355g2225092230529 88 14 PLATFORM OVERLOAD LED 3 5 DK 188 T T E 8 3274 1 L40 AXLE EXTENDED LED 5 En o 148 ALARM LED E 5 JC3 DRIVE PROPORTIONAL JOYSTICK STEER LEFT RIGHT C28TTA RD BK 2 JC2 BOOM PROPORTIONAL JOYSTICK SECONDARY BOOM UP DOWN 919 JC1 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE abs ee U13 ALC500 13 BOOM 7 3 Pr 26 AXLE CUTOUT RELAY 4 GND RD BK JIB CABLE a GR WH 157 en E N J Si Tol To 222222222222 BKLS CABLE CIP 12 1 i 3 18 de 8
232. L D 8 1 25 u R C27AUX GR WH 9 EE Zeal gt i oral a 1 i Q S P23BAT RD C gt e 1 i 5 o 6584 a a Eu P 1 i i i i 55 F i i og E a e 5 ENGINE STARTING 2 8 SUN C21IGN WH 5 e se E e se 9 59 ER EE P116HYD N a 58 Hie E 9 Basen 24 i APU BATTERY OPTION iN em J a i i BATGND BRN BATGND BRN i
233. LOW PLUG LED RD WH J1 8 BRN J1 10 OR J1 9 YEL J1 3 JC1 BOOM RD C1P 1 TS14 DRIVE SPEED EXTEND RETRACT GR BK 6 OOO 5 TS1 AUXILIARY PUMP GR WH CABLE x J2 DIODE WH BRN e 5 4 e 4 o u OR RD C2P 4 mor BES SE xc 5 amp s lt 3looo z BL C1P 10 Ee BL BK 11 8 BL RD 1 BRN J1 12 OR 21 11 258 RD J1 1 5 BK J1 2 BR 20 4 Be 2246 gt 92050 2 5 4 2 x e C2P 5 MODELS SEE DETAIL 7 31 5 80 amp 5 85 77832 2004 Section 7 Schematics ERN Platform Control Box Wiring Diagram S 80 Perkins 704 30 Models after serial number 3576 Section 7 Schematics January 2004 Rr Ground Control Box Wiring Diagram S 85 Deutz FAL 913 Models before serial number 3577 Section 7 Schematics 2004
234. MP a RDC4 IGNITION POWER WH CR17886 WH 5 3 amp 5 11 21 WHSP if HORN C7B 1 22 CR5 30 Ld 3 2 RD C4b 12 KEY SWITCH PWR PWR TO PLAT RD C6 23 RD 06 24 23 RD ISM 7 I KS 91 KEY SWITCH PWR PWR WH C7B 2 RD C6 38 2 RD 6 30 B FUSED 12V DC RD ISM 6 24 RD CR2 30 RD S P CB1 IS 3 OIL COOLER 24A RD CR17 30 RD S P CB3 91 AUXILIARY PUMP RD C6 27 amp C1B 1 RD 27 RDISM 4 Ro s P lt x i lt WT RD 5 23 WH RD 6 32 WH RD C6 32 RD 23A Te SS Qi ENGIEN START 7 33 BK ISM 3 BK S P START RELAY C5 5 1 22 i l l MA saad l 1 GLOW PLUG BK WH C5 22 BK WH C1B 8 34 BK WH S P ENGINE RPM BK RD C1B 9 35 BK RD CR3 30 BK RD S P RD 27A i STEER RIGHT AXLE EXTEND C6 37 C1B 11 37 BL BK 6 20 RD WH 3A LABEL DESCRIPTION RD BK 2A STOP BUTTON LIMIT SWITCH 1 WH 2 2 6 40 40 OR 6 10 KS1 KEY SWITCH ENGINE RPM OR BK C2B 3 OR BK C5 2 41 OR BK ISM 2 1 ER TS51 AUXILIARY POWER TOGGLE SWITCH 4 LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD C6 22 D34 TS52 ENGINE START SWITCH LIMIT SWITCH POWER RD C6 31 07 08 JEE 4e I 7554 FUNCTI
235. NE START e 4 C6 24 P23FB RD us ENA 0 E 4 FLASHING BEACON m AUXILIARY PUMP CES RD 2 2 5 C6 32 C32TA WH RD TRAVEL ALARM oo m gt E gt 2 2 C6 19 C2DA RD BK DESCENT ALARM a amp ST l 1 2 C28TTA RD BK 1 2 ma C6 16 C43HRN BK n HORN 5 BATGND mt 6 i a 2 5 GR 2 5 s ER 4 5 22 C34SA BK WH i 5 P23BAT WH Es E 1 im P22BAT 57624781 1 7 3 BATGND BRN pee T I eem i wes le 2 50 rd o BATGND BRN gl E E P22BAT 7 1 C5 18 lt P23BAT WH 7 2 RETRACT C6 27 C27AUX RD C9PERF BK RD E B i 25 n WH S 6 LEFT TURNTABLE ROTATE 05 16 C5TRR WH BK ar ae Fig 1001 20 S gt WH RD M Bitte I ao 5 C5 15 C24TSPS BL RD b 8g el le 2 1 I C1PBU sur amp TH PRIMARY BOOM p pows C2PBD RD BK C5 14 C26TSR GR BK 4 8 i e on C14PLU OR WH 5 11 C211GN2 WH sur 5 HOLD
236. ON IE 2 gt gt 14 nen 1 a n lt C1P 6 C32BRK WH RD C523 C26 1 C26 2 lt BRAKE RELEASE VALVE C1P 3 C29MS RD WH C5 24 cogusRD WH 028 1 C28 2 20 MOTOR STROKE 2 ae 98 6 C6TRF WH RD 25 918 M u EE 5 C5TRR WH BK 2 5 4 C4TRL x FE 9 lt a 15 1 C152 185 4 C4TRL WH I TURNTABLE ROTATE LEFT 24 2 RIGHT j ET LEFT TURNTABLE ROTATE B ces C14 1 I 14 2 Sigs 5 WE TURNTABLE ROTATE RIGHT In lt eo BRN gt 12 CETTREWHIRD C3l 1 31 2 TURNTABLE ROTATE FLOW CONTROL 50 IS R2 2 i PRIMARY BOOM UP CUTOUT RELAY C64 C12 1 6 12 2 far u HD 7 PRIMARY BOOM UP m ee PRIMARY BOOM C13 1 C13 2 DOWN Ibi t C2PBD RD BK PRIMARY BOOM DOWN T 5 E 5 gt cea 029 1 A PRIMARY BOOM FLOW CONTROL I ia e N 5 1 1 C1PBU RD 8 JE 1 on s 7 2 C2PBD RD BK 19 BRN gt 10 1 E C3P 3 RD WH LQ 1 8 9 C9PERF BK RD lt 5 5 5 PRIMARY BOOM EXTEND 8 C8PBR BK WH EK 1 CUTOUT RELAY 3 E 7 C7PBBE BK 8 067
237. ON ENABLE RPM SELECT TOGGLE SWITCH BK WH 34A 7557 PLATFORM ROTATE TOGGLE SWITCH BASE TERMINATION BLOCK 1 BK CR1486 5 TS58 BOOM UP DOWN TOGGLE SWITCH 1 START RELAY i Ecc Mee LO 2 TACHOMETER 128 7559 PLATFORM LEVEL TOGGLE SWITCH os BOTE START GE GLOW PLUG TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH 5 BRN GND STUD 80 278 15 4 AUX ON U1 G6 LED TS62 TURNTABLE ROTATE TOGGLE SWITCH opm BK 22D BBN GND Og GROUND 1 HOUR METER TS61 sen BED __ d 1 7963 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH RD CR1 30 IGNITION START BOOM gt WH 23AB 6 BATTERY 1 a al Tl WH 23B Sz KEY POWER MODULE BRN CR19 85 F UP DOWN CIRCUIT BREAKER ENGINE 15A 1 i 8 KEY BYPASS 10 TS63 2 CIRCUIT 15 5 RD B1 20C TT 9 IGN FUEL ON TR BOOM EXTENT CIRCUIT BREAKER OIL COOLER OPTION 204 B1 1 RD B120D 9 t0 ENG FAULT G1 VOLT METER GAUGE OPTIONAL P 24 1 i OIL PRESSURE GAUGE OPTIONAL I 12 G2 BK RD 35B CHECK ENGINE LED OO G3 WATER TEMP GAUGE OPTIONAL GR C2B 5 RD 23 RO H H G6 HOUR METER 5 em ems ene BK 22B BL RD ISM 10 j age L ee 1 no RD BK 6 19 1 552 128 GLOW PLUG LED u 1 BURD 05 15 COOLER TS58 RD 24AA ENGINE START
238. OOM RETRACT C3B 8 BK WH C6 8 8 C6 38 BKWH S P RD 023 6 EXTEND RETRACT FLOW CONTROL C3B 9 06 9 9 BK PD S P WH 23A 1 SBD DESCENT ALARM 10 22 1 a PLATFORM LEVEL UP C4B 2 6 14 14 OR S P me N PLATFORM LEVEL DOWN OR BK C4B 3 OR BK C6 15 Dig 15 OR BK S P AXLE DUMP VALVE OR RD C6 11 OR RD CR38 87A 16 OF RD CR amp 87A 034 4 PLATFORM ROTATE LEFT C4B 5 C6 17 17 GR S P I PLATFORM ROTATE RIGHT GR BK C4B 6 GR BK C6 18 18 GR BK S F 1 7351 1 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P AUXILIARY 3 IGNITION POWER WH 17 86 WH 5 3 8 5 11 21 lt WHSP KEY SWITCH 1 HORN 23 4 22 BK CR5 30 BK S P 1 2 i KEYSWITCH PWR PWR TO PLAT WH 7 2 RD C6 30 23 WH ISM 7 WH S P D2 JO FUSED 12V DC RD CR28 30 CR39 30 24 RD CR2 30 EDS OIL COOLER FAN 24 RD CR17 30 RD S NC AUXILIARY PUMP RD CR39 87 amp C1B1 RD 5 6 27 RDISM 4 RD S BRAKE WT RD 5 23 WH RD C18 6 32 WH RD 66 32 D 1 ENGINE START BK C1B 7 BK SP RD 134A START RELAY pos 5 5 BK CR28 86 ISM 1 1 GLOWPLUG BK WH 5 22 BK WH 1 8 34 BK WH S P 1 LABEL DESCRIPTION ENGINE RPM BK RD C1B 9 35 BK RD CR3 30 BK RD S P BEA STEER RT AXLE EXT BL BK
239. OTATE RIGHT WHIBK C3B 5 WH BK 6 5 5 WH BK S P BL BK 5 16 4 TURNTABLE ROTATE WH RD C3B 6 WH RD 06 6 6 057 WH RD S P C4B 12 BOOM EXTEND BK C3B 7 BK C6 7 7 stud BES BOOM RETRACT BK WH C3B 8 BK WH C6 8 8 BKWH C6 38 BK WH S P 8016238 1 GND EXTEND RETRACT FLOW CONTROL BK RD C3B 9 C6 9 9 BRIRD S P WH 23A SBD DESCENT ALARM 10 22 I 11 i 1 PLATFORM LEVEL UP OR C4B 2 6 14 14 OR S P PLATFORM LEVEL DOWN OR BK 48 3 6 15 042 15 OR BK S P AXLE DUMP VALVE OR RD C6 11 OR RD CR38 67A pr I 16 8 87 034 e I PLATFORM ROTATE LEFT C4B 5 GR C6 17 17 GR S P PLATFORM ROTATE RIGHT GRIBK C4B 6 GR BK C6 18 18 GR BK S P P1 TS51 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P ksi AUXILIARY IGNITION POWER WH CR17 86 WH 5 3 amp 5 11 21 052 sr wHsP KEY SWITCH 3 HORN BK C23 4 22 BK CR5 30 KEYSWITCH PWR PWR TOPLAT WHC7B2 6 30 05 19 23 WH 15 7 ID Nc Al FUSED 12V DC CR39 30 24 RD CR2 30 RD S P CB1 Ira vs SET OIL COOLER FAN 24 CR17 30 oe RD S P CB3 AUXILIARY PUMP RD CR39 86 amp C1B 1 RD C5 6 27 RDISM 4 RD S P BRAKE WT RD 5 23 WH RD C1B 6 32 WH RD C6 32 I T 1 ENGINE START 1 7 BK
240. P CB3 O wc AUXILIARY PUMP RD CR39487 amp C1B1 RD C5 6 27 RDISM 4 RD S P BRAKE WT RD C5 23 WH RD C18 6 32 WH RD C6 32 06 ENGINE START 1 7 BK ISM 3 BK S P 134 1 START RELAY gt BK 5 5 BK CR28586 15 1 Nr GLOW PLUG BK WH 5 22 BK WH 1 8 34 BK WH S P 1 LABEL DESCRIPTION ENGINE RPM BK RD C1B 9 35 CR3 30 BK RD S P RDS7A STEER RT AXLE EXT BL BK C6 37 BL BK C1B 11 37 C6 20 I ADWHSA Pt RED EMERGENCY STOP BUTTON 38 RDIBK2A 4 LP 39 BK 7A 7551 AUXILIARY TOGGLE SWITCH LIMIT SWITCH 1 WH 2 2 OR 6 40 40 OR C6 10 I EER 1 ESWITO ENGINE RPM OR BK C2B 3 OR BK C5 2 41 OR BK ISM 2 L45 7852 ENGINE START TOGGLE SWITCH LIMIT SWITCH 2 OR RD C4B 4 OR RD CR23 86 42 OR RD 06 22 BK RD 9A u PLATFORM 7556 GLOW PLUG TOGGLE SWITCH LIMIT SWITCH POWER RD C6 31 46 07 lt lt ENG LED N TS54 FUNCTION ENABLE TOGGLE SWITCH KEY SWITCH POWER RD C6 23 C2 6 134 RD H6 RD KSI SP BL RD 15 10 7557 PLATFORM ROTATE TOGGLE SWITCH KEY SWITCH POWER RD 06 24 TON BLOCK TS59 PLATFORM LEVEL TOGGLE SWITCH TERMINA SEIBICHE 1561 PRIMARY BOOM UP DOWN TOGGLE SWITCH 7562 TURNTABLE ROTATE TOGGLE SWITCH WH 21A 1 I 7563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH I G6 9 1
241. PLATFORM CR39 AUXILIARY PUMP RELAY I RD B1 20A LEVEL ROTATE R2 5 OHM RESISTOR o WH 21B IGNITION START MODULE 2 Rp 24aD 7 m 4 GR 17A 8 WH C6 34 GR WH C4B 7 GR BK 18A 1 2 MEME CIRCUIT DESCRIPTION FROM TO 1 GROUND STUD BURD C4B 1 1 1 12 BLMH C6 12 BL WH 12 WH 4A 19 VALVE GR WH 7 WH BK 5A 25 PRESSURE SENDER 5 16 BUBK S P w l 26 WATER TEMP SENDER 5 14 GRIBK S P B D ALL BRN WIRES WH RD 6A 5 8 1 28 ALARM RD BK C1 2 RD BK C6 28 z 9 WIRING S IS i HARNESS 29 2WD AWD RD WH C5 24 C1B 3 al 2 30 E D C REV WH 1 4 5 21 1 CONTROL 8 CONNECTIONS 31 E D C FWD WH BK C5 20 WH BK C1B 5 2 mui m 36 STEER LEFT AXLE RETRACT 1 10 BL C6 36 1 5 I 1 I 43 HORN GR C2B 5 GR CR5 86 5 45 GEN OPTION GR WHC2B GR WH C5 12 60 AXLE EXT RET SELECT OR RD C6 39 OR RD C2B 4 61 AXLE RETRACT BL BK C3B 11 BL BK C6 21 I He PS EE ON wel mern 7 54 5 80 8 5 85 77832 Section 7 Schematics 2004 Platform Control Wiring Diagram 5 85 REV Perkins 704 3
242. PUT GLOW PLUG 1562 TURNTABLE ROTATE TOGGLE SWITCH BRN GND STUD BD 278 aux ON LED 7563 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 3 BRN GND U1 TS61 BK 22D BBN GND 3015 GROUND HOUR METER 1 CIRCUIT ENGINE 15 WH 23AB 6 BATTERY IGNITION START j BOOM 2 5 2 WH 23B MODULE BRN CR19 85 UP DOWN CIRCUIT BREAKER CONTROLS 15 1 7 KEY POWER i CIRCUIT BREAKER OIL COOLER OPTION 20 8 KEY BYPASS 3 I RD B1 20C WH CR2 86 IGN FUEL 7563 G1 VOLT METER GAUGE OPTIONAL 15 RD 1A BOOM EXTEND 20D 10 ENG FAULT RETRACT i G2 OIL PRESSURE GAUGE OPTIONAL SP RD 248 12 G3 COOLANT TEMPERATURE GAUGE OPTIONAL BK RD 35B O G6 HOUR METER GR 2 5 i RD 23 A p Ns 9 H _ 12 m 128 GLOW PLUG LED CRT CR2 moe EURDISMEIO CB RD BK 6 19 1552 3 CR IGNITION START RELAY 86 86 86 86 BL RD 5 15 m RD 24AA ENGINE START OIL COOLER TS62 CR2 IGNITION POWER RELAY i OPTION 20A 2 8 16 OR BK 15A TURNTABLE CR3 HIGH IDLE CUTOUT RELAY 9 BK RD 5 18 RD B2 H1 ROTATE 5 HORN RELAY 6 5 OR RD 168 1 CR8 BOOM FUNCTION CUTOUT
243. PWR TO PLAT RD 6 23 23 RD 06 24 RD S P L2 KEY SWITCH PWR PWR TO PLAT WH C7B 2 RD C5 19 23 RD C6 30 RD S P D2 3 FUSED 12V DC 24 RD CR2 30 RD S P OIL COOLER FAN RD CR17 30 RD CR23 30 24 RD S P AUXILIARY PUMP RD 6 278 1 1 RD 27 RD 5 6 RD S P BRAKE WT RD C5 23 WH RD 1 6 32 WH RD C6 32 ENGINE START BK 5 5 1 7 38 BK S P START RELAY 33A GLOW PLUG BK WH 5 22 BK WH 8 34 ENGINE RPM BK RD C1B 9 35 BK RD C5 18 BK RD S P STEER RIGHT AXLE EXTEND 6 37 BUBK C1B 11 37 6 20 38 BL RD C2B 1 39 BL RD C5 10 BURD S P LIMIT SWITCH 1 WH C2B 2 6 40 40 OR C6 10 4 ENGINE RPM OR BK C2B 3 OR BK C5 2 41 LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD C6 22 034 LIMIT SWITCH POWER RD C6 31 ove 46 TERMINATION BLOCK BRN GND STUD S sc O 25 2 WH 23AD 5 l RD B1 20C 0D WH 5 11 RD B2 S P RD 248 3 RD BK 6 19 0 m a e 6 9 5 BK C6 16 io m OR RD 16B N El 9 BK 7B C6 13 o OR C6 33 o I WH 21B z 6 RD 24AD 7 5 WH C6 34 7 5 P OR RD 42C BURD C4B 1 1 GROUND STUD RD BK 28 2 ALL BRN WIRES 2 8 HIHI GROUND STUD 7 44 5 80 8 5 85 77832 VOLT METE
244. Platform Control Wiring Diagram 5 85 GM 3 0L Models before serial number 3577 RD BK REV A gt ANSI CSA DOMESTIC MACHINE ADD 148 January 2004 Electrical Schematic S 85 GM 3 0L Models after serial number 3576 Section 7 Schematics s E a i 1 9 BK RD A C2BPSRBLUBK PRESSURE HIGH FS 1 SENDER OPTION 7 ENGINE SPEED 5 Q 5 C26TSR GR BK WATER T DA SENDER OPTION 9 FUNC ENABLE A a a HIGH RPM 4 gt 5 VOLT METER OPTION px e ciem qeu e c xe seio saspe cape Up AE SE LE GENERATOR amp TON C27 C45GEN GRWH C512 T o 1 E BIBATTERY 9 WAS ES OOND EN EN
245. R 5 16 PRESSURE GR BK 5 14 1 JO 1851 AUXILIARY PUMP RD 23A Gi m 22 RD 27A RD WH 3A RD BK 2A BK 7A BK WH 8A 9 BL RD 39A WH 21A BRN GND G6 HOUR METER BL 10A Fon RD 1A BOOM EXTEND TS63 RETRACT TS61 BOOM UP DOWN RD 23A CHECK ENGINE LED BL RD C5 13 RD 24AA OR BK 15A EED ENGINE START 850 OIL 20 1558 JIB BOOM RD B2 H1 BK RD 35A TS54 HIGH LOW 28 ope 562 TURNTABLE ROTATE ch Als RPM CB1 ENGINE 15A RD B1 20A CB2 CONTROLS 15A OR 14A GR 17A 90 557 ROTATE 559 PLATFORM LEVEL GR WH 4 7 GR BK 18A BRN G6 BRN GND WH 4A WH BK 5A WH RD 6A WIRING HARNESS TO BASE CONTROL BOX CONNECTIONS CR19
246. R RPM RELAY 012 J TS TS54 LOW RPM HIGH RPM C21IGN WH D42 C41RPM OR BK P46 RD P23 RD D14 C27AUX C45GEN GR WH D13 TB35 le 5 18 RPM RELAY RPM SOLENOID GENERATOR OPTION 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION 2 ROCKER STEER OPTION ONLY gt ADD 040 ONLY IF UNIT HAS 14 148 NOTES L24 C34SA TB34 128 5 22 BK WH C33STR BK TS2 P26ESTP P25FS RD 24 5 WH 5 19 005 GLOW PLUG 46 08 23 IGNITION START MODULE 15 8 KEY BYPASS BL RD 6 5 5 15 C24TSTP BL RD 2 WATER AND OIL PRESSURE LED e WATER TEMPERATURE SWITCH 8 TISTART RELAY 10 ENG FAULT TB41 TB33 C27AUX RD H 5 GROUND OIL PRESSURE SWITCH D6 CR2 NO TB21 P26ESTP BK P25FS C21IGN WH WH gt A lt WH NI Tid POWER RELAY BK FUEL SOLENOID
247. R MODULE m 1 G3 TEMPERATURE GAUGE OPTIONAL KEY BYPASS 1 I WH CR2 86 BK 33 7952 CB3 HOURMETER 9 IGN FUEL ON OIL COOLER 1 8081200 __ 2 f 1 ENGINE I 12 z J FO 10 ENG FAULT START OPTION D248 145 OVERLOAD LED ia BK RD 35B e q I CR2 IGNITION POWER RELAY GR C2B 5 7556 ago CR3 HIGH IDLE CUTOUT RELAY m Lo CRE CRS BK WH 34A GLOW PLUG EL cR5 HORN RELAY CR17 HYDRAULIC COOLER FAN RELAY 6 56 OR BK 15A ROTATE m H i RD B2 H1 i CR23 DRIVE LIGHT RELAY OPTION 2 8 _ BK C6 16 BADER CR25 AXLE RETL O RELAY BK RD 5 18 CR28 TROMBETTA PULL IN RELAY OR RD 168 I CR29 AXLE EXTEND LED RELAY 9 BK7B HIGH LOW CR38 EXTEND FUNCTION CUTOUT RELAY n BL RD C6 13 cm CR39 AUXILIARY PUMP RELAY CB1 5 1 BK 33AB I ENGINE CONTROLS eer R2 5 OHM RESISTOR ee RD 24A PLATFORM PLATFORM u IGNITION START MODULE zZ LES RD B1 20A LEVEL o WH 21B 2 86 86 86 sel RD 24AD 14 7 icra 1 8 WH C6 34 GR WH C4B 7 i 2 GR BK 18A OR RD 42C i CIRCUIT DESCRIPTION FROM TO I GROUND STUD i 12 DRIVE ENABLE BLMH C6 12 BL WH C3B 12 Fus BL RD C4B 1 WH 4A
248. RIGHT E DRIVE ENABLE C1P 10 C636 C36STCC BL ere STEERLEFT LEFT 1 CDE1 BL WH 5 21 WH lt BL CS0EDCEWEI Ne DRIVE EDC FORWARD g RKoUr e 5 1 5 C31EDC WH BK C520 CSIEDEWHBK Re He E DRIVE EDC REVERSE 1 E 42 5 ETFF 7744444444422 227 Si 0 i 4 3 lt OR 6 32 Ds 7 id gt L1 TRAVEL ALARM OPTION IE OND 2 BRN Jpn if C26 1 C262 C32BRK WH RD C523 ee E GIES CS2BRK WERD 4 BRAKE RELEASE VALVE ees C29MS RD WH 0524 251 D S MOTORSTROKE 2 YV 2 Ins KEPE CETRF WH RD 16 C5TRR WHIBK 3P 5 ee lt lt lt E C15 1 C152 6 4 Is E 6 185 s lt TURNTABLE ROTATE LEFT gt EE 95 gt Honig TURNTABLE ROTATE 8 8158 LEFT C6 5 C14 1 Pil C14 2 5 18 8 4 lt 5 8 It ei LEK TURNTABLE ROTATE RIGHT i pwr s oR EI m 01 8 lt 2 E gt 6 6 cerrewump 0871 p 03172 TURNTABLE ROTATE ES lt FLOW CONTROL en d 8 PRIMARY BOOM UP CUTOUT RELAY 12 1 q C12 2 CIPBU RD PRIMARY BOOM UP e PRIMARY BOOM B C13 1 C132 DOWN ed oa C6 2 Bil 5 it 4 EK PRIMARY BOOM DOWN 8 I is C63 caper
249. ROPORTIONAL JOYSTICK BOOM EXTEND RETRACT 5 5 9 92 5 52980 25 8 8 98 2999259 92855 9 3 JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE 3 og8769z 07 N 8 g 8 8 8 2 8 925299 83 T 22004 Se y ER CR13 CUTOUT RELAY 2338 eR eae ep ge 2758 9559 2 959 51266 013 ALCS00 S Y 3 2 5 C28TTA RD BK C1P 2 EE 2 2 1 LLL j BATGND C7P 3 2 GR WH 7 CR13 BRN HO 2 9 amp 10 GND GR WH TS7 fe 9 RED BLK CABLE S 2 12 5 9 18 5 IS C9 JIB OPT H1 BRN WM TILT ALARM GND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH 5 w w w w lt S 9 cma 998 sBSSS bi 29ppzsm 5 2 5 2 5 23003 z EI x E Z TS16 9 I ooo Tm Ai TE QJIE PIY le 4 2 a Q CUTOUT m s fale IS 2949 Q P a 5 55 AXLE 5 5 di 5 S IS 2 28 extenor Hs 9 o 5 5 5 TS47 6 m GENERATOR 7 ON 7 OPTION d CE LIFT DRIVE OPTION af 5 2 JC2 5 JC1 5
250. ROTATE 187 N i i I 1 RD WL1 RDWL2 I 7815 8 GE 194 BK on P3 Qo 9 O HIGH LOW Q4 adl RPM NC i iss n 5 I TS48 TS49 LOW PLU LLLI uon HORN pu TS1 EIE OPTION START DRIVE AUXILIARY i LEVEL SPEED PUMP 55 EMERGENCY STOP ee ee nn l 6 MODELS SEE DETAIL Part 77832 5 80 amp 5 85 7 19 2004 Section 7 Schematics Platform Control Wiring Diagram 5 80 Models Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 BP ANT Ground Control Box Wiring Diagram S 80 GM 3 0L Models before serial number 3577 Section 7 Schematics a Ground Control Box Wiring Diagram S 80 GM3 0L Models before serial number 3577 19 18 CABLES FUNCTIONS ENGINE 12V DC TO January 2004
251. SELECT 4 AXE en SO WEL 3 2 AXLE DUMP VALVE D 6 OR RD 4 ER RETRACT 2 4 6 21 C61AXRTBL AXLE C6 22 42152 GR o9 152 ANGLE OPERATIONAL 2 DRIVELIMIT SWITCH 5 m WET 4 C40LS OR RD lt e 81 0 9 J4BK __ 29 152 5 ANGLE 2 06 10 C40LS2 BK SA DRIVELIMITSWITCH 2 2 C40LS1 OR 9 C6 40 40151 OR A 15180 RETRACT OPERATIONAL t DRIVE ROTATE SPEED LIMIT SWITCH J2WH 3 lt lt 15 5 Hi RD BK 215 doek 5 9 21 2 paivE move a d OT 15186 RETRACT SAFETY C6 31 RD DRIVE ROTATE SPEED RD WH gt gt 81 LIMIT SWITCH 5 5 66 20 LEDBURD 5 5 1 11 C37STC BL BK 0637 6251 Al TEER RIGHT _ CDE2 BL BK lt iaar 2 ORE ENABLE 1 10 C36STCC BL 6 36 BL earl 3 dl ee LEFT 17 lt tpe CDE BUWH gt gt _ C5 21 WH Kap 15 eee DRIVE EDC FORWARD RKOUT 6 3 iz 5 20 C31EDC WH BK gt YoUT 5 55 4 hs ce lt GIPS NEDO WHEE Re gt DRIVE REVERSE Sib 4 lt 5 5 M 6 5 PwR sC OR 2213 E TRAVEL ALARM OPTION i IE 2 lt 4
252. Section 5 Repair Procedures January 2004 TEE MANIFOLDS REVB 9 2 Function Manifold Components View 2 The function manifold assembly is located on the tank side tray behind the ground control box Index Schematic No Description Item Function Torque 1 Check valve 30 psi 2 bar Platform rotate circuit prevents hydraulic hoses from draining back to tank 25 30 ft Ibs 34 41 Nm 2 Check valve 30 psi 2 ll uuu Blocks flow from charge pump to auxiliary pump 25 30 ft lbs 34 41 Nm 3 Flow regulator valve 0 3 1 14 L min Jd seni Dump circuit source from charge pump 25 30 ft lbs 34 41 Nm 4 Solenoid valve 2 position 2 way Allows boom functions to operate with the boom in the stowed position 10 12 ft lbs 14 16 Nm 5 Check valve 30 psi 2 bar Blocks flow from auxiliary pump to charge pump 25 30 ft Ibs 34 41 Nm 6 Solenoid valve 2 position 3 way MM Provides pilot signal to redirect steer flow to axle extension system 10 12 ft lbs 14 16 Nm 7 Directional valve 2 position 2 way pilot operated NN Dump valve that allows boom functions to operate when 130 140 ft Ibs axles are fully extended
253. TICK BOOM EXTEND RETRACT JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE CR13 JIB CUTOUT RELAY 013 PLATFORM CONTROLS CIRCUIT BOARD ALC500 TILTALARM 1 CE LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND GND STUD CR27 WERTSZ e WH TS1 WH RD C32BRK SPLICE TO C32BRK CR40 zn OR RD R40LS2 R40LS2 its Ve uu EE m BT ESE EE N OE EI P 3 232 o gt 9 s ALC 500 3 BES 5 9 559 59 J3 25 2 z 528
254. TROLS gt R2 5OHMRESISTOR OR 06 33 PLATFORM PLATFORM IGNITIONSTART MODULE eis RD B1 20A LEVEL ROTATE U33 PLATFORM OVERLOAD MODULE 5 WH 21B 2 86 al MI EUST 14 7 2 h h GR 17A rs 28 TE 1 GR BK 18A B OR RD 426 CIRCUIT DESCRIPTION FROM TO 05 7 12 DRIVE ENABLE BLWH C6 12 C3B 12 I GROUND STUD BL RD C4B 1 1 BAN 19 VALVE GRWHC4B 7 GR WH S P I RD BK 2B WH BK SA 25 PRESSURE BL BK C5 16 BUBK S P 26 OIL GR BK 05 14 GR BK S P z 8 WH RD 6A JWE 28 ALARM RD BK 1 2 RD BK 6 28 2 gt z gs 5 Wr SIR R2 29 2WD 4WD RD WH C5 24 RD WH C18 3 AE 8 2 30 E D C REV WH 4 WH C5 21 I CONTROL BOX gt 8 5 5 CONNECTIONS 31 E D C FWD WH BK 5 20 WHIBK 1 5 5 CR38 RSS 1 36 STEER LEFT AXLE RETRACT BL 1 10 BL C6 36 9 mm 5 86 43 GR C2B 5 GR CR5 86 5 I 45 GEN OPTION GR WH C2B 7 5 12 I 60 SELECT OR RD 6 39 OR RD C2B 4 61 RETRACT BL BK C3B 11 6 21 ei 7 18 Genie 5 80 8 Genie 5 85 77832 2004 Section 7 Schematics E
255. TS7 n WORK LIGHT PLATFORM 2 5 L1 1 Le N O ITS4 Gu HIGH LOW NC HORN 51 990 8 AUXILIARY PUMP TS6 TS2 59 ies GLOW PLUG ENGINE START Ss PLATFORM LEVEL ee CE Lift Drive Option SPEED EMERGENCY STOP O AO EN EE DO EO AR OR NS OS DE OE ONCOL 1 No 77832 Genie 5 80 8 Genie 5 85 7 9 2004 Section 7 Schematics I i Platform Control Box Wiring Diagram S 80 Deutz F4L 913 Models before serial number 3577 January 2004 Section 7 Schematics REVA Electrical Schematic S 80 Deutz F4L 913 Models after serial number 3576
256. V Perkins 704 30 Models after serial number 3576 5 c SE zx 69 z IE aH 93 5 5 Bee s 2666 EGIS I 558 E GE E 515 5 49 99 588 De alz o ET x 818 855 IGE 0 0 LL gt gt gt 9 8 555 Ss 2 3181314 5 gt 55 m E ueb e Eege Shai 9558 S SEE Soo us 5 25 61 amp lt 3 l 225 5 3 L i u z lt lt gt 56 9525 ES 56 14191515 991315 218 95 lt 5 2 5 aaa 98 s e e n s e EE 4513935 MEE a UI ss a TI a a o o uj P2 P26FS BK C9 1 a TS2 P25STR RD C9 3 x
257. WH 5 PRIMARY BOOM EXTEND 9 CUTOUT RELAY BRN ss exe lt Coe 8 PAFS WH 5 3 lt lt lt J gt PRIMARY BOOM EXTEND 1 P24FSWH 8 9 BOOM i C17 1 C17 2 1 BRIT OER ODE Il PRIMARY BOOM RETRACT P26ESTPBK BK RD 4 069 cePERFBKmD 02771 Core 4 BOOM EXTEND RETRACT 2 FLOW CONTROL 3 C3P 12 C12DRE BLWH 8 lt 06 12 CI2DREBUWH _ EX C2P 3 lt 1 6 29 R16PBRBKWH z i 7E 58 PRIVE ENABLE LIMIT SWITCH 2 06 38 9t S 8 59 06 30 2 RD ME ME C4P 2 C14PLU OR sup 1 PLATFORM LEVEL E 2 DOWN C4P 3 C15PLD ORBK 20 1 20 2 2 C6 14 8 5 OFEHREMH Itl 4 PLATFORM LEVEL UP I TN PLATFORM LEVEL DOWN C6 15 TT t lt ORBICIE MN lt lt 55 9 PLATFORM LEVEL DOWN 2 C21 1 C21 2 1 1 6 RIGHT wr ROTATE 5 m E 0231 140242 028 8 Caer i GE BICISML PLATFORM ROTATE RIGHT JIB DOWN LEFT PLATFORM ROTATE C6 17 t ti PLATFORM ROTATE LEFT JIB UP E C22 1 C22 2 EI OO EO EO AE 06 19 DESCENT ALARM OPTION xg x mou
258. WH RD C32BRK SPLICE TO C32BRK CR40 IE OR RD R40LS2 SPLICE TO R40LS2 b x IE IE n alt 9889899989999 ALC 500 8 1585 2 S 5 GRE e 2 S ERR 2327353197383 18 e a i 200 gt DEO D12 Sg J2 GND STUD 5 89 J1 11 ele e G O Q 00 9000200007000 AdA AAAEAAAAESEYYSAY 9898 AG 98 395 9838888 533 9 2 Que C328 3513 3 5 502
259. WHIBK S P 05 16 1 TURNTABLE ROTATE WH RD 38 6 WH RD 6 6 6 057 WH RD S P C5 14 C4B 12 BOOM EXTEND BK C3B 7 BK C6 7 7 stud 5 BOOM RETRACT BKWH C3B 8 8 8 BKWH C6 38 BK WH S P 23 6 BRN GND EXTEND RETRACT FLOW CONTROL BK RD C3B 9 BK RD 06 9 9 BRIRD S P WH 23A SBD DESCENTALARM 10 11 t PLATFORM LEVEL UP 4 2 OR 06 14 14 OR S P i PLATFORM LEVEL DOWN C4B 3 C6 15 042 15 ORBK SP 1 1 AXLE DUMP VALVE OR RD C6 11 OR RD 8 87 16 OR RD CR8 87A D34 e 1 1 1 PLATFORM ROTATE LEFT GR C4B 5 GR C6 17 17 GR S P PLATFORM ROTATE RIGHT GR BK C4B 6 GR BK 18 GRIBK S P TS51 12V DC BATTERY SUPPLY RD B1 H1 RD B1 H1 20 RD B1 S P 1 docu AUXILIARY IGNITION POWER WH 17 86 5 3 amp C5 11 21 4 1 KEY SWITCH PUMP 1 3 HORN BK 23 4 22 BK CR5 30 1 1 KEYSWITCH PWR PWR TOPLAT 7 2 RD 6 307 C5 19 23 WHISM 7 WH S P D2 Q l FUSED 12V DC CR39 30 24 RD CR2 30 RD S P CB1 1 OIL COOLER FAN 24 CR17 30 De RD S P CB3 AUXILIARY PUMP RD CR39 86 amp C1B 1 RD C5 6 27 RD ISM 4 eb RD S BRAKE WT RD 5 23 WH RD C1B 6 32 WH RD 06 32 1 1 ENGINE START
260. XT BL BK 6 37 BL BK 1 11 37 C6 20 RDAWH SA 38 BURD 1553 1 IA 2A LABEL DESCRIPTION 1 LIMIT SWITCH WH C2B 2 66 40 40 6 10 TER Pi EMERGENCY STOP BUTTON ENGINE RPM OR BK C2B 3 5 2 41 1 4 LIMIT SWITCH 2 OR RD C4B 4 OR RD CR29 86 42 OR RD 06 22 BK RD 9A KS1 KEY SWITCH LIMIT SWITCH POWER RD C6 31 46 27 4 8 gt 7551 AUXILIARY POWER TOGGLE SWITCH KEY SWITCH POWER RD C6 23 2 6 11 5 AD KSI SP L2 7552 ENGINE START TOGGLE SWITCH KEY SWITCH POWER RD C6 24 34 GETS CHECK ENG LED 7553 LP GAS SELECT TOGGLE SWITCH BL RD 39A 7554 FUNCTION ENABLE RPM SELECT TOGGLE SWITCH 1557 PLATFORM ROTATE TOGGLE SWITCH WH 21A G6 9 xoci 7558 BOOM UP DOWN TOGGLE SWITCH 1 2 Boom 7559 PLATFORM LEVEL TOGGLE SWITCH BRN GND UP BOWN TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH oz 7853 BRN GNDSTUD asl TS63 TS62 TURNTABLE ROTATE TOGGLE SWITCH cms TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH 5 sk WH 23AB 1 RD 1A RETRACT CIRCUIT BREAKER ENGINE 15 ds CB2 CIRCUIT BREAKER CONTROLS 15 RD B1 20C 1 011 1 20 ERGNE CIRCUIT BREAKER OIL COOLER OPTION 204 TO
261. XTEND RETURN t LE Si T q 0 1 gpm ses En Sies PRESSURE SWITCH DRIVE PUMP FILTER 8 L min t t Umin NE 65 E H3 Ar 4 5 bar Sn sal r ise erm Yp 4 e mim asas Lo 39 g T2 ST1 572 oc2 LS TEST AXLE cP LIM SW RESERVOIR COUNTERBALANCE VALVE RATIO PRESSURE A 1000 PSI A 31 2000 PSI 5 AN 31 3000 PSI k OE N EE TAT TE ees te A 3300 PSI HYDRAULIC ROTARY COUPLER A 3 1 3500 PSI Bee ee 1 Al 5 3500 PSI Ta EE EE 7023 eB NN NG NE STEER rg CYLINDERS ren E E zl es La A ww nf r m ae 1 TEN 6 maa ai J 34 wal T 4 Ld Le 1 ME l P S SLE P orr N E uM S 50 LIttv ra 1 T AXLE EXTEND OSCILLATE CYLINDERS 280 psi AXLE SELECT 4 CYLINDERS 7 to bar LEFT MANIFOLD 0 070 4 X TEST __ 681 50 Lx E es T See t y Ho CYLINDER EED 8 A O 2WD DRIVE MANIFOLD L L een NERI PI APEE IE VEE AI eere OT rt PartNo 77
262. Z DRIVE LIMIT SWITCH 5 B ge 4 4 C40LS OR RD 4 lt gt m ABK 8 5 LS2AS BOOM ANGLE SAFETY C640 C40LS2BK OS DRIVELMIT SWITCH o5 z 40151 a 0262 oo 9 06 40 40151 OR 75 99 LS1RO BOOM RETRACT OPERATIONAL lt DRIVE ROTATE SPEED LIMIT SWITCH HIRDER 245 58 J5BK 5 2 9 LS1RS BOOM 4 3 bave a 4d 6 DRIVEROTATE SPEED 53 06 31 RD 2 LIMIT SWITCH C29MS RD WH a 5 66 20 5 8 6 37 25 1 25 2 1 11 C37STC BUBK 6375 STEER RIGHT CDE2 7 18 ui e 2 RIGHT 8 24 1 24 2 e DRIVE ENABLE 1 10 C36STCC BL 06 386 C36STCC BL 3 LEFT 5 17 lt ope STEER LEFT CDETBLWH 22 C30EDC WH 05 21 C30EDC WH 56 US hs lt DRIVE EDC FORWARD g RKour lt 1 x N 12 05 20 C81EDC WH BK C Nu E Your 5 lt wH 4 m 5 C31EDC WH BK Re He DRIVE EDC REVERSE G Sib lt a gt 5 5 RN FR OE Fa i 2 6 OR 213 2 TRAVEL ALARM OPTION 12 2 lt gt gt 14 a nn nn 1 if lt 05 23 026 1 I C26 2 C32BRK WH RD 2 WH RD 19 lt lt lt m lt lt ca d M BRAKE RELEASE VALVE 0 1 3
263. arate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second When the red LED is flashing the code the yellow LED will be on solid Determine the error type The yellow LED indidates the error type and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second When the yellow LED is flashing the code the red LED will be on solid Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected 6 2 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 6 Fault Codes REV Fault Code Chart Value at 0V indicating fault Error Source Error Type Condition Solution 21 Boom 1 Joystick 11 Value at 5V Limited speed and primary boom up 12 Value too hiqh direction frozen at Power up down 15 Valuetoo ms zero and neutral controller with 16 Alarm sounds problem corrected 17 Not calibrated Joystick speed and direction frozen at zero and neutral Calibrate joystick 18 Just calibrated Initiate 1 second beep of alarm Self clearing transient 22 Boom 1 directional Limited speed and control valve 12 Value
264. ate gradually Do not allow oil to squirt or spray Perform all troubleshooting ona firm level surface Two persons may be required to safely perform some troubleshooting procedures Part No 77832 Genie S 80 and Genie S 85 6 1 Section 6 Fault Codes January2004 FAULT CODES Fault Codes Control System How to Retrieve Control System Fault Codes At least one fault code is present when the alarm platform controls produces two short beeps every 30 seconds for 10 minutes Perform this procedure with the engine off the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls 1 Open the platform control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Locate the red and yellow fault LEDs on the ALC 500 circuit board inside the platform control box Do not touch the circuit board Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap REVA Determine the error source The red LED indicates the error source and will flash two sep
265. bs 11 14 Nm Solenoid valve 2 position 3 way WW Jib boom 8 10 ft lbs 11 14 Nm Orifice plug 0 035 inch 0 89 mm XX Valve Coil Resistance Specification 2 position 3 way solenoid valve 10V DC 60 schematic items VV and WW Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair lt lt MANIFOLDS This page intentionally left blank Part No 77832 Genie S 80 and Genie S 85 5 51 Section 5 Repair Procedures January 2004 TEE MANIFOLDS REVB 9 7 Axle Select Manifold Components The axle select manifold is mounted next to the drive manifold at the non steer end of the machine Index Schematic No Description Item Function Torque 1 Directional valve pilot operated 2 position BA Directs flow from steer cylinders to axle extend circuit 10 12 ft Ibs 14 16 Nm 2 Pressure reducing valve 1000 psi 69 BB Limits pressure to tie rod cylinder during axle extension 35 40 ft lbs 47 54 Nm 3 Directional valve pilot operated 2 position BC Directs flow from steer cylinders to axle retract circuit 10 12 ft Ibs 14 16 Nm 4 Directional valve pilot operat
266. clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap Repeat steps 4 and 5 until a pressure differential between the charge pump reading and the hot oil shuttle relief valve of 40 psi 14 5 bar is obtained Hot oil shuttle relief valve specification Pressure 280 psi 19 3 bar 5 58 Genie 5 80 amp Genie 5 85 Part No 77832 January 2004 Section 5 Repair Procedures REV 9 11 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification Description Specification Solenoid valve 3 position 4 way 10V DC 51070 schematic items S Solenoid valve 2 position 3 way 10V 51070 schematic items X TT UU WW Solenoid valve 2 position 3 way 10V 2 5 to 4 50 schematic
267. d Fitting Torque Specifications Perform this procedure with the boom in the stowed position and boom between the non steer end tires 1 Extend the axles Steer end 2 Remove the drive chassis cover 3 2WD models Remove the yoke and hub assembly See 12 1 How to Remove the Yoke and Hub 4WD models Remove the yoke and drive hub See 13 1 How to Remove the Yoke and Drive Hub Assembly 4 AWD models Remove the hose bracket from the steer cylinder barrel end pivot pin 5 Remove the remaining steer cylinder pivot pin Remove the steer cylinder and lay off to the side Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched EXTENDABLE AXLE COMPONENTS 6 Remove the steer cylinder mounting lug from the inner axle 7 Place blocks under the axle extension cylinder for support 8 Remove the external snap ring from the axle extension cylinder pivot pin Use a soft metal drift to remove the pin 9 Attach a lifting strap from an overhead crane to the inner axle for support 10 Remove all wear pads from the outer axle Pay careful attention to the location and number of shims used when removing the wear pads 11 Carefully remove the inner axle from the outer axle AWARNING Crushing hazard The inner axle could become unbalanced and fall if not properly supported when it is removed from the outer axle Non steer end 2 Remove the drive chassis cover 3 Loosen the wheel lug nuts
268. d neutral controller with 16 Value at 0V Alarm sounds problem corrected indicating fault Joystick speed and 17 Not calibrated direction frozen at Calibrate Joystick zero and neutral Initiate 1 second Self clearing of alarm transient 62 Steer directional Limited speed and valves direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds indicating fault problem corrected Part No 77832 Genie S 80 and Genie S 85 Section 6 Fault Codes January2004 9r This intentionally left blank 6 6 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 7 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie 5 80 and Genie 5 85 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution haza
269. drive hub assembly 6 Install the drive hub Torque the back lash pivot plate mounting bolts to 260 ft lbs 352 5 Nm 7 Install the brake and then the motor onto the drive hub Torque the motor brake mounting bolts to 75 ft Ibs 102 Nm 8 Adjust turntable rotation gear backlash See 11 1 How to Adjust the Turntable Rotation Gear Backlash Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REVA How to Remove the Turntable Rotation Hydraulic Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the motor AWARNING 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very
270. e 4 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 5 Remove the wheel lug nuts then the tire and wheel assembly Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 4WD STEER AXLE COMPONENTS 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack 7 Remove the drive hub mounting bolts that attach the drive hub to the axle Remove the drive hub AWARNING Crushing hazard The drive hub could become unbalanced and fall if not properly supported and secured to the lifting jack when removed from the machine Torque specifications REV A 13 4 Steer Cylinders How to Remove a Steer Cylinder This procedure is the same as the 2WD procedure See 12 2 How to a Steer Cylinder 13 5 Tie Rod Cylinder How to Remove the Lug nut dry 420 ft lbs 7695 Tie Rod Cylinder Beg eee se Mun This procedure is the same as the 2WD procedure See 12 3 How to Remove the Tie Rod Cylinder Drive hub mounting bolts dry 165 ft lbs 224Nm How to Perform the Toe in Drive hub mounting bolts lubricated 124 ft lbs Adjustment 168 an This procedure is the same as the 2WD procedure Drive motor mounting bolts dry 125 ft Ibs See 12 3 How to Perfrom the Toe in Adjustment 169 Nm Drive motor mounting bolts lubricated 94 ft lbs 127 Nm
271. e CR23 DRIVE LIGHT RELAY OPTION 6 T 7 I 1 CR28 PULL IN RELAY a C6 13 554 CR29 AXLE EXTEND LED RELAY 5 BK 33AB HIGHILOW m H H 2 R2 10OHMRESISTOR RPM 5 OHM RESISTOR OR C6 33 CB1 CB2 M Ui IGNITION START MODULE i WH 21B RD 24A ENGINE CONTROLS 15A TS59 TS57 RD B1 20A PLATFORM PLATFORM I RD 24AD 1 LEVEL ROTATE I I 9 WH C6 34 ORISA gt GR 17A 2 ORD 426 GR WH 4 7 7 5 7 GR BK 18A GROUND P BL RD C4B 1 BRN G6 SAN RD BK 2B BRN GND WH 4A CIRCUIT DESCRIPTION FROM TO u i ALL BRN WIRES WH BICA 12 DRIVE ENABLE 6 12 BLAWH C3B 12 5 8 WH RD 6A 19 VALVE GR WH 4 7 GR WH S P 2 WIRING i HARNESS 25 OIL PRESSEURE SENDER BL BK C5 16 BL BK S P 26 WATER TEMP SENDER GR BK C5 14 GRBK SP 1 28 TILT ALARM RD BK C1B 2 RD BK 6 28 CONNECTIONS L l 29 2WD 4WD RD WH 5 24 RD WH C1B 3 8 I CR19 R3 I 30 E D C REV WHC1B 4 WH C5 21 GROUND STUD 31 E D C FWD WH BK C5 20 WH BK C1B 5 36 STEER LEFT AXLE RETRACT 1 10 6 36 43 HORN GR C2B 5 GR CR5 86 i i 45 GR WH 2 7 C5 12 O 60 SELECT OR RD 6 39 OR RD C2B 4 3 J 61 AXLE RETRACT BL BK
272. e Toe in Adjustment Perform this procedure on a firm level surface Block the non steer tires and be sure that the machine is in the stowed position 1 Straighten the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture 3 Center a lifting jack of ample capacity under the steer axle and raise the machine until the steer tires are off the ground 4 Loosen the jam nut on the adjustable end of the tie rod cylinder 5 Remove the pin retaining fasteners from the adjustable end of the tie rod cylinder Remove the pivot pin REVA 6 Slide the tie rod cylinder off of the yoke and adjust it by turning the end One half turn on the adjustable end equals approximately 1 8 inch 3 2 mm change in the front and rear measurements 7 Slide the tie rod cylinder onto the yoke Install the pivot pin and the pin retaining fastener 8 Tighten the jam nut against the tie rod cylinder 9 Lower the machine recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 Toe in specification 0 1 8 inch 6 35 mm 5 70 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REVA 13 1 Yoke and Drive Hub How to Remove the Yoke and Drive Hub Assembly When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specificatio
273. e the cap item T on the function manifold 5 Adjust the internal hex socket Turn it clockwise to increase pressure or counterclockwise to decrease pressure Install the relief valve cap AWARNING TiP over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 through 5 to confirm relief valve pressure REV B How to Adjust the Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a to 5000 psi 0 to 350 bar pressure gauge to the diagnostic nipple PTEST port on the function manifold 2 Startthe engine from the ground controls 3 Hold function enable rpm select toggle switch to the high idle position and activate and hold the boom down toggle switch with the boom fully lowered Observe the pressure reading on the pressure gauge Boom down relief valve specification Pressure 2100 psi 145 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item OO on the function manifold 5 Adgjust the internal hex socket Turn it clockwise to increase pressure or counterclockwise to decrease pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 through 5 and confirm relief valve pressure Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair REV MANIFOLDS How t
274. ed 2 position 2 BD ss Locks out steer cylinders during axle extend retract 10 12 ft Ibs 14 16 Nm 5 Directional valve pilot operated 2 position 2 BE Locks out steer cylinders during axle extend retract 10 12 ft Ibs 14 16 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm 6 1 4 18 ft Ibs 24 Nm 5 52 Genie 5 80 amp Genie 5 85 77832 January 2004 Section 5 Repair MANIFOLDS Part No 77832 Genie S 80 amp Genie S 85 5 53 Section 5 Repair Procedures January 2004 MANIFOLDS 9 8 2WD Drive Manifold Components REV B The drive manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Item 1 Relief valve 280 psi 19 3 bar 2 Flow divider combiner valve 8 Orifice Plug 0 070 inch 1 77 mm BH Function Torque 35 40 ft Ibs 47 54 Nm 130 140 ft lbs 176 190 Nm Charge pressure circuit Controls flow to drive motors in forward and reverse Equalizes flow across flow divider combiner valve item BG Charge pressure circuit that gets hot oil out of low pressure side of drive pump 15 18 ft
275. ed to the lifting jack when it is removed from the machine Torque specifications Lug nut dry 420 ft lbs 569 5 Nm Lug nut lubricated 320 ft lbs 434 Nm How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and center a lifting jack of ample capacity under the steer axle 3 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 2WD STEER AXLE COMPONENTS 5 Remove the dust cap cotter pin and castle nut Always replace the cotter pin with new one when installing the castle nut 6 Pull the hub off the spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle CAUTION Component damage hazard Do not apply excessive force or damage to the li
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278. g 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 steer cylinder from the machine 2WD STEER AXLE COMPONENTS 12 3 Tie Rod Cylinder How to Remove the Tie Rod Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the tie rod cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 Support and secure the tie rod cylinder to a lifting jack 3 Remove the pin retaining fasteners from each tie rod cylinder pivot pin 4 Remove the pivot pin from each end of the tie rod cylinder 5 Remove the tie rod cylinder from the machine Crushing hazard The tie rod ACAUTION cylinder may become unbalanced and fall if not properly supported and secured to the lifting jack when it is removed from the machine Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 2WD STEER AXLE COMPONENTS How to Perform th
279. ge hazard CAUTION Hoses can be damaged if they are kinked or pinched 16 2 Axle Extension Cylinder How to Remove the Axle Extension Cylinder 1 Extend the axles Steer end 2 Remove the engine side yoke and hub 2WD models Remove the yoke and hub assembly See 12 1 How to Remove the Yoke and Hub 4WD models Remove the yoke and drive hub See 13 1 How to Remove the Yoke and Drive Hub Assembly Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures Remove drive chassis cover Remove the access cover at the end of the inner axle 5 Tag disconnect and plug the axle extend cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 6 Place blocks under the axle extension cylinder for support 7 Remove external snap rings from the axle extension cylinder pivot pins Use a soft metal drift to remove the pins 8 Carefully remove the axle extension cylinder from the machine by pulling it out the end of the inner axle AWARNING Crushing hazard The axle extension cylinder could become unbalanced and fall if not properly supported when it is removed from the axle Non steer end 2 Remove the drive chassis cover 3 Remove the drive motor
280. gt D12 D12 88 42 GND STUD 515 J1 2 11 zt IS AE SE 9999 1824404 26 S828 2 eo DISS SSE omy 22 99 2802653 200m az2z90gog g 5ogoZ2o9 o 285 APL EmA EI 9 95950 52 I 722 ERoPBpgcomaAg22g x mo 2295 9 mx DoCUggoOaFADR 2429 2 0 228222686 5 ON 599 259 099226245 50 3 5338 8 90 8 5 9885582809258 8159 9358 2152527209 259 52 98 2552895382 BOS POSE Pas e qae RA x 36 095507597 gt 2 o M e C28TTA RD BK C1P 2 Le BATGND C7P 3 GR WH 7 CR13 BRN C2P 9 10 GND T57 RED BLK CABLE N 2 2 2 5 2 5 9 5 C9 JIB H1 TILT ALARM GROUND STUD 19 18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH 5 Ik omg vc Mr RE RM ee M PS X ere rur ER Ge A 1 5 EES OE RTT LIE T TANE eg ME ERE E EIE RE EER e EE OE EE ER CUT w lt ox w w Omm 5 5 35 3 CR13 2 Xbb y C 5 19 0 2 0 5 mm 229 25 55 262000 Blo os lt lt fe Q Q lt
281. head crane to stowed position the barrel end of the oscillating cylinder When removing a hose assembly 6 Remove the pin retaining fasteners from the or fitting the O ring on the fitting barrel end pivot pin Use a soft metal drift to and or hose end must be replaced remove the pin and then tordued to speciicaton 7 Remove the cylinder from the machine during installation Refer to Section Two Hydraulic Hose and AWARNING Crushing hazard The oscillate Fitting Torque Specifications cylinder could become unbalanced and fall if not properly attached to the overhead crane when removed from the machine 1 Rotate the turntable until the boom is between the steer tires 2 Remove the fasteners from the drive chassis cover at the steer end Remove the cover 5 76 Genie S 80 and Genie S 85 Part No 77832 January 2004 EE Ee EE TE EE REVA 15 2 Valve Adjustments Oscillate Directional Valve How to Adjust the Oscillate Relief Valve Pressure 1 Remove the drive chassis cover from the non steer end of the machine Connect 0 to 2000 psi to 150 bar pressure gauge to the diagnostic nipple located near the oscillate directional valve Disconnect the directional valve linkage by removing the clevis yoke from the drive chassis Start the engine from the platform controls With the engine running manually activate the valve and observe the pressure reading on the pressure gauge Oscilla
282. ly tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock pin Key switch in the position with the key removed Wheels chocked Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 80 and Genie S 85 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissip
283. n during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the pin retaining fasteners from both the steer cylinder and the tie rod cylinder pivot pins Remove the pins 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor AWARNING 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 Loosen the wheel lug nuts Do not remove them 4 Block the non steer wheels and center a lifting jack of ample capacity under the steer axle 4WD Steer Axle Components Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts Remove the tire and wheel assembly Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin Remove the drive motor mounting fasteners Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 11 Support and secure the yoke and drive hub assembly to a lifting jack 12 Use a slide hammer to remove the upper yoke pivot pin Use a soft metal drift to drive the lower yoke pivot pin down and out AWARNING Crushing hazard The yoke and drive hub assembly c
284. o Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 1 3000 psi 0 to 200 bar pressure gauge to the diagnostic nipple PTEsT port on the function manifold 2 Startthe 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 Boom extend relief valve specification Pressure 2500 psi 172 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item F 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 AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 through 5 to confirm relief valve pressure Part No 77832 Genie S 80 amp Genie S 85 5 47 Section 5 Repair Procedures January 2004 LEER MANIFOLDS REV B 9 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 No Description Item Function Torque 1 Shuttle valve 2 position 3 way 10 13 ft lbs 14 18 Nm 2 Counterbalance valve 25 30 ft lbs 34
285. olt 1 2 turn counterclockwise Tighten the lock nut on the adjustment bolt 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 Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary 5 66 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REVA 12 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove the pin retaining fasteners from both the steering cylinder and the tie rod cylinder pivot pins Use a soft metal drift to remove the pins 2 Loosen the wheel lug nuts Do not remove them 3 Block the non steer wheels and center a lifting jack of ample capacity under the steer axle 4 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 5 Remove the lug nuts Remove the tire and wheel assembly 6 Remove the pin retaining fasteners from the yoke pivot pins 7 Support and secure the yoke and hub assembly to a lifting jack 2WD Steer Axle Components 8 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out 9 Remove the yoke and hub assembly from the machine Crushing hazard The yoke and ACAUTION hub assembly may become unbalanced and fall if not properly supported and secur
286. ould become unbalanced and fall when the yoke pivot pins are removed if not properly supported and secured to the lifting jack Part No 77832 Genie S 80 and Genie S 85 5 71 Section 5 Repair Procedures January 2004 prm H MM M aer 4WD STEER AXLE COMPONENTS REVA 13 Place the yoke and drive hub assembly on a flt 13 2 surface with the drive hub facing down Drive Motor 14 Remove the drive hub mounting fasteners that attach the drive hub to the yoke Remove the yokeromihedrive hub How to Remove a Drive Motor Component damage hazard CAUTION Repairs to the motor should only be performed by an authorized Rexroth dealer Replace the thrust washer when installing the yoke and drive hub assembly onto the axle Torque specifications CAUTION Component damage hazard The Lug nut dry 420 ft lbs work area and surfaces where this 569 5 Nm procedure will be performed must be clean and free of debris that Lug nut lubricated 320 ft lbs could get into the hydraulic system 434 Nm and cause severe component Drive hub mounting bolts dry 165 ft lbs damage Dealer service is 224 Nm recommended Drive hub mounting bolts lubricated 124 ft lbs When removing assembly 168 Nm or fitting the O ring on the fitting and or hose end must be replaced Drive motor mounting bolts dry 125 ft Ibs and then torqued to specification 16
287. p of the seal may occur Place the outer bearing into the hub Install the washer and castle nut REVA 7 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearings 8 Loosen the castle nut then re tighten to 8 ft lbs 11 Nm Install a new cotter pin 9 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 420 ft lbs 569 5 Nm Torque specifications Lug nut dry 420 ft lbs 569 5 Nm Lug nut lubricated 320 ft lbs 434 Nm Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REVA 12 2 Steer Cylinder 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 AWD Models Remove the hose bracket mountin
288. pply hoses and has an external return filter equipped with a filter condition indicator How to Remove the Hydraulic Tank Component damage hazard CAUTION 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Lower and retract the boom to the stowed position 2 Remove the fuel tank See 10 1 How to Remove the Fuel Tank REV Close the two hydraulic tank valves located at the hydraulic tank if equipped open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff 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 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank Tag and disconnect and plug the hose from the return filter Cap the fitting on the return filter housing Tag and disconnect and plug the supply hose for the auxiliary power unit Cap
289. ram 5 80 REVA Deutz F4L 913 Models before serialnumber 3577 EES EE 1 RD C3B 1 RD 6 1 1 RD S P VOLT M
290. rd Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING unl injury hazard Spraying ydraulic 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Perform repair Return to service problem solved Part No 77832 Genie S 80 and Genie S 85 7 1 Section 7 Schematics January 2004 EE SS SESS SS Electrical Components before serial number 3577 REVA Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number 1 Battery 1000 CCA 12V DC 30143 Trojan aus iba CS TXHCZ2 RE 1 2 Battery 1000 CCA 12V DC 67325 Trojam snenie C31XH 2 w studs 1 Batteryseparator 12V DC 61343 Sure Power Industries ISA 1 CB2 Circuit breaker 15A 24018 ETA L uuu ann 45 700 IG1 P10 2 CBS Circuit breaker 204 47899 DRE 45 700 IG1 P10 1 CR1 2 3 5 8 17 28 and CR29 Relay SPDT 12V DC 34052 Potter Brumfield
291. read sealant when installing the drain plug and strainers FUEL AND HYDRAULIC TANKS Hydraulic oil capacity specifications Hydraulic tank 45 gallons 170 liters Hydraulic system 55 gallons including tank 208 liters Hydraulic Oil Specifications Before serial number 3349 Hydraulic oil type Shell Donax TG Dexron 111 After serial number 3348 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Part No 77832 Genie S 80 amp Genie S 85 Section 5 Repair Procedures Januar
292. rkins 704 30 Models before serialnumber 3577 Section 7 Schematics January 2004 2 2 22 7 Ground Control Wiring Diagram 5 85 REV Perkins 704 30 Models before serialnumber 3577 1 SUTI OE
293. s Extend and retract the axle through an entire cycle Check for tight spots that could cause binding or scraping Always maintain squareness between the inner and outer axle tubes REV A Top and bottom wear pads 2 Center a lifting jack of ample capacity under the outer axle that needs to be shimmed Do not raise the machine Block the wheels at the opposite end of the machine Raise the machine just until the weight of the machine is relieved off of the inner axle Do not raise the wheels off of the ground Remove the drive chassis cover Loosen the wear pad mounting fasteners from the top and bottom wear pads on both the inner and outer axles Install the new shims under the wear pads of the inner and outer axle to obtain zero clearance and zero drag Use a round punch through the wear pad mounting holes to align the shims with the wear pad Install the wear pad retaining fasteners Extend and retract the axle through an entire cycle Check for tight spots that could cause binding or scraping of the axle tubes Always maintain squareness between the inner and outer axle tubes Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REVA How to Remove an Inner Axle When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose an
294. t direction is frozen at controller with neutral problem corrected 6 4 Genie S 80 and Genie S 85 PartNo 77832 January 2004 Section 6 Fault Codes REV A FAULT CODE CHART Error Source Error Type Condition Solution ID Name ID Name 51 Drive joystick 11 Value at 5V Limited speed and 12 Value too high direction frozen at Power up 15 Value too low zero and neutral controller with 16 Value at 0V Alarm sounds problem corrected indicating fault Joystick speed and 17 Not calibrated direction frozen at Calibrate joystick zero and neutral Initiate 1 second Self clearing RES of alarm transient 53 Drive flow valve Limited speed and EDC 12 Value too high direction frozen at Power up zero neutral controller with 15 Value too low arm sounds problem corrected indicating fault Normal function Calibrate valve except threshold for thresholds both directions Self clearing 18 Just calibrated ls Saye transient 54 Drive brake valve Limited speed and direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault 55 drive 2 2 2 in power up MOE VAVE 21 Fault uis ds indicating controller with fault problem corrected 61 Steer joystick 11 Value at 5 Limited speed and 12 Value too high direction frozen at Power up 15 Value too low zero an
295. te relief valve specification Pressure 850 psi 58 6 bar 6 Turn the engine off 7 Locate the relief valve on the directional valve and remove the cap Section 5 Repair Procedures OSCILLATING AXLE COMPONENTS 8 Adjust the internal screw Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 9 Repeat steps 4 through 7 and manually activate the valve to confirm the valve pressure 10 Turn the engine off remove the pressure gauge and assemble the directional valve linkage 11 Install the cover on the non steer end of the drive chassis Part No 77832 Genie S 80 and Genie S 85 5 77 Section 5 Repair Procedures January 2004 Extendable Axle Components 16 1 Extendable Axles The extendable axles are used to widen the foot print of the drive chassis for stability How to Shim an Extendable Axle 1 Measure each wear the wear pad if it is less than 1 2 inch 12 7 mm thick If the pad is more than 1 2 inch 12 7 thick perform the following procedure Extend the axles Side wear pads 2 Loosen the side wear pad mounting fasteners on the outer axle Install the new shims under the wear pads to obtain zero clearance and zero drag Use a round punch to align the shim to the wear pad Tighten the mounting fastener
296. too high 15 Value too low direction frozen at zero and neutral Alarm sounds indicating fault valves direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault 23 Boom 1 flow Limited speed and Power up controller with problem corrected 17 Not calibrated 18 Just calibrated Normal function except threshold for one or both directions is zero Calibrate valve thresholds Self clearing transient 31 Boom 2 Joystick secondary boom up down or primary boom extend retract 11 Value at 5V 12 Value too high 15 Value too low 16 Value at OV Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected 17 Not calibrated Joystick speed and direction frozen at zero and neutral Calibrate joystick 18 Just calibrated Initiate 1 second beep of alarm Self clearing transient 32 Boom 2 directional valves 21 Fault Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected N Continued on next page 77832 Genie 5 80 Genie 5 85 6 3 on Fault Codes 2004 FAULT CODE CHART REV A
297. uui PER BEE BEN HE ss x 5 I Pi DI i 6 19 T EE DESCENTALARMOPTION 4 7 C19JSV ij EE EN OE see ne eee enon code cae ces SE EN EN 1 i E g 5 Hie AF A JIB VALVES EE JIB VALVES u z a Section 7 Schematics January 2004 i Ground Control Box Wiring Diagram S 85 Deutz F4L 913 Models after serial number 3576 Section 7 Schematics January 2004 _ Ground Control Wiring Diagram 5 85 REV A1 Deutz F4L 913 Models after serial number 3576 A B D E F G H J K L M N
298. y 2004 Turntable Rotation Components 11 1 Turntable Rotation Drive Hub Assembly How to Remove the Turntable Rotation Drive Hub Assembly When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the motor AWARNING 2odily 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 REVA 3 Loosen the backlash pivot plate and adjustment bolts gt 20 2 SSS d 11 6 backlash pivot plate b adjustment with lock nut backlash pivot plate mounting bolts 4 Attach a suitable lifting device to the lifting eyes on the drive hub assembly 5 Remove the backlash pivot plate mounting bolts Carefully remove the drive hub assembly from the machine AWARNING Crushing hazard The turntable rotation drive hub assembly could become unbalanced and fall when itis removed from the machine if not properly supported When installing the

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