Contents - Introduction
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Machine Specifications
- Performance Specifications
- Hydraulic Component Specifications
- Valve Coil Resistance Specifications
- Machine Torque Specifications
- Hydraulic Hose and Fitting Torque Specifications
- Pre-Delivery Preparation
- Maintenance Inspection Report
- A-1 Inspect the Manuals and Decals
- A-2 Perform Pre-operation Inspection
- A-4 Perform Function Tests
- A-6 Check the High Pressure Hydraulic Filter Condition Indicator
- A-8 Perform Engine Maintenance - Deutz and Continental Models
- A-10 Grease the Turntable Rotation Bearing and Rotate Gear
- A-11 Perform Engine Maintenance
- A-12 Replace the Drive Hub Oil
- A-13 Perform Engine Maintenance - Perkins Models
- B-1 Inspect the Battery(s)
- B-2 Inspect the Electrical Wiring
- B-3 Test the Key Switch
- B-5 Inspect the Engine Air Filter
- B-6 Check the Oil Cooler and Cooling Fins - Deutz Models
- B-7 Confirm the Proper Brake Configuration
- B-10 Check and Adjust the Engine RPM
- B-11 Perform Engine Maintenance
- B-13 Test the Ground Control Override
- B-15 Test the Engine Idle Select Operation
- B-16 Test the Fuel Select Operation - Gasoline/LPG Models
- B-17 Test the Drive Enable System
- B-18 Test the Drive Brakes
- B-20 Test the Drive Speed - Raised or Extended Position
- B-21 Test the Alarm Package (if equipped) and the Descent Alarm
- B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems
- B-23 Perform Hydraulic Oil Analysis
- C-2 Grease the Platform Overload Mechanism (if equipped)
- C-3 Test the Platform Overload System (if equipped)
- C-5 Replace the Fuel Filter/ Water Separator Element - Diesel Models
- C-6 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X
- D-1 Check the Boom Wear Pads
- D-2 Check the Free-wheel Configuration
- D-3 Check the Turntable Rotation Bearing Bolts
- D-5 Perform Engine Maintenance
- D-7 Replace the Drive Hub Oil
- D-8 Perform Engine Maintenance - Deutz Models
- E-1 Test or Replace the Hydraulic Oil
- E-2 Perform Engine Maintenance - Perkins Models
- ALC-500 Circuit Board
- Joysticks
- Platform
- Platform Leveling Slave Cylinder
- Platform Rotator
- Calibrate the Platform Overload System
- Jib Boom Components,
- Function Manifold Components
- Valve Adjustments - Function Manifold
- Brake/Two-speed Manifold Components
- Turntable Rotation Manifold Components
- Platform Rotate Manifold Components
- Platform Manifold Components, S-80
- Platform Manifold Components, S-85
- WD Traction Manifold Components
- Drive Oil Diverter Manifold Components (welder option)
- Valve Adjustments - Traction Manifold
- Valve Coils
- Fuel Tank
- Hydraulic Tank
- Turntable Rotation Drive Hub Assembly
- Yoke and Hub
- Steer Cylinder
- Yoke and Drive Hub
- Drive Motor
- Steer Cylinders
- Oscillate Axle Cylinders
- Oscillate Directional Valve
- Fault Codes - Control System
- Electrical Symbols Legend
- Hydraulic Symbols Legend
- Connector Pin Legend - View 1
- Connector Pin Legend - View 2
- Deutz TD2011L04i Models
- Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS Deutz TD2011L04i Models
- Electrical Schematic, S-80 and S-85 (CE Deutz TD2011L04i Models (before serial number 8111)
- Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (before serial number 8111)
- Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (before serial number 8111)
- Platform Control Box Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (before serial number 8111)
- Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (before serial number 8111)
- Electrical Schematic, S-80 and S-85 (CE Deutz TD2011L04i Models (after serial number 8110)
- Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (after serial number 8110)
- Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (after serial number 8110)
- Deutz TD2011L04i Models (after serial number 8110)
- Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz TD2011L04i Models (after serial number 8110)
- Electrical Schematic, S-80X Deutz TD2011L04i Models
- Ground Control Box Terminal Strip Wiring Diagram, S-80X Deutz TD2011L04i Models
- Platform Control Box Wiring Diagram, S-80X Deutz TD2011L04i Models
- Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS Perkins 804D-33 Models
- Perkins 804D-33 Models
- Electrical Schematic, S-80 and S-85 (CE Perkins 804D-33 Models (before serial number 8111)
- Perkins 804D-33 Models (before serial number 8111)
- Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (before serial number 8111)
- Platform Control Box Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (before serial number 8111)
- Electrical Schematic, S-80 and S-85 (CE Perkins 804D-33 Models (after serial number 8110)
- Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after serial number 8110)
- Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after serial number 8110)
- Platform Control Box Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after serial number 8110)
- Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after serial number 8110)
- Electrical Schematic, S-80X Perkins 804D-33 Models
- Ground Control Box Terminal Strip Wiring Diagram, S-80X Perkins 804D-33 Models
- Platform Control Box Wiring Diagram, S80X Perkins 804D-33 Models
- Platform Control Box Switch Panel Wiring Diagram, S80X Perkins 804D-33 Models
- Continental TME27 Models
- Ground Control Box Terminal Strip Wiring Diagram S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
- Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS Continental TME27 Models
- Electrical Schematic, S-80 and S-85 (CE Continental TME27 Models (before serial number 8111)
- Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before serial number 8111)
- Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before serial number 8111)
- Platform Control Box Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before serial number 8111)
- Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before serial number 8111)
- Electrical Schematic, S-80 and S-85 (CE Continental TME27 Models (after serial number 8110)
- Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (after serial number 8110)
- Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (after serial number 8110)
- Continental TME27 Models (after serial number 8110)
- Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (after serial number 8110)
- Electrical Schematic, S-80X Continental TME27 Models
- Ground Control Box Terminal Strip Wiring Diagram, S-80X Continental TME27 Models
- Platform Control Box Wiring Diagram, S-80X Continental TME27 Models
- Continental TME27 Engine Harness
- Platform Level Cutout, CTE Option
- Continental Options Schematic
- Deutz and Perkins Options Schematic
- kW Hydraulic Generator Wiring Diagram
- kW Hydraulic Generator Electrical Schematic
- Belt Driven Generator Option
- Relay and Fuse Panel Legend
- Hydraulic Schematic, 2WD Models
- Hydraulic Schematic, 4WD Models
- kW Hydraulic Generator Hydraulic Schematic
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February 2012Section 6 • Schematics12345678A B C D E F G H I J K L M N6 - 154 S-80 • S-85 • S-80X Part No. 122985Continental TME27 Engine HarnessWHITE/LT GREEN 1854TAN/BLACK 18PINK/TAN 18RED/TAN 14WHITE/BLUE 18RED 148530868685AUX PWM4 RECIRCAUX PWM3 RECIRCAUX PWM5 RECIRCBLACK/RED 1686PINK/BLACK 18AUX PWM4AUX PWM2AUX PWM1AUX PWM3 87888990RED/BLACK 18GRAY/RED 18RED/TAN 14PINK/TAN 18PINK/BLACK 18WHITE/BLUE 18RED 14 308685WHITE 14 3085PINK/YELLOW 16863070TAN/ORANGE 1877AUX PWM5FPUMPV BATGROUNDDBW+/STEP +DBW-/STEP - 8485788082817983MILEGOH 2EGOH 3FUEL LOCKOFFBUZZRELAYEGOH 1STARTER767173757472TAN/BLACK 18LT BLUE/BLK 18PINK/WHITE 18PINK/YELL 16BLACK 16RED/TAN 16BLACK/YELLOW 16BLACK/WHITE 16WHITE/BLACK 18WHITE/BLUE 18YELLOW/LT GREEN 18ORANGE 1861INJ1 LSINJ8 LSINJ7 LSINJ6 LSINJ5 LSINJ4 LSINJ3 LSINJ2 LSGROUND6862646366676569TACHPULSE INV BATV BAT PROTPC RXPC TXAUX ANA PUD1575958605655BROWN/BLUE 16BROWN/WHITE 16BROWN/GREEN 16BROWN/YELLOW 16BLACK 16PINK/YELLOW 16DK GREEN 18RED/TAN 16F4BAT +PINK/TAN 18RED/TAN 145AF2F120AFUEL PUMP RELAYPINK/DK GREEN 16POWER RELAY87PINK/YELLOW 1687F315A15ARED 12RED 14PINK 18RED 14PINK/DK GREEN 16PINK/YELLOW 16PINK/DK GREEN 16PINK/DK GREEN 16BLACK 16PINK/TAN 18WHITE/BLACK 18STARTER RELAYLT BLUE/PINK 14BLUE/GREEN 14EPR RELAY87A87PINK/YELLOW 168715AF5FUEL LOCKOFFPINK/YELLOW 16WHITE 14ABSTARTER RELAYBLACK 16BLACK 16 BLACK 12 GROUNDSPLICE WITHIN 6" FROM CONNECTORWHITE/PURPLE 18TAN/BROWN 18GRAY/WHITE 18GRAY/DK BLUE 18TAN/BROWN 18LT GREEN/BLACK 18GRAY/DK BLUE 18GRAY/WHITE 18YELLOW/GRAY 185V EXTAUX ANA PU3AUX ANA PU2AUX ANA PU1OIL PGOV 2GOV 15V RTN4748464952535150SPK COIL 4BECTV SWITCHAUX DIG 3AUX DIG 2AUX DIG 1EGT38403941IAT45434442DK BLUE/YELLOW 18LT GREEN/WHITE 18DK BLUE/YELLOW 18TAN 18PINK/TAN 18YELLOW/BLACK 1830KNK 2 -SPK COIL 4ASPK COIL 3BSPK COIL 3ASPK COIL 2BSPK COIL 2ASPK COIL 1BSPK COIL 1A 31323637353433CAM POSCRK NEGSPD NEGSPD POSCAM NEGKNK 1 -KNK 2 +KNK 1 +2223292826272524YELLOW/RED 18YELLOW/LT GREEN 18YELLOW 18PURPLE/ORANGE 18GRAY/BROWN 18LT BLUE/DK BLUE 186TPS1/STEP2 +PURPLE/YELLOW 18DK BLUE 18WHITE/RED 18DK BLUE 18LT GREEN 1814CAN 1 +5V RTN5V EXTCAN 2 TERM +CAN 2 +CRK POSCAN 2 -CAN 1 - 15211719201816TPS2/STEP2 -MAPAUX ANA PD2FPP2-IVSAUX ANA PD1FPP1AUX ANA PD3CAN 1 TERM + 13101211987PURPLE/WHITE 18LT GREEN/RED 18BLACK/LT GREEN 18TAN/DK GREEN 18PURPLE/LT BLUE 18DK GREEN/ORANGE 18EGO 2EGO 4EGO 3EGO 135412LT GREEN/BLACK 18TXDK GREEN 18BLK/LT GREEN 18LT GREEN/RED 18BC5VDRTNCOMMORANGE 18 ARXOIL PRESSURE SWITCHDK BLUE/YELLOW 18PINK/DK GREEN 16PINK/DK GREEN 16YELLOW/BLACK 18BLACK/LT GREEN 18PINK/DK GREEN 16YELLOW/RED 18BLACK/LT GREEN 18PINK/DK GREEN 16BLACK/LT GREEN 18BLACK/LT GREEN 18YELLOW/LT GREEN 18NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2BNOTE: INJECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDERINJECTOR 2BROWN/GREEN 16BROWN/YELLOW 16INJECTOR 4 INJECTOR 3BROWN/WHITE 16COIL 4BA BLACK 16C DCOIL 3A BBLACK 16C DBROWN/BLUE 16INJECTOR 1COIL 2A BLACK 16DCBCOIL 1A BLACK 16DB C YELLOW 18TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTHBLUE/WHITE 18WHITE/ORANGE 18LT BLUE/BLACK 18TAN/BROWN 18ORANGE 18GRAY/RED 18ESL/TEST SWITCHFUEL SELECTTEMP SENDER1211109 MILBLACK 16BLUE/GREEN 14PURPLE/YELLOW 18WHITE/ORANGE 18BLUE/WHITE 18RED/BLACK 18LT BLUE/PINK 14BLACK/RED 16GRAY/WHITE 18GRAY/DK BLUE 18YELLOW/LT GREEN 18PINK/YELLOW 16PINK 18VEHICLE INTERFACE 1DEUTSCH DT04 RECEPTACLEFUEL PUMP -FUEL PUMP +GOV SELECT 2GOV SELECT 1START COMMAND2467835TACHIGN OUT1 VSWNOT USED (PLUGGED)NOT USED (PLUGGED)START IN (AUTOCRANK)NOT USED (PLUGGED)CAN LOW1112FPP2 IVSGROUNDCAN HIGHAUX ANA PU147658910POST CAT HEGODBW THROTTLE CONNECTORACACPRE CAT HEGOTAN/ORANGE 18BLK/LT GREEN 18LT GREEN/RED 18PURPLE/LT BLUE 18LT BLUE/DK BLUE 18PINK/WHITE 18TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTHPURPLE/ORANGE 18GRAY/BROWN 18263451BLK/LT GREEN 18PURPLE/ORANGE 18GRAY/BROWN 18 BTWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTHWHITE/PURPLE 18PURPLE/WHITE 18TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTHLT GREEN/RED 18BLK/LT GREEN 18PURPLE/WHITE 18WHITE/PURPLE 18BLT GREEN/RED 18LT GREEN 18BLACK/LT GREEN 18TAN/DK GREEN 18PINK/DK GREEN 16BLACK/YELLOW 16BLACK/LT GREEN 18DK GREEN/ORANGE 18PINK/DK GREEN 16BLACK/WHITE 16ABDC4ABDCLT GREEN/RED 18TAN 18BLACK/LT GREEN 18BLACK/LT GREEN 18YELLOW/GRAY 18 ECT321BTMAPASPLICE WITHIN 6" OF CONNECTORBLACK/LT GREEN 18LT GREEN/RED 18DK BLUE 18GASOLINE SENSOR INTERFACEWHITE/LT GREEN 18 4LT GREEN/WHITE 18LT GREEN/RED 18BLACK/LT GREEN 18CAM SENSOR312VEHICLE INTERFACE 2DEUTSCH DT06 PLUGVREFANA RETURNFPP1132PINK/YELLOW 16CRANK SENSORBLACK/LT GREEN 18WHITE/RED 18 AB LPG TEMPWHITE/ORANGE 18WHITE/ORANGE 18BLUE/WHITE 18JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTORJUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTORBLUE/WHITE 18WHITE/ORANGE 18WHITE/ORANGE 18BLUE/WHITE 18WHITE/ORANGE 18COBRA EPR367BLACK 16 GROUNDCAN +VBATWHITE/ORANGE 18BLUE/WHITE 18CAN + TERM21 CAN -
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