Genie S-100 Service And Repair Manual
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Genie S-100 Service And Repair Manual

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See also: Service Manual , Maintenance Manual
ServiceandRepairManual
TM
TM
TM
TM
Serial Number Range
from S-10015D-1001
to S-10016D-1549
from S-10515D-983
to S-10516D-1549
from S-12015D-1012
to S-12016D-1549
from S-12515D-984
to S-12516D-1549
from S-100D-1550
from S-105D-1550
from S-120D-1550
from S-125D-1550
This manual includes:
Repair procedures
Fault Codes
Electrical and Hydraulic
Schematics
For detailed maintenance
procedures, Refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268494
Rev A4
March 2017

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Summary of Contents for Genie S-100

  • Page 1 ServiceandRepairManual Serial Number Range from S-10015D-1001 This manual includes: to S-10016D-1549 Repair procedures from S-10515D-983 Fault Codes to S-10516D-1549 Electrical and Hydraulic Schematics from S-12015D-1012 to S-12016D-1549 from S-12515D-984 to S-12516D-1549 For detailed maintenance procedures, Refer to the appropriate Maintenance from S-100D-1550 from S-105D-1550 Manual for your machine.
  • Page 2 Unrestricted with proper operation, inspection and Hyper link is:http://www.genielift.com/en/service- scheduled maintenance. support/manuals/index.htm Copyright © 2015 by Terex Corporation 1268494 Rev A4 March 2017 First Edition, Fifth Printing Genie is a registered trademark of Terex South Dakota, Inc.in the U.S.A and many other countries. S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 3: Introduction

    Serial Number Legend 2/2017 Specifications Performance Specifications 3/2017 Repair Procedures Update illustration for cable adjustment Reference Examples: Section - Repair Procedure Section - Fault Codes Section - Schematics,Legends and schematics Part No. 1268494 S-100 • S-105 • S-120 • S-125...

  • Page 4: Introduction

    Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model 4 Serial label (located under cover) 2 Facility code 5 Serial number (stamped on chassis) 3 Sequence number S-100 • S-105 • S-120 • S-125 Part No. 1268494 iii...

  • Page 5: Safety Rules

    Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-100 & Genie S-105 Operator's Manual or the Genie S-120 & Genie S-125 Operator's Manual will result in death or serious injury.
  • Page 6 Be sure to properly dispose of old oil or property damage. other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 7: Table Of Contents

    Machine Torque Specifications ................2 - 25 Manifold Plug Torque Specifications ..............2 - 25 Hydraulic Hose and Fitting Torque Specifications ..........2 - 26 SAE and Metric Fasteners Torque Charts ............2 - 26 Part No. 1268494 S-100 • S-105 • S-120 • S-125...
  • Page 8 Jib Boom Lift Cylinder, S-105 and S-125 Models ........3 - 28 Boom Components Cable Track ....................3 - 30 Boom ......................3 - 33 Boom Lift Cylinder ..................3 - 44 Extension Cylinders ..................3 - 46 Boom Extend/Retract Cables ..............3 - 50 Turntable Covers Turntable Covers ..................3 - 54 S-100 • S-105 • S-120 • S-125 Part No. 1268494 viii...
  • Page 9 10-2 Function Manifold Components, S-100 and S-105 Models (after serial number 136) ................3 - 81 10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models .....3 - 85 10-4 Proportional Valves - Function Manifold ............3 - 86 Part No. 1268494...
  • Page 10 10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models .....3 - 99 10-9 Proportional Valves - Function Manifold ............3 - 100 10-10 Platform Manifold Components, S-100 and S-120 Models .......3 - 101 10-11 Platform Manifold Components, S-105 and S-125 Models .......3 - 103 10-12 Proportional Valves - Platform Manifolds ..........3 - 105...
  • Page 11 Diagnostic Code Chart ....................4 - 3 Control System Fault Codes ...................4 - 9 Deutz TD 2.9 L4 Engine Fault Codes ..............4 - 13 Perkins 854F-34T Engine Fault Code ..............4 - 28 Software ........................4 - 37 Part No. 1268494 S-100 • S-105 • S-120 • S-125...
  • Page 12 Engine Options- Perkins and Cummins (S-100/105 before serial number 219) (S-120/125 before serial number 933) ............5 - 23 Engine Options- Perkins (S-100/105 from serial number 219 to 247) (S-120/125 from serial number 933 to 984) ..........5 - 25 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 13 (S-100/105 from serial number 248) (S-120/125 from serial number 985) ............5 - 27 Engine Options- Perkins (S-100/105/120/125 from serial number 874) ..........5 - 29 Engine Options- Cummins (S-100/105 from serial number 219 to 247) (S-120/125 from serial number 933 to 984) ..........5 - 31...
  • Page 14 Deutz TD2.9 Engine Electrical Schematic ............5 - 45 Deutz TD2.9 Engine Electrical Harness ..............5 - 47 Hydraulic Schematic - 12 kW Generator (welder option) ........5 - 49 Hydraulic Schematic, S-100 • S-105 (serial number 136) ..................5 - 51 Hydraulic Schematic, S-100 • S-105 (from serial number 137 to 290) ..............5 - 53...

  • Page 15: Specifications

    366 cm Lug nut torque, lubricated 320 ft-lbs Turning radius, outside, 22 ft 2 in 22 ft 2 in 434 Nm axles retracted 6.75 m 6.75 m Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 1...
  • Page 16 0 to 120 ft / 0 to 36.6 m 170 to 190 seconds Boom retract vertical, 120 ft to 0 / 36.6 m to 0 170 to 190 seconds 2 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 17 20 ft / 6.1 m axles retracted 4.14 m 4.14 m 10 ft / 3 m LSB3RO LSB3RS 3 ft (0.9 m) 3.5 ft (1.1 m) 0 ft / 0 m Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 3...
  • Page 18 57 cm Wheel width 11.75 in 30 cm Wheel lugs 10 @ Lug nut torque, dry 420 ft-lbs 570 Nm Lug nut torque, lubricated 320 ft-lbs 434 Nm 2 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 19 LSB7DS LSB1DO 20 ft / 6.1 m 10 ft / 3 m LSB3RO LSB3RS 3 ft (0.9 m) 3.5 ft (1.1 m) 0 ft / 0 m Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 5...

  • Page 20: Hydraulic Specifications

    4 Chevron Rando HD premium oil MV temperature consistently exceeds 200 °F / 90°C an optional oil cooler may be required. 2 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 21 Note: Do not operate the machine when the ambient equivalent, when ambient temperature is below -20°F / -29°C with Rando HD temperatures are consistently Premium MV. above 32°F / 0°C may result in component damage. Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 7...

  • Page 22: Hydraulic Component Specifications

    Displacement 0 to 1.71 cu in Maximum continuous operating 189°F / 87°C 0 to 28 cc temperature Flow rate @ 2350 rpm, maximum 17.4 gpm 65.9 L/min 2 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 23 2) 207 bar test Jib and platform manifolds Platform rotate and platform level 0.3 gpm flow regulator 1.14 L/min Jib manifold flow regulator 2 gpm 7.6 L/min Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 9...
  • Page 24 1.7 bar Hydraulic tank 10 micron with return filter 25 psi / 1.7 bar bypass Beta 10 ≥ 2 Drive motor case drain return filter 2 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 25 Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 11...

  • Page 26: Deutz Engine Bf4L 2011 Specifications

    80A @ 14V DC alternative engine oils. For oil requirements, refer to the Fan belt deflection inch Engine Operator Handbook on your machine. 9 to 12 mm 2 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 27 Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 13...

  • Page 28: Deutz Engine Td 2.9 Specifications

    Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. 2 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 29 Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 15...
  • Page 30 Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. 2 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 31 Reserve capacity @ 25A rate 745 Minutes Battery - Engine starting and control system Type 12V DC, Group 31 Quantity Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 17...

  • Page 32: Perkins Engine 1004-42 Specifications

    Unit ships with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. 2 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 33: Perkins Engine 1104C-44 Specifications

    For fuel requirements, refer to the engine Operator's Valve clearance, cold Manual on your machine. Intake 0.008 in 0.2 mm Exhaust 0.018 in 0.45 mm Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 19...

  • Page 34: Perkins Engine 804D-33T Specifications

    0.0098 in 0.25 mm Lubrication system Oil pressure, hot 40 to 60 psi (at 2000 rpm) 2.8 to 4.1 bar Oil capacity 10.6 quarts (including filter) 10 liters 2 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 35 Reserve capacity @ 25A rate 745 minutes Battery - Engine starting and control system Type 12V DC, Group 31 Quantity Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 21...

  • Page 36: Cummins Engine B3.3T Specifications

    Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. 2 - 22 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 37: Cummins Engine B3.9L Specifications

    Unit ships with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 23...

  • Page 38: Cummins Engine B4.5L Specifications

    For oil requirements, refer to the 110°C Engine Operator Handbook on your machine. Alternator output 95A, 12V DC Fan belt deflection inch 10 to 12.5 mm 2 - 24 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 39: Machine Torque Specifications

    Drive motor mounting bolts, dry 110 ft-lbs 149 Nm Drive motor mounting bolts, lubricated 80 ft-lbs 108 Nm Drive hub oil plug, O-ring seal 13 ft-lbs 18 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 25...

  • Page 40: Hydraulic Hose And Fitting Torque Specifications

    135 ft-lbs / 183 Nm -16 (All types) 200 ft-lbs / 271.2 Nm -20 (All types) 250 ft-lbs / 339 Nm -24 (All types) 305 ft-lbs / 413.5 Nm 2 - 26 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 41 Refer to illistration 1. fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. 3 Be sure that the face seal O-ring is seated and retained properly.
  • Page 42 Illustration 2 a body hex fitting b reference mark c second mark 2 - 28 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 43 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 29...
  • Page 44 Section 2 • Specifications March 2017 SPECIFICATIONS This page intentionally left blank. 2 - 30 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 45: Repair Procedures

    Used to indicate the presence of Read, understand and obey the safety rules and operating instructions in the Genie S-100 & an imminently hazardous situation Genie S-105 Operator’s Manual and the which, if not avoided, will result in Genie S-120 &...

  • Page 46: Display Module

    Language Spanish, Portuguese, Italian, position. Dutch and Swedish. Release the button and press Deutz 2.9L Turbo (D2.9T) Deutz TD2011L0.4i (DL04i) Perkins 1104D-44T (P1104) Perkins 854F (P854T) 3 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 47 100% (default) Turntable rotate speed % >75 ft 120% max and 50% min, 100% (default) Jib boom up/down speed % 120% max and 50% min, 100% (default) Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 3...
  • Page 48 Calibration Turntable X-axis millivolts button and turn per degree the key switch to Platform level to gravity position. Platform millivolts per degree Release the button and press 3 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 49 Disable steer mode change while driving Rocker joystick steering Generator off delay (0-10 sec) o to seconds is the default shown only when hyd gen is selected Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 5...

  • Page 50: Platform Controls

    How to Calibrate a Joystick Controller. left/right joystick controller Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. 3 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 51: Circuit Boards

    2 Remove the platform control box lid retaining control box. fasteners. Open the control box lid. 6 Remove the platform control box lid retaining fasteners. Open the control box lid. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 7...

  • Page 52: Membrane Decal

    Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 3 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 53: Joystick Controllers

    Note: Perform this procedure with the engine off. The calibration procedure for each joystick begins on the next page. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 9...
  • Page 54 Result: If the alarm does not sound, repeat the Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1. calibration procedure, beginning with step 1. 3 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 55 Result: If the alarm does not sound, repeat the Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1. calibration procedure, beginning with step 1. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 11...
  • Page 56 Result: The alarm at the ground controls should sound for a successful calibration. Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1. 3 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 57 Do not let go of the joystick. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 13...
  • Page 58 When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center. 3 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 59 1 Pull out the red Emergency Stop button to the accelerate 2 seconds on position at both the ground and platform controls. 2 Press and hold the enter button on the Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 15...

  • Page 60: Platform Components

    Note: Do not rest the entire weight of the boom on fall when it is removed from the blocks. the machine if it is not properly supported. 3 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 61 Protect the cylinder rod 10 Carefully pull the platform leveling cylinder out from damage. of the boom. Component damage hazard. Hoses can be damaged if they are kinked or pinched. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 17...

  • Page 62: Platform Rotator

    Hose and Fitting Torque Specifications. 1 Remove the platform. See Repair Procedure, How to Remove the Platform. 2 Disconnect the electrical connector from the platform angle sensor. 3 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 63 Remove all rings, watches rotator is dropped or sustains and other jewelry. any physical shock, even if the damage is not visible. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 19...
  • Page 64 1 At the ground controls, simultaneously hold the container auxiliary power button and the platform rotate right button until the platform is fully rotated to the right. 3 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 65: Platform Level Sensor

    Emergency Stop button. S-100, S-120, S-105 (after serial number 250) and S-125 models (after serial number 998): 4 Press the plus button , then press the enter button twice before again pressing the plus 1.

  • Page 66: Platform Overload System

    Note: Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform. 3 - 22 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 67 Note: The platform will need to be moved up and down and allowed to settle between each adjustment. Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 23...
  • Page 68 8 Add an additional test weight to the platform. controls. S-105 and S-125- 10 lb / 4.5 kg S-100 and S-120- 12 lb / 5.4 kg. Note: There may be a 2 second delay before the overload indicator lights and alarm turn off.

  • Page 69: Platform Overload Recovery Message(Software V3.14 And Later)

    2 Press and hold the enter button on the ground sontrol panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 25...
  • Page 70 4 Support the jib boom with a suitable lifting Crushing hazard. The jib boom device. may become unbalanced and fall when it is removed from the machine if it is not properly supported. 3 - 26 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 71: Jib Boom Components, S-105 And S-125 Models

    Protect and fall if it is not properly the cylinder rod from damage. supported when it is removed from the machine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 27...

  • Page 72: Jib Boom Lift Cylinder, S-105 And S-125 Models

    Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported. 3 - 28 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 73: Boom Components

    S-100 and S-105 Models Pivot end Number 1 Platform end Number 2 Number 3 S-120 and S-125 Models Pivot end Platform end Number 0 Number 1 Number 2 Number 3 Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 29...

  • Page 74: Cable Track

    Note: If your machine is equipped with an airline to platform option and/or weld cable option, the airline and/or cable must be disconnected from the platform before the cable track is removed. 3 - 30 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 75 23 Tag and disconnect the electrical cables from the cable track to the ground controls side of the machine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 31...
  • Page 76 If the cable track has been pinched. replaced using cable track kit, Genie part number Component damage hazard. 102054, use part number 102214. If unsure which Cable tracks can be damaged if cable track is on the machine, contact Genie they are twisted.

  • Page 77: Boom

    8 Install the cable track snap-on spacers. 12 Replace the covers. 13 Extend and retract the boom through an entire cycle. Check for tight spots that may cause binding of the boom. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 33...
  • Page 78 7 Attach an overhead 10 ton / 10,000 kg crane to primary boom extension cylinder at the pivot the platform end of the boom for support. Do end of the boom. not lift the boom. 3 - 34 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 79 Crushing hazard. The boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead cranes. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 35...
  • Page 80 9 Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the pivot end of the boom. 3 - 36 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 81 2 boom tube at the platform end of the lifting eye on the primary boom extension the boom. Do not remove the proximity or limit cylinder. switches. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 37...
  • Page 82 38 Attach a lifting strap from an overhead crane to amount of shims used with each wear pad. the number 2 boom tube at the platform end of the boom. 3 - 38 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 83 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 39...
  • Page 84 3 Secure the number 2 and number 3 boom tubes together with a strap or chain to prevent them from moving. 4 Remove the cable clamp from the cable break limit switch wiring. 3 - 40 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 85 9 Locate the number 3 boom tube extension cable clevis pins on both sides of the number 2 boom tube at the pivot end of the boom. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 41...
  • Page 86 Component damage hazard. Cables can be damaged if they are kinked or pinched. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. 3 - 42 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 87 Note: During removal, the overhead crane strap Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. will need to be adjusted for proper balancing. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 43...

  • Page 88: Boom Lift Cylinder

    4 Remove the boom storage area cover retaining fasteners. Remove the cover from the machine. gradually. Do not allow oil to squirt or spray. 3 - 44 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 89 15 Support the boom lift cylinder with an overhead crane. 16 Use a slide hammer to remove the boom lift cylinder barrel-end pivot pin through the access hole in the engine side turntable riser. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 45...

  • Page 90: Extension Cylinders

    Remove the cover from the machine. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 - 46 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 91 16 Remove the upper plate and actuator pivot pin. red cable adjustment Do not remove the cable break limit switch from locking bracket the mounting plate. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 47...
  • Page 92 Note: During removal, the overhead crane strap the machine with the covers will need to be adjusted for proper balancing. removed could result in death or serious injury. 3 - 48 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 93 Component damage hazard. The boom lift cylinder rod can become damaged if the barrel end of the secondary boom extension cylinder is allowed to come in contact with it. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 49...

  • Page 94: Boom Extend/Retract Cables

    Do not remove inches / 17 cm. Loosen the jam nut and repeat the nuts. step 9. 3 - 50 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 95 3 boom tube and the end of the number 2 boom tube should be 16 Start the engine from the platform controls. to 6 inches / 17 to 17.5 cm (d). Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 51...
  • Page 96 8 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube. 3 - 52 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 97 18 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder. 19 Install the new boom retract pulleys to the pivot end of the boom extension cylinder. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 53...

  • Page 98: Turntable Covers

    Protect the strut cylinder rod from damage. Crushing hazard. The turntable cover will fall when the gas struts are removed if it is not properly supported. 3 - 54 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 99 Note: Alignment adjustments may be necessary when a new cover is installed. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 55...

  • Page 100: Rpm Adjustment

    Deutz models- .245 inch / 6.2 mm gap 8 Remove the flex plate mounting fasteners, Cummins or Perkins models- then remove the flex plate from the flywheel. .255 inch / 6.5 mm gap 3 - 56 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 101 Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur. Deutz 2011 Engines Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 57...

  • Page 102: Oil Pressure And Coolant Temperature Sending Units, Cummins And Perkins Models

    Component damage hazard. display at the ground controls. Do not crank the engine with a low oil pressure fault shown on the display at the ground controls. 3 - 58 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 103: Ground Controls

    Genie Industries Service Department. Note: When an ECM circuit board is replaced, the proportional valves will need to be calibrated. See 1-3, How to Calibrate a Joystick. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 59...

  • Page 104: Membrane Decal

    Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 3 - 60 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 105: Control Relays

    Note: Do not allow any solvent to come in contact How to Test a Single Pole Double with the LCD display screen. Throw Relay 7 Install the new membrane decal (Genie part number 50811) while guiding the ribbon cables Electrocution/burn hazard. Contact with electrically charged circuits through the control box lid.
  • Page 106 87 to 87a no continuity (infinite Ω) terminal 87a to 30 no continuity (infinite Ω) terminal 87 to 30 continuity (zero Ω) 85 87 Control Relay Schematic 3 - 62 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 107: Limit Switches

    3 ft (0.9 m) 3.5 ft (1.1 m) 0 ft / 0 m S-100 and S-105 Models S-120 and S-125 Models LSAX1RO LSAX2RO LSAX1EO LST10 LSAX2ES LSAX2EO LSAX1ES Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 63...
  • Page 108 D Down AX Axle A Angle Boom L Load moment Turntable E Extend O Operational LS Limit switch R Retract S Safety LS AX 1 R O 3 - 64 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 109 1 Fully retract the boom. 2 Place a digital protractor or digital level on top of the boom tube. Proximity switch target area Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 65...
  • Page 110 LIMIT SWITCHES S-120 and S-125 models: All models: 3 Raise boom until the protractor reads 67.5 14 S-100 and S-105 models: Raise the boom to degrees. 52.5 degrees. 4 Loosen the mounting fasteners from the 68 15 Loosen the mounting fasteners from the 53 degree proximity switch (LSB14AO).

  • Page 111: Limit Switch And Level Sensor Locations

    LSB4EO LSB3RS LSB9AS LSB4ES LSB8AS LSB1DO LSB7DS LSB13AO LSB14AO LSB19LO LSB6S LSB2RO LSB19LO LSB2RS PLATFORM LSAX2ES TURNTABLE LSAX1EO LEVEL LSAX1ES LSAX2RO LEVEL SENSOR LSAX1RO SENSOR LSAX2EO LST1O Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 67...

  • Page 112: Limit Switch Functions

    If this switch is tripped, then the axle is not fully extended. In this condition, if unit is out of stowed, power is cut to boom up, boom extend and axle retract. 3 - 68 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 113 120 feet. and the engine fuel solenoid when it is mechan- ically activated at 65 if the boom length is more than 101 feet. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 69...
  • Page 114 The safety cutout is set at +/- 10 from gravity and will disable the primary and secondary boom up/ down functions and the platform level up/down functions. 3 - 70 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 115: Hydraulic Pumps

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 71...

  • Page 116: Drive Pump

    (EDC) located on the drive pump. 6 Carefully pull the drive pump out until the pump coupler separates from the flex plate. 3 - 72 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 117 1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to one of the test ports located under the drive pump. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 73...
  • Page 118 Cummins and Perkins models: Connect the wire to the fuel shutoff solenoid at the injector pump. 8 Start the engine and check for hydraulic leaks. Cummins models fuel shutoff solenoid 3 - 74 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 119: Auxiliary Pump

    11 Remove the pressure gauge and reconnect the 3 Turn the key switch to ground control and hydraulic hose. pull out the Emergency Stop button to the position. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 75...
  • Page 120 1 Open the ground controls side turntable cover. 2 Tag, disconnect and plug the hydraulic hoses from the pumps. 3 Remove the pump mounting fasteners and remove the pump from the pump motor. 3 - 76 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 121: Function Manifold Components, S-100 And S-105 Models (Serial Number 136)

    March 2017 Section 3 • Repair Procedures Manifolds 10-1 Function Manifold Components, S-100 and S-105 Models (to serial number 136) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Relief valve, 1800 psi / 124.1 bar ..FA ..Boom extend pressure limit ......18-20 ft-lbs / 24-27 Nm Proportional solenoid valve ....
  • Page 122 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 78 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 123 March 2017 Section 3 • Repair Procedures MANIFOLDS Function Manifold Components, S-100 and S-105 Models, continued (to serial number 136) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Orifice - plug, 0.040 inch / 1.02 mm......FK ..Differential sensing dampening...
  • Page 124 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 80 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 125: Function Manifold Components, S-100 And S-105 Models (After Serial Number 136)

    March 2017 Section 3 • Repair Procedures MANIFOLDS 10-2 Function Manifold Components, S-100 and S-105 Models (from serial number 137) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Solenoid Valve Assembly, 3 position 4 way, DO3, 12V DC ..
  • Page 126 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 82 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 127 March 2017 Section 3 • Repair Procedures MANIFOLDS Function Manifold Components, S-100 and S-105 Models, continued (from serial number 137) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Relief Valve, 2600 psi / 179.3 bar ..FI ....Turntable, primary lift and boom retract pressure limit ....
  • Page 128 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 84 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 129: Valve Adjustments - Function Manifold, S-100 And S-105 Models

    7 Repeat steps 2 through 6 to confirm the relief the relief valve higher than valve pressure. specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 85...

  • Page 130: Proportional Valves - Function Manifold

    See Repair Procedure, How to Calibrate a Joystick. 3 - 86 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 131: Function Manifold Components, S-120 And S-125 Models (Before Serial Number 431)

    Check valve........BJ ...Load sensing circuit, boom up/down ........12-14 ft-lbs / 16-19 Nm Orifice - plug, 0.040 inch / 1.02 mm......BK ..Differential sensing dampening This list continues. Please turn the page. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 87...
  • Page 132 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 88 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 133 Solenoid valve, 2 position 3 way ..BQ ..Boom retract control .........52-60 ft-lbs / 71-82 Nm Solenoid valve, 2 position 3 way ..BR ..Boom extend control .........52-60 ft-lbs / 71-82 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 89...
  • Page 134 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 90 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 135: Function Manifold Components, S-120 And S-125 Models (From Serial Number 431 To 574)

    Relief Valve, 2600 psi / 179.3 bar ..BI ...Turntable, primary lift and boom retract pressure limit ......25-27 ft-lbs / 34-37 Nm This list continues on the next page. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 91...
  • Page 136 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 92 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 137 Solenoid Valve, 2 position 3 way ..BR ..Boom extend control ......52-60 ft-lbs / 71-82 Nm Relief Valve, 1800 psi / 124.1 bar ..BA ..Boom extend pressure limit ....18-20 ft-lbs / 25-27 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 93...
  • Page 138 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 94 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 139: Function Manifold Components, S-120 And S-125 Models (After Serial Number 574)

    Diagnostic Nipple ....... TP ..Testing Relief Valve, 3000 psi / 206.8 bar ..AC ..Platform manifold pressure limit ........18-20 ft-lbs / 25-27 Nm This list continues on the next page. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 95...
  • Page 140 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 96 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 141 Solenoid Valve, 2 position 3 way ..BQ ..Boom retract control ......52-60 ft-lbs / 71-82 Nm Solenoid Valve, 2 position 3 way ..BR ..Boom extend control ......52-60 ft-lbs / 71-82 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 97...
  • Page 142 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 98 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 143: Valve Adjustments - Function Manifold, S-120 And S-125 Models

    7 Repeat steps 2 through 6 to confirm the relief the relief valve higher than valve pressure. specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 99...

  • Page 144: Proportional Valves - Function Manifold

    See 1-3, How to Calibrate a Joystick Controller. 3 - 100 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 145: Platform Manifold Components, S-100 And S-120 Models

    March 2017 Section 3 • Repair Procedures MANIFOLDS 10-10 Platform Manifold Components, S-100 and S-120 Models The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Item Function Torque Proportional solenoid valve, 3 position 4 way ......... GH ..Platform level up/down ......18-20 ft-lbs / 24-27 Nm Check valve........
  • Page 146 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 102 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 147: Platform Manifold Components, S-105 And S-125 Models

    Differential sensing valve, N.C... CO ..Directs flow to functions ......23-25 ft-lbs / 31-34 Nm Proportional solenoid valve, 3 position 4 way ......... CD ..Platform rotate left/right ......18-20 ft-lbs / 24-27 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 103...
  • Page 148 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 104 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 149: Proportional Valves - Platform Manifolds

    Item Function Torque Counterbalance valve ......A ....Platform rotate left ........37-44 ft-lbs / 50-60 Nm Counterbalance valve ......B ....Platform rotate right ........37-44 ft-lbs / 50-60 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 105...

  • Page 150: Turntable Rotation Manifold Components

    Counterbalance valve ......B ....Turntable rotate right ........37-44 ft-lbs / 50-60 Nm Shuttle valve, 2 position 3 way ... C ....Turntable rotation brake release....10-12 ft-lbs / 14-16 Nm 3 - 106 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 151 1.4 gpm / 5.3 L/min ......EW ..Steering cylinder speed, square end, left side, retract ....18-20 ft-lbs / 24-27 Nm Solenoid Valve, 3 position 4 way ......... ES ..Axle extend contrrol ........25-27 ft-lbs / 34-37 Nm Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 107...
  • Page 152 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 108 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 153 Relief Valve, 3000 psi / 207 bar ..EZ ..Steering pressure limit ......18-20 ft-lbs / 25-27 Nm (Removed from S-120/125 at serial number 522, S-100/105 at serial number 148) Check Valve, 5 psi / 0.34 bar ..... EY ..Axle retract load sense, both ends .........12-14 ft-lbs / 16.3-19 Nm...
  • Page 154 Section 3 • Repair Procedures March 2017 MANIFOLDS EH EK EJJ ENN 3 - 110 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 155: Steer And Axle Extend/Retract Manifold Components - View 1

    Check Valve, 5 psi / 0.34 bar ..... EOO ..Steering cylinder lock, circle end, left side, retract ........12-14 ft-lbs / 16.3-19 Nm Diagnostic Nipple Cap......TP ..Testing Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 111...
  • Page 156 Section 3 • Repair Procedures March 2017 MANIFOLDS EH EK EJJ ENN 3 - 112 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 157: Valve Adjustments - Steer And Axle Extend/Retract Manifold

    Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 6 to confirm relief valve pressure. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 113...
  • Page 158 Section 3 • Repair Procedures March 2017 MANIFOLDS This page intentionally left blank. 3 - 114 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 159: Traction Manifold Components (S-100/105 Before Serial Number 291) (S-120/125 Before Serial Number 1195)

    2.7 gpm / 10.22 L/min ......DI ...Drive slip limit, front and rear ....35-40 ft-lbs / 47-54 Nm Check valve........DJ ..Anti-cavitation ...........35-40 ft-lbs / 47-54 Nm Check valve........DK ..Anti-cavitation ...........35-40 ft-lbs / 47-54 Nm This list continues. Please turn the page. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 115...
  • Page 160 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 116 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 161 March 2017 Section 3 • Repair Procedures MANIFOLDS Traction Manifold Components, continued (S-100/105- to serial number 290), (S-120/125- to serial number 1194) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index Schematic Description...
  • Page 162 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 118 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 163: Traction Manifold Components (S-100/105 After Serial Number 290) (S-120/125 After Serial Number 1194)

    2 gpm / 7.6 L/min ....... HL ..Equalizes pressure on both sides of divider/combiner valve FJ ....30-35 ft-lbs / 40.7-47.5 Nm This list continues. Please turn the page. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 119...
  • Page 164 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 120 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 165 March 2017 Section 3 • Repair Procedures MANIFOLDS Traction Manifold Components, continued (S-100/105- from serial number 291), (S-120/125- from serial number 1195) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index Schematic Description...
  • Page 166 Section 3 • Repair Procedures March 2017 MANIFOLDS 3 - 122 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 167: Valve Adjustments - Traction Manifold

    (Ω). Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 123...
  • Page 168 Solenoid valve, 2 position 3 way 12V (schematic items AA) multimeter 9V DC battery 10Ω resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 3 - 124 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 169 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 125...

  • Page 170: Fuel And Hydraulic Tanks

    When transferring fuel, connect a grounding wire between the machine and pump or container. Note: Be sure to only use a hand operated pump suitable for use with diesel fuel. 3 - 126 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 171: Hydraulic Tank

    1 Remove the ground controls side turntable drain into a suitable container. See capacity cover. See 5-1, How to Remove a Hinged specifications. Turntable Cover. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 127...
  • Page 172 11 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. 3 - 128 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 173: Turntable Rotation Components

    2 Remove the ground controls side fixed turntable cover. See 5-1, How to Remove a Fixed Turntable Cover. motor motor/brake mounting bolts brake drive hub mounting bolts drive hub Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 129...
  • Page 174 Apply pipe thread sealant to the plugs and install the plugs. Refer to Specifications, Specifications. 10 Adjust turntable rotation gear backlash. motor motor/brake mounting bolts brake drive hub mounting bolts drive hub 3 - 130 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 175 Torque the turntable rotate drive hub mounting bolts. Refer to Specifications, Machine Torque Specifications. 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 131...
  • Page 176 Section 3 • Repair Procedures March 2017 TURNTABLE ROTATION COMPONENTS This page intentionally left blank. 3 - 132 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 177: Axle Components

    2 Press down the foot switch and push the engine 5 Repeat step 4 for the other circle-end tire. idle select button until the engine switches to high rpm. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 133...
  • Page 178 5 Repeat step 4 until the tire is parallel with the chassis. 6 Tighten the steer sensor cover fasteners. 7 Repeat steps 2 through 6 for the other square- end steer sensor. 3 - 134 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 179: Yoke And Hub

    14 Repeat steps 9 through 13 for the other circle- gradually. Do not allow oil to squirt end steer sensor. or spray. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 135...
  • Page 180 15 Remove the pin retaining fasteners from the steering cylinder rod-end pivot pins. Remove the pins. 16 Remove the pin retaining fasteners from the upper and lower yoke pivot pins. 3 - 136 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 181: Drive Motor

    2 Remove the drive motor mounting fasteners. 3 Slide the drive motor shaft out of the brake and drive hub. Remove the drive motor from the machine. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 137...

  • Page 182: Drive Hub

    6 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. 7 Remove the wheel lug nuts. Remove the tire and wheel assembly. 3 - 138 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 183: Steering Cylinders

    Do not allow oil to squirt or spray. 5 Remove the pin retaining fasteners from the steer cylinder pivot pins. 6 Support the steer cylinder with a suitable lifting device. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 139...

  • Page 184: Extendable Axles

    5 Extend and retract the axle through an entire cycle. Check for tight spots that could cause binding or scraping of the axle tubes. Note: Always maintain squareness between the inner and outer axle tubes. 3 - 140 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 185 Measure the gap with the axles in both the retracted and extended positions. Adjust the proximity switches as necesary to obtain a inch / 3.1 mm gap. Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 141...
  • Page 186 Note: The wiring connectors for the switches can balancing. be accessed through the access holes on either side of the chassis end plate. 6 Place blocks under the axle extension cylinder for support. 3 - 142 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 187: Diagnostic Codes

    Note: Perform all troubleshooting on a firm, level surface. Note: Two persons will be required to safely perform some troubleshooting procedures. Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 1...
  • Page 188 8-bit occurrence counter. 3 The fault code table on the following pages lists the functions or components monitored by the system. 4 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 189 LCD corrected Power up controller with Limited Speed and Direction frozen at Axle Valves Fault Check problem zero and neutral, Alarm sounds corrected Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 3...
  • Page 190 Display message on LCD Stop all boom functions, allow only Power up controller with Fault Check boom retract. Display message on LCD Primary Boom Angle problem (unknown angle) corrected 4 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 191 P22 SAFETY SWITCH FAULT Display message on LCD SAFETY SWITCH P22R P22R SAFETY SWITCH FAULT Power up controller with Display message on LCD problem CAN Bus Fault Check corrected Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 5...
  • Page 192 Turntable Rotate CCW Valves Turntable Level Sensor X-Direction Display message on LCD and sound Fault Check audible alarm Turntable Level Sensor Y-Direction Correct problem Platform Level Sensor Y-Direction 4 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 193 Recycle power Footswitch Timeout Display message on LCD Power up controller with Disable Generator, Display message Hydraulic Generator/Welder - Bypass Fault Check problem on LCD Display Valve corrected Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 7...
  • Page 194 Alarm sounds corrected LR Steer Valves RR Steer Valves Power up controller with Display message on LCD Hydraulic Generator/Welder - Bypass Fault Check problem Valve corrected 4 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 195: Control System Fault Codes

    Boom Safety (max angle) Boom Safety (max length) Axle Retract Safety Cable Tension (#1 or #2) * P-9A and P-10 energized if boom is fully retracted as indicated by LSB3RS Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 9...
  • Page 196 Min Cal Too High Right Front Steer Sensor Left Rear Steer Sensor Right Rear Steer Sensor Rocker Steer Joystick PBMLS Safety Envelope (SCON) Front Axle Sensor Rear Axle Sensor 4 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 197 Turntable Rotate Power P39 Right Rear Steer Valve Valve Power P6R1 Axle Valve Engine Power P6R2 Boom Not Retracted and Chassis Tilted (SCON) Enable Input Power P7 Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 11...
  • Page 198 LTB1LO/LSB4EO Cross-Check Pressure Comp Enable #1 Valve Pressure Comp Enable #2/Generator Valve Check Machine Software Type at TCON Check Machine Software Type at SCON TCON/SCON Software Inconsistent 4 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 199: Deutz Td 2.9 L4 Engine Fault Codes

    Sensor error water fuel; signal 1223 Actuator EGR-Valve; open load range check low 1014 Actuator error EGR-Valve; signal 1157 Water in fuel level prefilter; range check high maximum value exceeded Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 13...
  • Page 200 Sensor error charged air Sensor error rail pressure; signal temperature; signal range check range check low high Sensor error charged air temperature; signal range check 4 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 201 Sensor camshaft speed; plausibility error disturbed signal Intake air sensor; plausibility error Sensor error intake air; signal range check high Sensor error intake air; signal range check low Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 15...
  • Page 202 (EGR) differential pressure High side to low side short circuit Sensor error differential pressure in the injector 1 (in firing order) Venturiunit (EGR); signal range check low 4 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 203 Cold start aid relay error Setpoint Cold start aid relay open load 1079 13 Sensor supply voltage monitor 1 error (ECU) 1080 13 Sensor supply voltage monitor 2 error (ECU) Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 17...
  • Page 204 1194 Physical range check low for 1231 14 CAN-Bus 2 "BusOff-Status" exhaust gas temperature upstream turbine 1180 1 1461 Turbocharger Wastegate CAN feedback; shut off threshold exceeded 4 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 205 Bank 0 4765 0 1039 Physical range check high for exhaust gas temperature upstream (DOC) 4765 1 1042 Physical range check low for exhaust gas temperature upstream (DOC) Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 19...
  • Page 206 Controller mode switch; short forced to open; performed by circuit to battery pressure shock 523006 4 Controller mode switch; short circuit to ground 523008 1 Manipulation control was triggered 4 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 207 523612 12 Internal ECU monitoring CAN-Receive-Frame TSC1AR; detection reported error Retarder 523612 12 Internal software error ECU; injection cut off 523612 12 Internal ECU monitoring detection reported error Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 21...
  • Page 208 Setpoint of metering unit in TSC1AE overrun mode not plausible 523767 9 Timeout Error of 523613 3 Metering unit (Fuel-System); CAN-Receive-Frame Passive short circuit to battery high side TSC1AE 4 - 22 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 209 Check of missing injector adjustment value programming (IMA) injector 1 (in firing order) 523896 13 Check of missing injector adjustment value programming (IMA) injector 2 (in firing order) Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 23...
  • Page 210 523932 1 Fuel Balance Control integrator EGR cooler downstream temp. injector 4 (in firing order); minimum value exceeded 523935 12 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages 4 - 24 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 211 523999 12 1328 Injector powerstage output Slave 524034 12 1437 Disc separator; powerstage over defect temperature 524014 1 1254 Air pressure glow plug flush line; below limit Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 25...
  • Page 212 CAN-Receive-Frame ComRxCustSCR3 ComRxDPFCtl 524105 9 1668 Timeout Error of CAN-Transmit-Frame ComEGRMsFlw 524106 9 1677 Timeout Error of CAN-Receive-Frame ComRxEGRMsFlw1 524107 9 1678 Timeout Error of CAN-Receive-Frame ComRxEGRMsFlw2 4 - 26 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 213 1684 Timeout Error of CAN-Receive-Frame ComRxUQSens 524123 9 1685 Timeout Error of CAN-Receive-Frame ComSCRHtCtl 524124 9 1686 Timeout Error of CAN-Receive-Frame ComTxAT1IMG 524125 9 1687 Timeout Error of CAN-Receive-Frame ComTxTrbChActr Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 27...

  • Page 214: Perkins 854F-34T Engine Fault Code

    Engine Air Filter 1 Differential Pressure: High - least severe Inlet Air Is Restricted Engine Air Filter 1 Differential Pressure: High - moderate Inlet Air Is Restricted severity (2) 4 - 28 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 215 ECM Memory - Test Engine Rated Power: Special Instruction ECM Memory - Test Battery Potential/ Power Input 1: Voltage Below Normal Ignition Keyswitch Circuit and Battery Supply Circuit - Test Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 29...
  • Page 216 Injector Solenoid Circuit - Test Engine Injector Cylinder #01: Data Drifted High Injector Data Incorrect- Test Engine Injector Cylinder #01: Data Drifted Low Injector Data Incorrect- Test 4 - 30 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 217 Width, or Period PTO Governor State: Erratic, Intermittent, or Incorrect PTO Switch Circuit - Test 1041 Start Signal Indicator: Erratic, Intermittent, or Incorrect Start Relay Circuit - Test Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 31...
  • Page 218 Fuel Rail Pressure Problem 1485 ECM Main Relay: Not Responding Properly Electrical Power Supply - Test 1485 ECM Main Relay: Special Instruction Electrical Power Supply - Test 4 - 32 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 219 After treatment #1 Intake 02: Out of Calibration Oxygen Level - Test 3217 After treatment #1 Intake 02: High - least severe (1) Oxygen Level - Test Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 33...
  • Page 220 Particulate Trap Lamp Command: Current Above Normal Indicator Lamp Circuit - Test 3698 Exhaust System High Temperature Lamp Command: Indicator Lamp Circuit - Test Current Below Normal 4 - 34 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 221 High Pressure Common Rail Fuel Pressure Relief Fuel Rail Pressure Problem Valve: High-moderate severity (2) 5826 Emission Control System Operator Inducement Severity Refer to "Operator Inducement High-moderate severity (2) Codes" Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 35...
  • Page 222 2 Select the Safety folder, then the Fault Status screen. 3 Change any safety switch drop down menus displaying . Press fault send 4 Exit Web GPI. 4 - 36 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 223: Software

    Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the Genie S-100 & Genie S-105 Operator’s Manual and the Genie S-120 & Genie S-125 Operator’s Manual. Be sure that all necessary tools and parts are available and ready for use.
  • Page 224 Section 4 • Diagnostic Codes March 2017 This page intentionally left blank. 4 - 38 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 225 Operator's Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 1...

  • Page 226: Circuit Numbering

    Extend/retract Lockout R ..Relay Output Filter Restricted Filter Switch S ..Safety Flashing Beacon V ..Valve Float Switch Footswitch Signal Forward Fuel Pump Fuel Select (gas/LP) Fuel Solenoid 5 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 227 Sec Boom Up Power Sec Boom Up/Dwn Flow Control Power to Length Sensor Secondary Boom Platform Tilt Alarm This list continues on the next page. Platform Tilt Sensor Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 3...

  • Page 228: Wire Color Legend

    Turntable Tilt Sensor Green Test Switch GN/BK Green/Black GN/WH Green/White RD/BK Red/Black RD/WH Red/White Orange OR/BL Orange/Blue OR/BK Orange/Black OR/RD Orange/Red White WH/BK White/Black WH/RD White/Red Yellow 5 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 229 RD/BK 28 Platform level alarm OR/RD 63 Power to boom envelope safety RD/WH 29 Drive motor shift (speed) switch This list continues on the next page. Forward/EDC-A Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 5...
  • Page 230 Tether ESTOP return WH/BK 126 Secondary boom lockout Tether power (Riser Down Enable) Tether ESTOP power ECU test switch J1708 + (high) OR/RD 128 Low engine speed 5 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 231 Speed select input WH/RD 160 Propel joystick signal OR/RD 195 Electric brake source WH/BK 161 Sec boom joystick signal 2.5V Sensor power Joystick 5 VDC power Ground or return Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 7...

  • Page 232: Limit Switches

    Boom L Load moment Turntable E Extend (•• S-120 and S-125 models only) O Operational R Retract LS Limit switch S Safety LS AX 1 R O 5 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 233 3.5 ft (1.1 m) 0 ft / 0 m S-100 & S-105 Models S-120 & S-125 Models (S-100 shown) (S-120 shown) LSAX1RO LSAX2RO LSAX1EO LST10 LSAX2ES LSAX2EO LSAX1ES Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 9...

  • Page 234: Relay Layout

    CR15 relay (K1) - powers P22R or C03PBF circuit (Boom up/down valve coil). CR13 relay (K5) - powers P_7 and throttle relay. CR11 relay (K3) - powers P-6R2 or P54ENG circuits. 5 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 235: Drive Chassis Controller Pin Legend

    21 = V37RFS - BL/BK 22 = (UNUSED) PIN NUMBERING FOR 22 = V36LFS - BL 23 PIN 23 = P61LS(A) - GN 23 = V37LFS - BL/BK CONNECTORS Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 11...

  • Page 236: Platform Controller Pin Legend

    21 = (UNUSED) 22 = PTSRET - BR 22 = (UNUSED) 23 = P87PTS - RD 23 = P23PCON - BK PIN NUMBERING FOR 23 PIN CONNECTORS 5 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 237: Turntable Controller Pin Legend

    22 = (UNUSED) 3 = BATGND - BR 35 = VLVRET1 - BR 35 = VLVRET1 - BR 4 = BATECU - RD 23 = P95TET - OR Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 13...

  • Page 238: Engine Relay And Fuse Panel Legend

    Fuse 20A Hydraulic Oil Cooler Horn B BAT Fused Power from B1 B1BAT Power from Battery R21PIGN Ignition 02PGND Ground Start Relay C 15 Glow Plug Relay 5 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 239: Engine Relay And Fuse Panel Legend - Deutz Td2.9 Models

    Fuse 60A Glow Plug Fuse 20A Hydraulic Oil Cooler Horn B3BAT Fused Power from B1 B1BAT Power from Battery R21PIGN Ignition 02PGND Ground C 17 Glow Plug Relay Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 15...

  • Page 240: Engine Relay And Fuse Panel Legend - Perkins 854F Models

    Fuse 60A Glow Plug Fuse 20A Hydraulic Oil Cooler Horn B3BAT Fused Power from B1 B1BAT Power from Battery R21PIGN Ignition 02PGND Ground Engine Starter C 81 ECU Power 5 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 241: Telematics Connector Pin Legend

    March 2017 Section 5 • Schematics Telematics Connector Pin Legend Genie installed Telematics connector is wried with an Active High digital input. Connector Pin Numbering Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector. Circuit Type Circuit Properties...

  • Page 242: Electrical Symbols Legend

    PCON KEYSWITCH Power relay TCON ALTERNATOR Starter motor Chassis ground EXCT STA. REGULATOR N.O.H.C N.C.H.O IND. Current limiting Main key switch Battery separator Limit switch device ALTERNATOR 5 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 243: Hydraulic Symbols Legend

    Pump prime mover (engine or motor) Flow divider/combiner valve with pressure balancing orifice and flow percentages 2 position, 2 way solenoid valve Double acting cylinder Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 19...
  • Page 244 Section 5 • Schematics March 2017 This page intentionally left blank. 5 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 245: Safety Circuit Schematic

    P_10 (P_18) STAT IN 1 OUT 1 LSB6S IN 2 OUT 2 TCON/J4/9 TO BOOM EXTEND VAVLE CABLE TENSION NFET TCON/J2/8 S59CNBK TCON/J2/10 C61AXRT MONITORED BY ECU DCON/J1/3 P53LS Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-21...
  • Page 246 Section 6 • Schematics March 2017 Safety Circuit Schematic 6-21 6-22...

  • Page 247: Engine Options- Perkins And Cummins

    March 2017 Section 6 • Schematics Engine Options- Perkins and Cummins S-100/105 (to serial number 218) S-120/125 (to serial number 932) 6-24 6-23...
  • Page 248 TROMBETTA MOM N.O. TIME DELAY 87 85 +BAT STARTER WAS 10A BEFORE: RELAY S100/105- SN 159 HORN +AUX S120/125- SN 619 -BAT RELAY S-500 REGULATOR SERVICE HORN ENGINE BLOCK 6-24 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 249: Engine Options- Perkins

    March 2017 Section 6 • Schematics Engine Options- Perkins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) J5 BLACK 4 PIN J3 WHITE 23 PIN POWER HARN ENGINE HARN C84TAY-GN/BK C83TAX-GN/WH 0-20 DEGREE P85TTSR-GN SENSOR ALARM SET AT 4.5 DEGREES...

  • Page 250: Engine Options- Perkins

    Section 6 • Schematics March 2017 Engine Options- Perkins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) 6-25 6-26...

  • Page 251: (S-100/105 From Serial Number 248) (S-120/125 From Serial Number 985)

    March 2017 Section 6 • Schematics Engine Options- Perkins S-100/105 (from serial number 248) S-120/125 (from serial number 985) 6-28 6-27...
  • Page 252 WH-PULL RD-HOLD 70 A FUSE +AUX -BAT BK-COM CB7 ADDED STARTER S100- S/N 710 RELAY 87 85 HORN S125- S/N 2589 RELAY FUEL PUMP REGULATOR SERVICE HORN ENGINE BLOCK 6-28 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 253: Engine Options- Perkins

    March 2017 Section 6 • Schematics Engine Options- Perkins S-100/105/120/125 (from serial number 874) 6-30 6-29...
  • Page 254 Fuse, 30A, Eng / Start / Fuel Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn B3PBAT Fused Power from B1 B1PBAT Power from Battery R21PIGN Ignition Fuse, 20A, RPM Solenoid 02PGND Ground 6-30 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 255: Engine Options- Cummins

    March 2017 Section 6 • Schematics Engine Options- Cummins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) CUMMINS B4.5 C80 ENGINE Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-31...

  • Page 256: Engine Options- Cummins

    Section 6 • Schematics March 2017 Engine Options- Cummins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) 6-31 6-32...

  • Page 257: (S-100/105 From Serial Number 248) (S-120/125 From Serial Number 985)

    March 2017 Section 6 • Schematics Engine Options- Cummins S-100/105 (from serial number 248) S-120/125 (from serial number 985) 6-34 6-33...
  • Page 258 March 2017 Engine Options- Cummins S-100/105 (from serial number 248) S-120/125 (from serial number 985) CUMMINS B4.5 C80 ENGINE CUMMINS B3.3T ENGINE CB7 ADDED S100- S/N 710 S125- S/N 2589 6-34 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 259: Electrical Schematic - Generator Options

    March 2017 Section 6 • Schematics Electrical Schematic - Generator Options 6-36 6-35...
  • Page 260 Section 6 • Schematics March 2017 Electrical Schematic - Generator Options Hydraulic Generator Option Belt-Driven Generator Option 110 VAC REGULATOR 120VAC GENERATOR W/REGULATOR. 220 VAC REGULATOR 220VAC GENERATOR W/REGULATOR. 6-36 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 261: Electrical Schematic - 12 Kw Generator (Welder Option)

    GR/BK WH/RD P23PWR(A) C30EDC+ WH/BK C31EDC- BK/RD GND1 WH/RD BL/RD P23PWR C30EDC+(A) RD/BK C31EDC-(A) OR/RD GND2 GR/WH C45GEN WH/BK GR/BK V150HG RD/WH P23PWR BK/RD BL/RD J159 RD/BK OR/RD RD/WH Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-37...
  • Page 262 Section 6 • Schematics March 2017 Electrical Schematic - 12 kW Generator (welder option) 6-37 6-38...

  • Page 263: Perkins 1104D-44T Engine Electrical Schematic

    March 2017 Section 6 • Schematics Perkins 1104D-44T Engine Electrical Schematic Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-39...
  • Page 264 Section 6 • Schematics March 2017 Perkins 1104D-44T Engine Electrical Schematic 6-39 6-40...

  • Page 265: Perkins 854F-34T Engine Electrical Schematic

    March 2017 Section 6 • Schematics Perkins 854F-34T Engine Electrical Schematic 6-42 6-41...
  • Page 266 Section 6 • Schematics March 2017 Perkins 854F-34T Engine Electrical Schematic 6-42 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 267: Perkins 854F-34T Engine Electrical Harness

    March 2017 Section 6 • Schematics Perkins 854F-34T Engine Electrical Harness Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-43...
  • Page 268 Section 6 • Schematics March 2017 Perkins 854F-34T Engine Harness 6-45 6-44...
  • Page 269 March 2017 Section 6 • Schematics Deutz TD2011L04i Engine Electrical Schematic 6-46 6-45...
  • Page 270 Section 6 • Schematics March 2017 Deutz TD2011L04i Engine Electrical Schematic 6-46 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 271: Deutz Td2.9 Engine Electrical Schematic

    March 2017 Section 6 • Schematics Deutz TD2.9 Engine Electrical Schematic 6-48 6-47...
  • Page 272 Section 6 • Schematics March 2017 Deutz TD2.9 Engine Electrical Schematic 6-48 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 273: Deutz Td2.9 Engine Electrical Harness

    March 2017 Section 6 • Schematics Deutz TD2.9 Engine Electrical Harness Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-49...
  • Page 274 Section 6 • Schematics March 2017 Deutz TD2.9 Engine Electrical Harness 6-51 6-50...

  • Page 275: Hydraulic Schematic - 12 Kw Generator (Welder Option)

    200 PSI / 13.8 BAR N.O. 270 PSI / 18.6 BAR @ 3.5 GPM / 13.25 L/min 21 GPM / 79.5 L/min MTR B MTR A TANK 21CC GENERATOR 12.5 KW Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-51...

  • Page 276: Hydraulic Schematic - 12 Kw Generator

    Section 6 • Schematics March 2017 Hydraulic Schematic - 12 kW Generator (welder option) 6-53 6-52...

  • Page 277: (Serial Number 136)

    March 2017 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (serial number 136) 6-54 6-53...

  • Page 278: Hydraulic Schematic

    2200 PSI 0.1GPM 0.030 Note: 'alpha' callouts refer BRAKE BRAKE to components shown in the FOUR WHEEL STEER MANIFOLD manifold illustrations. 2 SPD 2 SPD Refer to the Repair Section. 6-54 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 279 0.1GPM The manifold relief valve manifold illustrations. 2 SPD 2 SPD EZ was removed at Refer to the Repair Section. Serial No. 148 FOUR WHEEL STEER MANIFOLD Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-55...
  • Page 280 Section 6 • Schematics March 2017 Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290) 6-57 6-56...

  • Page 281: From Serial Number 291 To Serial Number 738)

    March 2017 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738) 6-58 6-57...
  • Page 282 L2SPEED 0.1GPM R2SPEED R2SPEED Note: 'alpha' callouts refer to components shown in the RBRAKE RBRAKE manifold illustrations. Refer to the Repair Section. 4WD TRACTION MANIFOLD FOUR WHEEL STEER MANIFOLD 6-58 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 283: From Serial Number 739)

    L2SPEED Note: 'alpha' callouts refer R2SPEED R2SPEED 0.1GPM to components shown in the RBRAKE RBRAKE manifold illustrations. Refer to the Repair Section. 4WD TRACTION MANIFOLD FOUR WHEEL STEER MANIFOLD Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-59...
  • Page 284 Section 6 • Schematics March 2017 Hydraulic Schematic, S-100 • S-105 Models (from serial number 739) 6-61 6-60...

  • Page 285: (From Serial Number 404 To Serial Number 430)

    March 2017 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430) 6-62 6-61...

  • Page 286: S-100 • S-105 • S-120 •

    2000 PSI 0.1GPM 0.030 Note: 'alpha' callouts refer BRAKE BRAKE to components shown in the FOUR WHEEL STEER MANIFOLD manifold illustrations. 2 SPD 2 SPD Refer to the Repair Section. 6-62 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 287: (From Serial Number 431 To Serial Number 1194)

    Manifold relief valve Note: 'alpha' callouts refer EZ was removed at 2 SPD 2 SPD Serial No. 522 to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-63...
  • Page 288 Section 6 • Schematics March 2017 Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194) 6-65 6-64...

  • Page 289: (From Serial Number 1195 To Serial Number 2634)

    March 2017 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634) 6-66 6-65...
  • Page 290 R2SPEED R2SPEED 600 PSI RBRAKE RBRAKE Note: 'alpha' callouts refer FOUR WHEEL STEER MANIFOLD 4WD TRACTION MANIFOLD to components shown in the manifold illustrations. Refer to the Repair Section. 6-66 S-100 • S-105 • S-120 • S-125 Part No. 1268494...

  • Page 291: (From Serial Number 2635 To Serial Number 3145)

    Note: 'alpha' callouts refer L2SPEED L2SPEED to components shown in the R2SPEED R2SPEED 0.1GPM manifold illustrations. RBRAKE RBRAKE Refer to the Repair Section. FOUR WHEEL STEER MANIFOLD 4WD TRACTION MANIFOLD Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-67...

  • Page 292: Hydraulic Schematic

    Section 6 • Schematics March 2017 Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to serial number 3145) 6-69 6-68...
  • Page 293 March 2017 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921) 6-70 6-69...
  • Page 294 Section 6 • Schematics March 2017 Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921) 6-70 S-100 • S-105 • S-120 • S-125 Part No. 1268494...
  • Page 295 March 2017 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922) Part No. 1268494 S-100 • S-105 • S-120 • S-125 6-71...
  • Page 296 Section 6 • Schematics March 2017 Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922) 6-73 6-72...
  • Page 297 LIMIT SWITCHES LIMIT SWITCHES STARTER AUX. LIMIT SWITCHES WHEN AXLES WHEN AXLES PUMP ARE RETRACTED ARE EXTENDED Genie Part Number 228879 Rev A REGULATOR S-120/125 IND. S-100/105 TERM 3 & 4 TERM 3 & 4 ARE CLOSED ARE CLOSED SERVICE...
  • Page 298 RELAY ES0427G AUX. LIMIT SWITCHES WHEN AXLES WHEN AXLES PUMP REGULATOR ARE RETRACTED ARE EXTENDED Genie Part Number 228880 Rev A TERM 3 & 4 TERM 3 & 4 IND. S-100/105 ARE CLOSED ARE CLOSED SERVICE AXLE RETRACTION AXLE EXTENTION...
  • Page 299 SPEED FUEL LIMIT SWITCHES AXLE NOT EXT ES0509C SOLENOID SOLENOID STA. RELAY LIMIT SWITCHES S-100/105 Genie Part Number 228882 Rev A LIMIT SWITCHES AUX. WHEN AXLES WHEN AXLES PUMP S-120/125 REGULATOR ARE RETRACTED ARE EXTENDED IND. TERM 3 & 4 TERM 3 &...
  • Page 300 P56PRV-RD 9 10 11 12 8 WAY 12 WAY RELAY D82CAN+ -YL GLOW PLUG HYD COOLER D81CAN- -GR RELAY RELAY Genie S-100(from serial number S10011D-114) HORN RELAY J2-BL/RD Genie S-105(from serial number S10511D-133) S56PRV-RD 10 A J1-BL/BK J4-GR/BK J3-OR/BL GNDDCON-BR...
  • Page 301 P56PRV-RD 9 10 11 12 8 WAY 12 WAY RELAY D82CAN+ -YL GLOW PLUG HYD COOLER D81CAN- -GR RELAY RELAY Genie S-100(from serial number S10014D-876) HORN RELAY J2-BL/RD Genie S-105(from serial number S10514D-877) S56PRV-RD 10 A J1-BL/BK J4-GR/BK J3-OR/BL GNDDCON-BR...
  • Page 302 P56PRV-RD 9 10 11 12 8 WAY 12 WAY RELAY D82CAN+ -YL GLOW PLUG HYD COOLER D81CAN- -GR RELAY RELAY Genie S-100(from serial number S10016D-1382) HORN RELAY J2-BL/RD Genie S-105(from serial number S10516D-1356) S56PRV-RD 10 A J1-BL/BK J4-GR/BK J3-OR/BL GNDDCON-BR...
  • Page 303 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

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