Genie S-105 Service Manual
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Genie S-105 Service Manual

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Summary of Contents for Genie S-105

  • Page 2: Introduction

    Read, understand and obey the safety rules and Genie Industries offers the following operating instructions in the Genie S-100 and Service Manuals for these models: Genie S-105 Operator's Manual or the Genie S- 120 and Genie S-125 Operator's Manual before Title Part No.

  • Page 3: Serial Number Legend

    This machine complies with: ANSI A92.5 CAN B.354.4 Genie Industries 18340 NE 76th Street Redmond, WA 98052 Serial label (located under cover) Serial number (stamped on chassis) PN - 77055 Part No. 102916 S-100 • S-105 • S-120 • S-125...
  • Page 4 June 2011 This page intentionally left blank. S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • 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: Personal Safety

    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. 102916...

  • Page 7: Table Of Contents

    Machine Specifications, S120 and S-125 Models ..........2 - 1 Performance Specifications, S120 and S-125 Models ..........2 - 2 Machine Specifications, S100 and S-105 Models ..........2 - 3 Performance Specifications, S100 and S-105 Models ..........2 - 5 Hydraulic Oil Specifications ...................
  • Page 8 Inspect the Engine Air Filter ............... 3 - 19 Perform Hydaulic Oil Analysis ..............3 - 20 Perform Engine Maintenance - Deutz Models ..........3 - 21 Perform Engine Maintenance - Cummins Models ........3 - 21 S-100 • S-105 • S-120 • S-125 Part No. 102916 viii...
  • Page 9 Replace the Engine Air Filter ..............3 - 45 Grease the Platform Overload Mechanism (if equipped) ......3 - 46 Test the Platform Overload System (if equipped) ........3 - 47 Part No. 102916 S-100 • S-105 • S-120 • S-125...
  • Page 10 E-11 Perform Engine Maintenance - Perkins Models .......... 3 - 68 E-12 Perform Engine Maintenance - Deutz Models ..........3 - 69 E-13 Replace the Boom Extend/Retract Cables ..........3 - 69 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 11 Platform Overload System ................. 4 - 22 Jib Boom Components, S-105 and S-125 Models Jib Boom, S-105 and S-125 Models ............4 - 24 Jib Boom Lift Cylinder, S-105 and S-125 Models ........4 - 26 Boom Components Cable Track ....................4 - 29 Boom ......................
  • Page 12 10-2 Function Manifold Components, S-100 and S-105 Models (after serial number 136) ................4 - 80 10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models ....4 - 84 10-4 Proportional Valves - Function Manifold ............. 4 - 85 S-100 •...
  • Page 13 10-9 Proportional Valves - Function Manifold ............. 4 - 99 10-10 Platform Manifold Components, S-100 and S-120 Models ......4 - 100 10-11 Platform Manifold Components, S-105 and S-125 Models ......4 - 102 10-12 Proportional Valves - Platform Manifolds ........... 4 - 104 10-13 Platform Rotate Counterbalance Valve Manifold Components ....
  • Page 14 13-6 Extendable Axles ..................4 - 139 Section 5 Diagnostic Codes Introduction ......................5 - 1 Diagnostic Code Chart ................... 5 - 3 Control System Fault Codes .................. 5 - 9 Software ......................5 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 15 (S-120/125 from serial number 985) ............6 - 28 Electrical Schematic - Generator Options ............6 - 30 Electrical Schematic - 12 kW Generator (welder option) ........6 - 31 Part No. 102916 S-100 • S-105 • S-120 • S-125...
  • Page 16 Hydraulic Schematic, S-120 • S-125 (from serial number 1195 to serial number 2634) ........6 - 48 Hydraulic Schematic, S-120 • S-125 (from serial number 2635) ................6 - 49 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 17 570 Nm Turning radius, outside, 22 ft 2 in 22 ft 2 in axles retracted 6.75 m 6.75 m Lug nut torque, lubricated 320 ft-lbs 434 Nm Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 1...
  • Page 18 1.2 to 1.8 m Gradeability (boom stowed) See Operators Manual Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 19: Machine Specifications

    21 ft 7 in axles retracted 6.58 m 6.58 m Turning radius, inside, 13 ft 7 in 13 ft 7 in axles retracted 4.14 m 4.14 m Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 3...
  • Page 20 570 Nm Lug nut torque, lubricated 320 ft-lbs 434 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 21 (time between fully raised and a fully lowered position) Boom extended to >80 ft / >24.4 m 50 to 55 seconds (time between fully raised and the 50° envelope limit) Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 5...

  • Page 22: Hydraulic Oil Specifications

    Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 23: Hydraulic Component Specifications

    Flow rate @ 2350 rpm, maximum 17.4 gpm 65.9 L/min Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 7...
  • Page 24 Displacement per revolution, 2.7 cu in low speed 45 cc Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 8 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 25 13.5 liters Oil viscosity requirements 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. 102916 S-100 • S-105 • S-120 • S-125 2 - 9...

  • Page 26: Deutz Engine Bf4L 2011 Specifications

    80A @ 14V DC alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Fan belt deflection inch 9 to 12 mm 2 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 27: Deutz Engine Td2011L04I Specifications

    Oil pressure switch point 22 psi 1.5 bar Exhaust 0.020 in 0.5 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 11...
  • Page 28 12V DC, Group 31 Quantity Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Alternator output 80A @ 14V DC Fan belt deflection inch 9 to 12 mm 2 - 12 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 29 For oil requirements, refer to the Engine Operator Handbook on your machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 13...

  • Page 30: Perkins Engine 1104C-44 Specifications

    Intake 0.008 in 0.2 mm Exhaust 0.018 in 0.45 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 31 13.2 liters Coolant temperature sending unit Torque 8-18 ft-lbs 11-24 Nm Temperature switch point 230°F 110°C Alternator output 85A @ 13.8V DC Fan belt deflection inch 10 mm Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 15...

  • Page 32: Perkins Engine 804D-33T Specifications

    Quantity (at 2000 rpm) 2.8 to 4.1 bar Cold cranking ampere 1000A Oil capacity 10.6 quarts Reserve capacity @ 25A rate 200 minutes (including filter) 10 liters 2 - 16 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 33 Coolant temperature sending unit Installation torque 8-18 ft-lbs 11-24 Nm Temperature switch point 230°F 110°C Alternator output 90A @ 12V DC Fan belt deflection 9 to 12 mm Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 17...

  • Page 34: 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 - 18 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 35: Cummins Engine B3.9L Specifications

    For oil requirements, refer to the Engine Operator Handbook on your machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 19...

  • Page 36: 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 - 20 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 37: Machine Torque Specifications

    250 ft-lbs / 334 Nm 305 ft-lbs / 414 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 21...

  • Page 38: Manifold Plug Torque Specifications

    O-rings. They are not standard SAE size O-rings. They are SAE No. 6 23 ft-lbs / 31.2 Nm available in the O-ring field service kit (Genie part number 49612). SAE No. 8 36 ft-lbs / 48.8 Nm 2 Lubricate the O-ring before installation.
  • Page 39 June 2011 Section 2 • Specifications REV E SPECIFICATIONS 10.9 12.9 Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 23...
  • Page 40 Section 2 • Specifications June2011 SPECIFICATIONS REV E This page intentionally left blank. 2 - 24 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 41: Observe And Obey

    • Key switch in the off position with the key removed • Wheels chocked • All external AC power supply disconnected from the machine Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 1...
  • Page 42 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 43: Pre-Delivery Preparation

    Genie UK 18340 NE 76th Street The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev B...
  • Page 44 Section 3 • Scheduled Maintenance Procedures June 2011 This page intentionally left blank. 3 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 45: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 5...
  • Page 46 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 47: Checklist A Procedures

    Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 7...

  • Page 48: Perform Pre-Operation Inspection

    Operator's Manual on your machine. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 3 - 8 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 49: Perform Engine Maintenance - Perkins Models

    Cummins B4.5 and B3.9L Operation and Maintenance Manual Perkins 1004 User's Handbook Genie part number 107527 Genie part number 61376 Perkins 1100 Series User's Handbook Genie part number 107526 Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 9...

  • Page 50: Check The Hydraulic Filter Condition Indicators

    See D-11, Replace the Hydraulic 2 Press and release the engine idle select button Filter Elements. to change the engine rpm to high idle. 3 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 51: Perform 30 Day Service

    , this indicates that a hydraulic filter is Elements being bypassed and the filter needs to be replaced. See D-11, Replace the Hydraulic Filter Elements. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 11...

  • Page 52: Perform Engine Maintenance - Perkins Models

    3 - 12 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 53: Grease The Turntable Rotation Bearing And Rotate Gear

    1 Locate the grease fittings on the extendable result in serious injury. Do not axles covers. operate the machine if the turntable rotation gear cover is not installed. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 13...

  • Page 54: Replace The Drive Hub Oil

    4 Fill the hub with oil from either plug hole until the oil level is even with the bottom of both plug holes. Install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs. 3 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 55: Bodily Injury Hazard. Spraying

    Crushing hazard. The turntable rotate drive hub may become unbalanced and fall when it is removed from the machine if it is not properly supported. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 15...

  • Page 56: Checklist B Procedures

    Note the results. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 3 - 16 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 57: Inspect The Electrical Wiring

    3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 17...
  • Page 58 Crushing hazard. Failure to install · Wire harness connectors to DCON module the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 3 - 18 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 59: Check The Engine Oil Cooler And Cooling Fins - Deutz Models

    2 Remove the retaining fasteners from the engine side cover. Remove the cover. 3 Inspect the oil cooler for leaks and physical damage. 4 Clean the oil cooler of debris and foreign material. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 19...

  • Page 60: Inspect The Engine Air Filter

    1 Open the engine side cover. Empty the dust discharge valve by pressing together the sides of the discharge slot. Clean the discharge slot as needed. clamp cannister end cap dust discharge valve 3 - 20 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 61: B-6 Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 21...

  • Page 62: Check The Exhaust System

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 22 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 63: Inspect The Tires, Wheels And Lug Nut Torque

    Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 23...

  • Page 64: Check The Dirve Hub Oil Level And Fastener Torque

    4 Install the plugs in the drive hub. 5 Check the torque of the drive hub mounting fasteners. Refer to Section 2, Specifications. 6 Repeat this procedure for each drive hub. 3 - 24 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 65: Confirm The Proper Brake Configuration

    6 If necessary, add oil until the oil level is even disengaged position with the bottom of the plug hole. 7 Install the plug into the drive hub. engaged position Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 25...

  • Page 66: Check And Adjust The Engine Rpm

    Result: Refer to Section 2, Specifications. Skip to step 5 if the low idle rpm is correct. 3 Loosen the locknut on the low idle adjustment screw. low idle adjustment screw 3 - 26 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 67 Result: Refer to Section 2, Specifications. engine pivot plate anchor hole engine pivot plate retaining fastener Perkins models low idle adjustment screw solenoid boot yoke lock nut Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 27...
  • Page 68 Cummins models low idle adjustment screw solenoid cable rpm solenoid 3 - 28 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 69: Test The Key Switches

    8 Turn the main key switch to the off position. Result: The engine should stop and no functions should operate. 9 Turn the main key switch to ground control and start the engine. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 29...

  • Page 70: Test The Ground Control Override

    20 Turn the main key switch to the off position. 21 Close the turntable side cover. 3 - 30 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 71: Test The Platform Self-Leveling

    4 Push and hold a function enable/speed select button and adjust the platform to a level position using the platform level up/down buttons. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 31...

  • Page 72: Test The Safety Envelope And Circuits

    Bodily injury hazard. If the boom 2 Raise the boom to approximately 60°. extends to more than 101 feet / Note: For S-100 or S-105 models, proceed to step 30.8 m without stopping the engine, stop immediately and retract the boom until the boom is 101 feet / 30.8 m Length Safety Switch, LSB2RS:...
  • Page 73 68°. Failure to raise the boom could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 33...
  • Page 74 75 feet / 37 Press the button until CLEAR ALL SAFETY SWITCH 22.9 m. Failure to retract the boom appears. FAULTS could result in death or serious injury. 3 - 34 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 75 53 Remove the arm from the cable break limit switch LSB6S. Note: LSB6S is located at the end of the boom tubes at the pivot end of the boom. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 35...
  • Page 76 2 feet between pin 3 and pin 4 of the deutsch / 0.6 m. Failure to retract the boom connector. could result in death or serious injury. 3 - 36 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 77 Failure to lower the boom could result in death or serious injury. 69 Remove the wire jumper installed in step 66 and connect the Deutsch connector to LSAX2ES. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 37...

  • Page 78: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    Dry using low pressure 1 Remove the cap from the fuel tank. compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank. 3 - 38 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 79: Test The Engine Idle Select Operation

    Result: The engine should change to high idle. 5 Push and release the rpm select button until low rpm is selected (turtle symbol). Result: The engine should return to low idle. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 39...

  • Page 80: Test The Drive Brakes

    6 Measure the distance between the test line and the machine reference point crosses the finish your machine reference point. Refer to line. Refer to Section 2, Specifications . Section 2, Specifications . 3 - 40 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 81: Test The Drive Speed - Raised Or Extended Position

    6 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 41...

  • Page 82: Inspect The Boom Extend/Retract Cables

    3 boom • No Broken or damaged pulleys tube on the S-100 and S-105, and the numbers 2 • No Unusual or excessive pulley wear and 3 boom tubes on the S-120 and S-125.
  • Page 83 June 2011 Section 3 • Scheduled Maintenance Procedures REV E CHECKLIST B PROCEDURES This page intentionally left blank. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 43...

  • Page 84: Checklist C Procedures

    Crushing hazard. Failure to install death or serious injury. the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 44 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 85: Perform Engine Maintenance - Perkins Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 45...

  • Page 86: Grease The Platform Overload Mechanism (If Equipped)

    3 Remove all weight, tools and accessories from the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an inaccurate test. 3 - 46 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 87 S-100 and S-120- 75 lbs / 34 kg 8 Test all machine functions from the platform S-105 and S-125- 50 lbs / 22.7 kg. controls. Result: The alarm should sound. Result: All platform control functions should not The platform overload indicator light should be operate.
  • Page 88 Result: All platform control functions should operate. Note: If the platform overload system is not operating properly, refer to Repair Section 2-4, Calibrate the Platform Overload System (if equipped). 3 - 48 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 89: Checklist D Procedures

    .090 in / 2.29 mm. Note: If the wear pads are still within specification, refer to Repair Section 4-2, How to Shim the Boom. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 49...

  • Page 90: Check The Extendable Axle Wear Pads

    1 Start the engine from the platform controls and extend the axles. 2 Measure each wear pad. Extendable axle wear pad specifications inch Minimum thickness 11.1 mm 3 - 50 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 91: Check The Free-Wheel Configuration

    4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the square-end of the machine. disengaged position engaged position Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 51...

  • Page 92: Check The Turntable Rotation Bearing Bolts

    Note: The lift cylinder safety chock is available through Genie (Genie part number 75097). drive pump screwdriver lift pump free-wheel valve 3 - 52 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 93: Check The Turntable Rotation Gear Backlash

    Refer to Section 2, Specifications. as far as it will go. Note: The turntable rotation bearing bolt torque sequence is the same from above the turntable and below the drive chassis. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 53...
  • Page 94 Note: Fasten a straight edge on the side of the rotator using tape so one end is just above the tape measure. 3 - 54 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 95: Replace The Drive Hub Oil

    Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. drive hub plugs Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 55...
  • Page 96 Drain the oil from the hub into a suitable container. 6 Install the drive hub assembly onto the machine. Lubricate and torque the drive hub mounting bolts to specification. Refer to Section 2, Specifications. 3 - 56 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 97: Inspect For Turntable Bearing Wear

    90° apart. 11 Lower the boom to the stowed position and turn the machine off. 12 Remove the dial indicator from the machine. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 57...

  • Page 98: Perform Engine Maintenance - Deutz Models

    3 - 58 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 99: Perform Engine Maintenance - Cummins Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 59...
  • Page 100 7 Install the new high pressure filter elements into the housings and tighten them securely. 8 Clean up any oil that may have spilled during the installation procedure. 3 - 60 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 101 10 Start the engine from the ground controls. 11 Inspect the filter housings and related components to be sure that there are no leaks. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 61...

  • Page 102: Checklist E Procedures

    9 Disconnect and plug the T-fitting located at the return filter with the 2 hoses connected to it. Cap the fitting on the return filter head. open closed 3 - 62 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 103 Refer to Repair Section 9-2, How to Prime the Pumps . 23 Install the ground control box assembly and assembly retaining fasteners onto the machine. 37 Install the turntable side cover. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 63...

  • Page 104: Perform Engine Maintenance - Cummins Models

    3 - 64 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 105: Perform Engine Maintenance - Perkins Models

    Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 65...

  • Page 106: Perform Engine Maintenance - Perkins Models

    3 - 66 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 107: Perform Engine Maintenance - Perkins Models

    Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 67...

  • Page 108: Perform Engine Maintenance - Deutz Models

    3 - 68 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 109: Perform Engine Maintenance - Deutz Models

    3 boom to good engine performance and service life. Failure tube on the S-100 and S-105, and the numbers 2 to perform the maintenance procedures can lead to and 3 boom tubes on the S-120 and S-125.
  • Page 110 Section 3 • Scheduled Maintenance Procedures June 2011 CHECKLIST E PROCEDURES This page intentionally left blank. 3 - 70 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 111: Repair Procedures

    Read, understand and obey the safety rules Used to indicate the presence of 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 112: Display Module

    Language selection English, German, French, button and turn Language Spanish, Portuguese, the key switch to Italian, Dutch and Swedish position. Release the button and press 4 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 113 100% (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. 102916 S-100 • S-105 • S-120 • S-125 4 - 3...
  • Page 114 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 4 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 115 Disable steer mode change while driving Rocker joystick steering O TO SECONDS IS THE DEFAULT Generator off delay (0-10 sec) SHOWN ONLY WHEN HYD GEN IS SELECTED Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 5...

  • Page 116: Platform Controls

    How to Calibrate a Joystick Controller. boom up/down and turntable rotate left/right joystick controller Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. 4 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 117: 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. 102916 S-100 • S-105 • S-120 • S-125 4 - 7...

  • Page 118: 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. 4 - 8 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 119: Joystick Controllers

    There should be no calibration faults shown on the display. If 9 Install a new platform controls decal (Genie part calibration faults exist, repeat steps 1 through 8 for number 65182) over the membrane decal.

  • Page 120: Return To

    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. 4 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 121 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. 102916 S-100 • S-105 • S-120 • S-125 4 - 11...
  • Page 122 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. 4 - 12 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 123 Do not let go of the joystick. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 13...
  • Page 124 When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center. 4 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 125: Specifications

    0.25 second 1 Pull out the red Emergency Stop button to the Drive on position at both the ground and platform accelerate 2 seconds controls. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 15...

  • Page 126: Platform Components

    Note: Do not rest the entire weight of the boom on when it is removed from the the blocks. machine if it is not properly supported. 4 - 16 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 127 Protect the cylinder rod 10 Carefully pull the platform leveling cylinder out of from damage. the boom. Component damage hazard. Hoses can be damaged if they are kinked or pinched. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 17...

  • Page 128: Platform Rotator

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform . 2 Disconnect the electrical connector from the platform angle sensor. 4 - 18 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 129 Remove all rings, watches and rotator is dropped or sustains any other jewelry. physical shock, even if the damage is not visible. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 19...
  • Page 130 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. 4 - 20 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 131: Platform Level Sensor

    Emergency Stop button. S-100, S-120, S-105 (after serial number 250) and S-125 models (after serial number 998): 3 Press the plus button , then press the enter button twice before again pressing the plus 1.

  • Page 132: 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. 4 - 22 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 133 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. 102916 S-100 • S-105 • S-120 • S-125 4 - 23...
  • Page 134 LCD display at the ground 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 135 June 2011 Section 4 • Repair Procedures Jib Boom Components, S-105 / S-125 Models REV A 5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the Jib Boom, cylinder. S-105 and S-125 Models Bodily injury hazard.

  • Page 136: Jib Boom Components, S-105 And S-125 Models

    Section 4 • Repair Procedures June 2011 JIB BOOM COMPONENTS, S-105 AND S-125 MODELS REV A 12 Remove the pin retaining fasteners from the jib 18 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Do not platform leveling cylinder rod-end pivot pin.

  • Page 137: Jib Boom Lift Cylinder, S-105 And S-125 Models

    June 2011 Section 4 • Repair Procedures REV A JIB BOOM COMPONENTS, S-105 AND S-125 MODELS 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the Jib Boom Lift Cylinder, cylinder. S-105 and S-125 Models Bodily injury hazard.

  • Page 138: Boom Components

    Section 4 • Repair Procedures June 2011 Boom Components REV A Number 1 Number 2 Number 3 Number 0 Number 1 Number 2 Number 3 4 - 28 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 139: 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 29...
  • Page 140 23 Tag and disconnect the electrical cables from the cable track to the ground controls side of the machine. 4 - 30 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 141 If the cable track has been Component damage hazard. replaced using cable track kit, Genie part number Cable tracks can be damaged if 102054, use part number 102214. If unsure which they are twisted.

  • Page 142: Boom

    11 Tighten the mounting fasteners. 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. 4 - 32 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 143 3 S-105 and S-125 models: Remove the Jib Boom. See 3-1, How to Remove the Jib Boom. 12 Carefully lower the rod end of the boom lift cylinder down onto the support blocks.
  • Page 144 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. 4 - 34 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 145 2 boom tube at the pivot end of mounting bolts to loosen and fall the boom. out which could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 35...
  • Page 146 Do not remove the proximity or limit 23 Attach a lifting strap from an overhead crane to switches. the lifting eye on the primary boom extension cylinder. 4 - 36 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 147 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 37...
  • Page 148 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 38 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 149 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 39...
  • Page 150 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. 4 - 40 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 151 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 41...
  • Page 152 Note: During removal, the overhead crane strap will Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. need to be adjusted for proper balancing. 4 - 42 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 153: Boom Lift Cylinder

    4 Remove the boom storage area cover retaining the oil pressure to dissipate fasteners. Remove the cover from the machine. gradually. Do not allow oil to squirt or spray. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 43...
  • Page 154 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. 4 - 44 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 155: Extension Cylinders

    Do not allow oil to squirt or spray. 2 Remove the retaining fasteners from the boom end cover at the pivot end of the boom. Remove the cover from the machine. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 45...
  • Page 156 Remove the lower plate. 16 Remove the upper plate and actuator pivot pin. Do not remove the cable break limit switch from red cable adjustment the mounting plate. locking bracket 4 - 46 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 157 Note: During removal, the overhead crane strap will the machine with the covers need to be adjusted for proper balancing. removed could result in death or serious injury. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 47...
  • Page 158 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. 4 - 48 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 159: Boom Extend/Retract Cables

    Do not remove inches / 17 cm. Loosen the jam nut and repeat the nuts. step 9. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 49...
  • Page 160 16 Start the engine from the platform controls. the number 3 boom tube and the end of the number 2 boom tube should be to 6 inches / 17 to 17.5 cm (d). 4 - 50 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 161 8 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 51...
  • Page 162 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. 4 - 52 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 163: 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 53...
  • Page 164 Note: Alignment adjustments may be necessary when a new cover is installed. 4 - 54 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 165: Rpm Adjustment

    8 Remove the flex plate mounting fasteners, Deutz models- .245 inch / 6.2 mm gap then remove the flex plate from the flywheel. Cummins or Perkins models- .255 inch / 6.5 mm gap Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 55...
  • Page 166 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 4 - 56 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 167: Oil Pressure And Coolant Temperature Sending Units, Cummins And Perkins Models

    Do not crank the engine with a low display at the ground controls. oil pressure fault shown on the display at the ground controls. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 57...

  • Page 168: 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. 4 - 58 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 169: 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 59...

  • Page 170: 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 hazard. Contact with through the control box lid.
  • Page 171 Desired result terminal 87 to 87a no continuity (infinite ) terminal 87a to 30 no continuity (infinite ) terminal 87 to 30 continuity (zero ) Control Relay Schematic Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 61...

  • Page 172: Limit Switches

    1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 S-100 and S-105 Models S-120 and S-125 Models 4 - 62 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 173 1 to 3 and 4 no continuity (infinite ) (infinite ) terminal 5 to 6 no continuity terminal 2 to 3 and 4 no continuity (infinite ) (infinite ) Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 63...
  • Page 174 1 Fully retract the boom. 2 Place a digital protractor or digital level on top of the boom tube. Proximity switch target area 4 - 64 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 175 1 2 3 4 5 6 7 8 9 0 1 2 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 176: Limit Switch And Level Sensor Locations

    LSB4EO LSB3RS LSB4ES LSB9AS LSB8AS LSB1DO LSB7DS LSB13AO LSB14AO LSB19LO LSB6S LSB2RO LSB19LO LSB2RS PLATFORM LSAX2ES TURNTABLE LSAX1EO LEVEL LSAX1ES LSAX2RO LEVEL SENSOR LSAX1RO SENSOR LSAX2EO LST1O 4 - 66 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 177: Limit Switch Functions

    Extend. 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 67...
  • Page 178 65 if the boom length is more than 101 feet. 4 - 68 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 179 . 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 69...

  • Page 180: Hydraulic Pumps

    CLOSED 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. 4 - 70 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 181: Drive Pump

    (EDC) located on the drive pump. 6 Carefully pull the drive pump out until the pump coupler separates from the flex plate. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 71...
  • Page 182 1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to one of the test ports located under the drive pump. 4 - 72 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 183 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 Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 73...

  • Page 184: Auxiliary Pump

    11 Remove the pressure gauge and reconnect the 3 Turn the key switch to ground control and pull hydraulic hose. out the Emergency Stop button to the position. 4 - 74 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 185 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 75...

  • Page 186: Function Manifold Components, S-100 And S-105 Models (Serial Number 136)

    Section 4 • Repair Procedures June 2011 Manifolds REV A 10-1 Function Manifold Components, S-100 and S-105 Models (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 ..
  • Page 187 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 77...
  • Page 188 Section 4 • Repair Procedures June 2011 MANIFOLDS REV A Function Manifold Components, S-100 and S-105 Models, continued (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 ......
  • Page 189 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 79...

  • Page 190: Function Manifold Components, S-100 And S-105 Models (After Serial Number 136)

    Section 4 • Repair Procedures June 2011 MANIFOLDS REV A 10-2 Function Manifold Components, S-100 and S-105 Models (after serial number 136) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function...
  • Page 191 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 81...
  • Page 192 Section 4 • Repair Procedures June 2011 MANIFOLDS REV A Function Manifold Components, S-100 and S-105 Models, continued (after serial number 136) 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 ..
  • Page 193 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 83...

  • Page 194: Valve Adjustments - Function Manifold, S-100 And S-105 Models

    7 Repeat steps 2 through 6 to confirm the relief Tip-over hazard. Do not adjust valve pressure. the relief valve higher than specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. 4 - 84 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 195: Proportional Valves - Function Manifold

    See 1-3, How to Calibrate a Joystick. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 85...

  • Page 196: Function Manifold Components, S-120 And S-125 Models (Before Serial Number 431)

    ........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. 4 - 86 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 197 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 87...
  • Page 198 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 4 - 88 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 199 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 89...

  • Page 200: 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. 4 - 90 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 201 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 91...
  • Page 202 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 4 - 92 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 203 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 93...

  • Page 204: Function Manifold Components, S-120 And S-125 Models (After Serial Number 574)

    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. 4 - 94 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 205 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 95...
  • Page 206 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 4 - 96 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 207 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 97...

  • Page 208: Valve Adjustments - Function Manifold, S-120 And S-125 Models

    7 Repeat steps 2 through 6 to confirm the relief Tip-over hazard. Do not adjust valve pressure. the relief valve higher than specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. 4 - 98 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 209: Proportional Valves - Function Manifold

    See 1-3, How to Calibrate a Joystick Controller. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 99...

  • Page 210: Platform Manifold Components, S-100 And S-120 Models

    Differential sensing valve, N.C..GC ..Directs flow to functions ....23-25 ft-lbs / 31-34 Nm Proportional solenoid valve, 3 position 4 way ........ GD ..Platform rotate left/right ..... 18-20 ft-lbs / 24-27 Nm 4 - 100 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 211 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 101...

  • Page 212: Platform Manifold Components, S-105 And S-125 Models

    Section 4 • Repair Procedures June 2011 MANIFOLDS REV A 10-11 Platform Manifold Components, S-105 and S-125 Models The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Item Function Torque Proportional solenoid valve, 3 position 4 way ........ CH ..Platform level up/down ..... 18-20 ft-lbs / 24-27 Nm Check valve ........
  • Page 213 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 103...

  • Page 214: Proportional Valves - Platform Manifolds

    1 2 3 1 2 3 1 2 3 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 4 - 104 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 215: Turntable Rotation Manifold Components

    1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 105...

  • Page 216: Steer And Axle Extend/Retract Manifold Components - View 1

    ..... 18-20 ft-lbs / 24-27 Nm Solenoid Valve, 3 position 4 way ........ ES ..Axle extend contrrol ......25-27 ft-lbs / 34-37 Nm 4 - 106 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 217 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 107...

  • Page 218: Steer And Axle Extend/Retract Manifold Components - View 2

    Check Valve, 5 psi / 0.34 bar .... EJJ ..Steering load sense, square end, left side, extend ......12-14 ft-lbs / 16.3-19 Nm This list continues. Please turn the page. 4 - 108 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 219 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS EH EK EJJ ENN Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 109...
  • Page 220 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 4 - 110 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 221 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS EH EK EJJ ENN Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 111...

  • Page 222: 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. 4 - 112 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 223 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 This page intentionally left blank. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 113...

  • Page 224: Traction Manifold Components (S-100/105 Before Serial Number 291) (S-120/125 Before Serial Number 1195)

    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. 4 - 114 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 225 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 115...
  • Page 226 0.030 inch / 0.762 mm ....... DN ..Brake release and 2 speed shift control Solenoid valve, 2 position 3 way ..DO ..Brake control ........25-30 ft-lbs / 38-41 Nm 4 - 116 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 227 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 117...

  • Page 228: 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. 4 - 118 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 229 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 119...
  • Page 230 Flow Divider/Combiner Valve ... HQ ..Controls flow to divider/combiner valves FJ and FP ..... 90-100 ft-lbs / 122-135.6 Nm Check Valve ........HR ..Anti-cavitation ......20-25 ft-lbs / 27.1-33.9 Nm 4 - 120 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 231 June 2011 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 121...

  • Page 232: Valve Adjustments - Traction Manifold

    (. Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. 4 - 122 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 233: Electrocution Hazard. Contact With Electrically Charged Circuits Could Result In Death Or Serious Injury

    Solenoid valve, 2 position 3 way 12V 9V DC battery (schematic items AA) 10 resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 123...
  • Page 234 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. 4 - 124 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 235: Fuel And Hydraulic Tanks

    Note: Be sure to only use a hand operated pump suitable for use with diesel fuel. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 125...

  • Page 236: Hydraulic Tank

    1 Remove the ground controls side turntable a suitable container. See capacity cover. See 5-1, How to Remove a Hinged specifications. Turntable Cover. 4 - 126 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 237 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 127...

  • Page 238: 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 4 - 128 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 239 Apply pipe thread sealant to the plugs and install the plugs. Refer to Section 2, Specifications. 10 Adjust turntable rotation gear backlash. motor motor/brake mounting bolts brake drive hub mounting bolts drive hub Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 129...
  • Page 240 Refer to Section 2, Specifications. 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. 4 - 130 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 241 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 This page intentionally left blank. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 131...

  • Page 242: 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. 4 - 132 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 243 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 133...

  • Page 244: 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. 4 - 134 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 245 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 135...

  • Page 246: 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. 4 - 136 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 247: 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 137...

  • Page 248: 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. 4 - 138 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 249: 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. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 139...
  • Page 250 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. 4 - 140 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 251 Note: The wiring connectors for the switches can be accessed through the access holes on either side of the chassis end plate. 6 Place blocks under the axle extension cylinder for support. Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 141...
  • Page 252 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 This page intentionally left blank. 4 - 142 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 253: Be Sure That All Necessary Tools And Test Equipment Are Available And Ready For Use

    Note: Perform all troubleshooting on a firm, level surface. Note: Two persons will be required to safely perform some troubleshooting procedures. Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 1...
  • Page 254 8-bit occurrence counter. 3 The fault code table on the following pages lists the functions or components monitored by the system. 5 - 2 S-100 • S-105 • S-120 • S125 Part No. 102916...
  • Page 255 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. 102916 S-100 • S-105 • S-120 • S-125 5 - 3...
  • Page 256 Display message on LCD Stop all boom functions, allow only Power up controller with Fault Check boom retract. Display message on Primary Boom Angle problem (unknown angle) corrected 5 - 4 S-100 • S-105 • S-120 • S125 Part No. 102916...
  • Page 257 P22 SAFETY SWITCH FAULT Display message on LCD SAFETY SWITCH P22R P22R SAFETY SWITCH FAULT Power up controller with Display message on LCD CAN Bus Fault Check problem corrected Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 5...
  • Page 258 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 5 - 6 S-100 • S-105 • S-120 • S125 Part No. 102916...
  • Page 259 Recycle power Footswitch Timeout Display message on LCD Power up controller with Disable Generator, Display message Hydraulic Generator/Welder - Fault Check problem on LCD Display Bypass Valve corrected Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 7...
  • Page 260 Alarm sounds corrected LR Steer Valves RR Steer Valves Power up controller with Display message on LCD Hydraulic Generator/Welder - Fault Check problem Bypass Valve corrected 5 - 8 S-100 • S-105 • S-120 • S125 Part No. 102916...

  • Page 261: Control System Fault Codes

    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. Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 9...

  • Page 262: Software

    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. 5 - 10 S-100 • S-105 • S-120 • S125 Part No. 102916...
  • Page 263 Be sure that all necessary tools and test Malfunction Identify equipment are available and ready for use. Troubleshoot discovered symptoms problem still exists Inspect Perform Return to and test repair service problem solved Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 1...

  • Page 264: Circuit Numbering

    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 6 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 265 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. 102916 S-100 • S-105 • S-120 • S-125 6 - 3...

  • Page 266: 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 6 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 267: Section 6 • Schematics

    RD/BK 28 Platform level alarm OR/RD 63 Power to boom envelope safety RD/WH 29 Drive motor shift (speed) switch Forward/EDC-A This list continues on the next page. Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 5...
  • Page 268 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 6 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 269 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. 102916 S-100 • S-105 • S-120 • S-125 6 - 7...

  • Page 270: Limit Switches

    S-100/105- sn 160 S-120/125- sn 628) LSB13AO Boom 53° angle proximity LSB14AO •• Boom 68° angle proximity LSB19LO Load moment mechanical (•• S-120 and S-125 models only) 6 - 8 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 271 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. 102916 S-100 • S-105 • S-120 • S-125 6 - 9...

  • Page 272: 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. 6 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 273: Drive Chassis Controller Pin Legend

    22 = V36LFS - BL (WIRE SIDE) 23 = P61LS(A) - GN 23 = V37LFS - BL/BK 23 = P61LS(A) - GR 23 = V37LFS - BL/BK Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 11...

  • Page 274: Platform Controller Pin Legend

    22 = PTSRET - BR 23 = P87PTS - RD 23 = P23PCON - BK 22 = (UNUSED) 23 = P87PTS - RD 23 = P23PCON - BK 6 - 12 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 275: Turntable Controller Pin Legend

    35 = VLVRET1 - BR 4 = BATECU - RD 4 = BATECU - RD 23 = P95TET - OR 35 = VLVRET1 - BR 35 = VLVRET1 - BR Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 13...

  • Page 276: 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 6 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 277: 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. 102916 S-100 • S-105 • S-120 • S-125 6 - 15...
  • Page 278 Section 6 • Schematics June 2011 REV A This page intentionally left blank. 6 - 16 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 279: 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 P53LS DCON/J1/3 Part No. 102916 S-100 • S-105 • S-120 • S-125 6-17...
  • Page 280 Section 6 • Schematics June 2011 Safety Circuit Schematic 6-17 6-18...

  • Page 281: Engine Options- Perkins And Cummins

    June 2011 Section 6 • Schematics Engine Options- Perkins and Cummins S-100/105 (before serial number 219) S-120/125 (before serial number 933) 6-20 6-19...
  • Page 282 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 6-20 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 283: Engine Options- Perkins

    PERKINS 1104C-44 ENGINE 15 A FUSE P34SA-RD P46HRN-WH +BAT WH-PULL RD-HOLD 70 A FUSE +AUX -BAT BK-COM STARTER RELAY HORN 87 85 RELAY FUEL PUMP REGULATOR SERVICE HORN ENGINE BLOCK Part No. 102916 S-100 • S-105 • S-120 • S-125 6-21...

  • Page 284: (S-100/105 From Serial Number 219 To 247) (S-120/125 From Serial Number 933 To 984)

    Section 6 • Schematics June 2011 Engine Options- Perkins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) 6-21 6-22...

  • Page 285: (S-100/105 From Serial Number 248) (S-120/125 From Serial Number 985)

    June 2011 Section 6 • Schematics Engine Options- Perkins S-100/105 (from serial number 248) S-120/125 (from serial number 985) 6-24 6-23...
  • Page 286 WH-PULL RD-HOLD 70 A FUSE +AUX BK-COM -BAT CB7 ADDED STARTER S100- S/N 710 RELAY HORN 87 85 S125- S/N 2589 RELAY FUEL PUMP REGULATOR SERVICE HORN ENGINE BLOCK 6-24 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 287: Engine Options- Cummins

    June 2011 Section 6 • Schematics REV A 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. 102916 S-100 • S-105 • S-120 • S-125 6-25...

  • Page 288: (S-100/105 From Serial Number 219 To 247) (S-120/125 From Serial Number 933 To 984)

    Section 6 • Schematics June 2011 Engine Options- Cummins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) 6-25 6-26...

  • Page 289: (S-100/105 From Serial Number 248) (S-120/125 From Serial Number 985)

    June 2011 Section 6 • Schematics Engine Options- Cummins S-100/105 (from serial number 248) S-120/125 (from serial number 985) 6-28 6-27...
  • Page 290 Engine Options- Cummins REV A 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 6-28 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 291: Electrical Schematic - Generator Options

    June 2011 Section 6 • Schematics Electrical Schematic - Generator Options 6-30 6-29...

  • Page 292: A Electrical Schematic - Generator Options

    Section 6 • Schematics June 2011 REV A Electrical Schematic - Generator Options Hydraulic Generator Option Belt-Driven Generator Option 6-30 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 293: Electrical Schematic - 12 Kw Generator (Welder Option)

    June 2011 Section 6 • Schematics REV A REV A Electrical Schematic - 12 kW Generator (welder option) Part No. 102916 S-100 • S-105 • S-120 • S-125 6-31...
  • Page 294 Section 6 • Schematics June 2011 Electrical Schematic - 12 kW Generator (welder option) 6-31 6-32...

  • Page 295: Hydraulic Schematic - 12 Kw Generator (Welder Option)

    June 2011 Section 6 • Schematics REV A Hydraulic Schematic - 12 kW Generator (welder option) Part No. 102916 S-100 • S-105 • S-120 • S-125...

  • Page 296: Hydraulic Schematic

    Section 6 • Schematics June 2011 Hydraulic Schematic - 12 kW Generator (welder option) 6-33 6-34...

  • Page 297: (Serial Number 136)

    June 2011 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (serial number 136) 6-36 6-35...

  • Page 298: Hydraulic Schematics

    June 2011 Hydraulic Schematic, S-100 • S-105 Models REV A (serial number 136) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. 6-36 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 299: Hydraulic Schematic

    Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 102916 S-100 • S-105 • S-120 • S-125 6-37...
  • Page 300 Section 6 • Schematics June 2011 Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290) 6-37 6-38...

  • Page 301: From Serial Number 291 To Serial Number 738)

    June 2011 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738) 6-40 6-39...
  • Page 302 Hydraulic Schematic, S-100 • S-105 Models REV A (from serial number 291 to serial number 738) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. 6-40 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 303: From Serial Number 739)

    Section 6 • Schematics REV A Hydraulic Schematic, S-100 • S-105 Models (from serial number 739) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 102916 S-100 • S-105 • S-120 • S-125 6-41...
  • Page 304 Section 6 • Schematics June 2011 Hydraulic Schematic, S-100 • S-105 Models (from serial number 739) 6-41 6-42...

  • Page 305: Hydraulic Schematic

    June 2011 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430) 6-44 6-43...

  • Page 306: Hydraulic Schematic

    Hydraulic Schematic, S-120 • S-125 Models REV A (from serial number 404 to serial number 430) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. 6-44 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 307: (From Serial Number 431 To Serial Number 1194)

    Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 102916 S-100 • S-105 • S-120 • S-125 6-45...
  • Page 308 Section 6 • Schematics June 2011 Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194) 6-45 6-46...

  • Page 309: (From Serial Number 1195 To Serial Number 2634)

    June 2011 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634) 6-48 6-47...
  • Page 310 Hydraulic Schematic, S-120 • S-125 Models REV A (from serial number 1194 to serial number 2634) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. 6-48 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 311: (From Serial Number 2635)

    Section 6 • Schematics REV A Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635) Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 102916 S-100 • S-105 • S-120 • S-125 6-49...
  • Page 312 Section 6 • Schematics June 2011 Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635) 6-49 6-50...
  • Page 313 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 314 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 315 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 316 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 China Genie Scandinavia Phone +86 21 53852570 Phone +46 31 575100...

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