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

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Service and Repair Manual
S-100HD
S-120HD
Serial Number Range
from S100HD14D - 200
to S-100HD16D-229
from S120HD14D - 201
to S-120HD16D-229
from S-100HDD-230
from S-120HDD-230
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. 1268495
Rev A1
September 2016

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Summary of Contents for Terex Genie S-100HD

  • Page 1 Service and Repair Manual Serial Number Range from S100HD14D - 200 S-100HD This manual includes: to S-100HD16D-229 Repair procedures Fault Codes S-120HD from S120HD14D - 201 to S-120HD16D-229 Electrical and Hydraulic Schematics from S-100HDD-230 from S-120HDD-230 For detailed maintenance procedures, Refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Introduction

    First Edition, Third Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A and many other countries. "S" is a trademark of Terex South Dakota, Inc. Printed on recycled paper Printed in U.S.A. S-100HD • S-120HD...

  • Page 3: Revision History

    September 2016 INTRODUCTION Revision History Revision Date Section Procedure / Page / Description 9/2015 Release 9/2016 Introduction Serial Number Legend Reference Examples: Electronic Version Section - Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section - Fault Codes, All charts the update.

  • Page 4: Serial Number Legend

    September 2016 INTRODUCTION Serial Number Legend To August 31, 2016 S120HD 1 D - 12345 Model: Serial number: S120HD16D-12345 Manufacture date: 1/2/16 Model year: 2016 Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model...

  • Page 5: Safety Rules

    September 2016 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-100DH Operator's Manual or the Genie S-120HD Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Section 1 - Safety Rules September 2016 SAFETY RULES Personal Safety Be sure to wear protective eye wear and other protective clothing if the situation Any person working on or around a machine must warrants it. be aware of all known safety hazards. Personal Be aware of potential crushing hazards safety and the continued safe operation of the such as moving parts, free swinging or...

  • Page 7: Table Of Contents

    September 2016 Table of Contents Introduction Important Information ....................ii Find a Manual for this Model ..................ii Revision History......................iii Serial Number Legend ....................iv Section 1 Safety Rules General Safety Rules ....................v Section 2 Specifications Machine Specifications, S-100HD and S-120HD Models ........2 - 1 Performance Specifications, S-120HD Models ............2 - 2 Performance Specifications, S-100HD Models ............2 - 3 Hydraulic Specifications ..................2 - 5...
  • Page 8 September 2016 TABLE OF CONTENTS Section 3 Repair Procedures Introduction ......................3 - 1 Display Module......................3 - 2 Platform Controls Circuit Boards ....................3 - 8 Membrane Decal ...................3 - 9 Joystick Controllers ..................3 - 10 Platform Components Platform .......................3 - 17 Platform Leveling Cylinder ................3 - 17 Platform Rotator ..................3 - 19 Platform Level Sensor .................3 - 20...
  • Page 9 September 2016 TABLE OF CONTENTS Section 3 Repair Procedures, continued Engines RPM Adjustment ..................3 - 50 Flex Plate ....................3 - 50 Oil Pressure and Coolant Temperature Sending Units, Cummins and Perkins Models ..............3 - 52 Oil Pressure and Temperature Sending Units, Deutz Models .....3 - 52 Ground Controls Circuit Boards ....................3 - 53 Membrane Decal ..................3 - 54...
  • Page 10 September 2016 TABLE OF CONTENTS Section 3 Repair Procedures, continued Manifolds 10-1 Function Manifold Components, S-100HD Models ........3 - 71 10-2 Valve Adjustments - Function Manifold, S-100HD Models ......3 - 75 10-3 Proportional Valves - Function Manifold ............3 - 76 10-4 Function Manifold Components, S-120HD Models ........3 - 77 10-5 Valve Adjustments - Function Manifold, S-120HD Models ......3 - 81 10-6 Proportional Valves - Function Manifold ............3 - 82...
  • Page 11 September 2016 TABLE OF CONTENTS Section 3 Repair Procedures, continued Fuel and Hydraulic Tanks 11-1 Fuel Tank ....................3 - 99 11-2 Hydraulic Tank ..................3 - 100 Turntable Rotation Components 12-1 Turntable Rotation Hydraulic Motor and Drive Hub ........3 - 102 Axle Components 13-1 Steer Sensors ....................3 - 105 13-2 Yoke and Hub ....................3 - 106...
  • Page 12 September 2016 TABLE OF CONTENTS Section 5 Schematics Introduction ......................5 - 1 Circuit Numbering ....................5 - 2 Wire Color Legend ....................5 - 4 Limit Switches ......................5 - 8 Relay Layout ......................5 - 10 Drive Chassis Controller Pin Legend ..............5 - 11 Platform Controller Pin Legend ................5 - 12 Turntable Controller Pin Legend ................5 - 13 Electrical Symbols Legend ..................5 - 14...
  • Page 13 September 2016 TABLE OF CONTENTS Section 5 Schematics, continued Electrical Schematic, S-120HD Models, View 1............5 - 34 Electrical Schematic, S-120HD Models, View 2............5 - 35 Electrical Schematic, S-120HD Models, View 3............5 - 38 Electrical Schematic, S-120HD Models, View 4............5 - 39 Electrical Schematic, S-120HD Deutz Engine Models, View 5 ......5 - 42 Electrical Schematic, S-120HD Cummins Engine Models, View 6 .......5 - 43 Electrical Schematic, S-120HD Models, View 7............5 - 46...
  • Page 14 September 2016 This page intentionally left blank. S-100HD • S-120HD Part No. 1268495...

  • Page 15: Specifications

    September 2016 Section 2 • Specifications Specifications Machine Specifications, Operational dimensions S-100HD S-120HD Platform height, maximum 100 ft 120 ft S-100HD and S-120HD Models 30.48 m 36.58 m Stowed dimensions S-100HD S-120HD Working height, maximum 106 ft 126 ft 32.48 m 38.58 m Length, transport position 40 ft 8 in...

  • Page 16: Performance Specifications, S-120Hd Models

    Section 2 • Specifications September 2016 SPECIFICATIONS Performance Specifications, Platform dimensions Length 60 in S-120HD Models 152 cm Drive speeds Width 30 in 76 cm High drive speed, stowed 8.0 - 8.4 sec 36 ft / 11 m Fluid capacities Low drive speed, stowed 14.4 - 16.4 sec 18 ft / 5.5 m Hydraulic tank...

  • Page 17: Performance Specifications, S-100Hd Models

    September 2016 Section 2 • Specifications SPECIFICATIONS Performance Specifications, Boom extend vertical, 0 to 120 ft / 0 to 36.6 m 170 to 190 seconds S-100HD Models Boom retract vertical, 120 ft to 0 / 36.6 m to 0 170 to 190 seconds Drive speeds Turntable rotate, 360°...
  • Page 18 Section 2 • Specifications September 2016 SPECIFICATIONS Boom extend, boom fully raised 0 to 100 ft / 0 to 30.5 m 120 to 140 seconds Boom retract, boom fully raised 100 ft to 0 / 30.5 m to 0 120 to 140 seconds Turntable rotate, 360°...

  • Page 19: Hydraulic Specifications

    September 2016 Section 2 • Specifications SPECIFICATIONS Hydraulic Specifications Do not top off with incompatible hydraulic fluids. Hydraulic Hydraulic Fluid Specifications fluids may be incompatible due to the differences in base Genie specifications require hydraulic oils which are additive chemistry. When designed to give maximum protection to hydraulic systems, have the ability to perform over a wide incompatible fluids are mixed,...

  • Page 20: Hydraulic Component Specifications

    Section 2 • Specifications September 2016 SPECIFICATIONS Hydraulic Component Rear Section Displacement 0 to 1.16 cu in Specifications 0 to 19 cc Drive pump Flow rate @ 2350 rpm, maximum 11.2 gpm 42.4 L/min Type: bi-directional variable displacement piston pump Pressure, maximum continuous 3350 psi Displacement...

  • Page 21: Deutz Engine Td2011L04I Specifications

    September 2016 Section 2 • Specifications SPECIFICATIONS Deutz TD2011L04i Engine Steer/Axle manifold Axle extend relief pressure 1800 psi Displacement 220.9 cu in 124 bar 3.62 liters Drive manifold Number of cylinders Hot oil relief pressure: 280 psi Bore and stroke 3.78 x 4.92 inches 19.3 bar 96 x 125 mm...
  • Page 22 Section 2 • Specifications September 2016 SPECIFICATIONS Deutz TD 2.9 Engine Oil temperature switch Installation torque 8-18 ft-lbs Displacement 177 cu in 11-24 Nm 2.9 liters Oil temperature switch point 275°F Number of cylinders 135°C Bore and stroke 3.6 x 4.3 inches Oil pressure switch 92 x 110 mm Installation torque...
  • Page 23 September 2016 Section 2 • Specifications SPECIFICATIONS Perkins 854F-34T Oil temperature switch Installation torque 8-18 ft-lbs Displacement 207 cu in 11-24 Nm 3.4 liters Temperature switch point 275°F Number of cylinders 135°C Bore and stroke 3.89 x 4.33 inches Oil pressure switch 99 x 110 mm Installation torque 8-18 ft-lbs...
  • Page 24 Section 2 • Specifications September 2016 Oil temperature switch Perkins 854F-34T cont. Installation torque 18.4 ft-lbs Engine coolant 25 Nm Capacity 16.5 quarts Pressure switch point 12 psi (50/50 extended life) 15.6 liters 0.82 bar Coolant temperature switch Oil Sensor Settings Installation torque 18.4 ft-lbs 0 psi...

  • Page 25: Cummins Engine B3.3T C80 Specifications

    September 2016 Section 2 • Specifications SPECIFICATIONS Cummins B3.3T C80 Engine Injection system Injection pump make Zexel Displacement 199 cu in Injection pump pressure 12,000 psi 3.3 liters 827 bar Number of cylinders Fuel requirement Bore and stroke 3.74 x 4.528 inches For fuel requirements, refer to the engine Operator's 95 x 115 mm Manual on your machine.

  • Page 26: Machine Torque Specifications

    Section 2 • Specifications September 2016 SPECIFICATIONS Machine Torque Specifications Manifold Plug Torque Specifications Platform rotator 1-8 center bolt, GR 5, dry 640 ft-lbs Plug torque 868 Nm SAE No. 2 50 in-lbs / 6 Nm 1-8 center bolt, GR 5, lubricated 480 ft-lbs SAE No.

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    September 2016 Section 2 • Specifications SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) SAE Dash size Torque Your machine is equipped with Parker Seal-Lok 14 ft-lbs / 19 Nm ORFS or 37° JIC fittings and hose ends. Genie 23 ft-lbs / 31.2 Nm specifications require that fittings and hose ends 36 ft-lbs / 54.2 Nm...

  • Page 28: Torque Procedure

    Section 2 • Specifications September 2016 SPECIFICATIONS Torque Procedure ° fittings JIC 37 1 Align the tube flare (hex nut) against the nose Seal-Lok fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, 1 Replace the O-ring.
  • Page 29 September 2016 Section 2 • Specifications SPECIFICATIONS 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine th ecorrect number of flats, for the proper tightening position.
  • Page 30 Section 2 • Specifications September 2016 SPECIFICATIONS 10.9 12.9 2 - 16 S-100HD • S-120HD Part No. 1268495...

  • Page 31: Repair Procedures

    September 2016 Section 3 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 32: Display Module

    Section 3 • Repair Procedures September 2016 Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be changed to alter the machine operating parameters. The key switch must be in the position before entering the programming mode.
  • Page 33 September 2016 Section 3 • Repair Procedures DISPLAY MODULE Screen or Procedure Description Range or Selection Menu Operator Default Hour meter (on power up) Engine speed Engine oil pressure PSI (English) Engine oil pressure kPa (metric) Engine temperature is not Engine temperature °F (English) displayed until engine is Engine temperature °C (metric)
  • Page 34 Section 3 • Repair Procedures September 2016 DISPLAY MODULE Screen or Procedure Description Range or Selection Menu Lift With key switch Boom up/down 5000 max and 100 min, ramp acceleration % 5000 (5.0 sec) (default) , press and Function Boom up/down 2600 max and 100 min, hold the Ramp ramp deceleration % 500 (0.50 sec) (default)
  • Page 35 September 2016 Section 3 • Repair Procedures DISPLAY MODULE Screen or Procedure Description Range or Selection Menu Level With key switch Set unit level to gravity Turntable Y-axis millivolts , press and hold Sensor per degree button Calibration Turntable X-axis millivolts and turn the key per degree switch to the Platform level to gravity...
  • Page 36 Section 3 • Repair Procedures September 2016 DISPLAY MODULE Screen or Procedure Description Range or Selection Menu (100 / 80 Limit boom height to 100 ft / 80 ft Options With key switch , press and AC generator none belt hold the button and turn Alarm motion...

  • Page 37: Platform Controls

    September 2016 Section 3 • Repair Procedures Platform Controls The platform controls contains two printed circuit boards: The membrane circuit board is mounted to the underside of the control box lid which contains the LEDs and touch-sensitive buttons for machine functions. The membrane circuit board sends the input from the operator to the platform controls ECM circuit board. The ECM circuit board sends the data to the turntable control box for processing.

  • Page 38: Circuit Boards

    Section 3 • Repair Procedures September 2016 PLATFORM CONTROLS 6 Remove the platform control box lid retaining fasteners. Open the control box lid. Circuit Boards 7 Locate the ECM circuit board mounted to the Note: When an ECM circuit board is replaced, the inside of the platform control box. joystick controllers will need to be calibrated. Refer Electrocution/burn hazard. Contact to Repair Procedure, How to Calibrate a Joystick with electrically charged circuits Controller. could result in death or serious How to Remove the ECM injury.

  • Page 39: Membrane Decal

    September 2016 Section 3 • Repair Procedures PLATFORM CONTROLS How to Remove the Membrane Circuit Board Membrane Decal 1 Push in the Emergency Stop button to the How to Replace the Membrane position at both the ground and platform Decal controls. 2 Remove the platform control box lid retaining The membrane decal is a special decal that fasteners. Open the control box lid.
  • Page 40 Section 3 • Repair Procedures September 2016 PLATFORM CONTROLS 4 Close the control box lid. Joysticks 5 Remove the decal from the platform control box. How to Calibrate a Joystick 6 Carefully remove the membrane decal from the platform control box while guiding the ribbon The joystick controllers on this machine utilize cables out of the control box lid. digital Hall Effect technology for proportional 7 Remove any decal adhesive from the control control.
  • Page 41 September 2016 Section 3 • Repair Procedures PLATFORM CONTROLS Drive functions: Steer functions: Note: If the calibration fault is already displayed at Note: If the calibration fault is already displayed at the ground box begin with step 6. the ground box begin with step 6. 1 Turn the key switch to the off position. Confirm 1 Turn the key switch to the off position. Confirm the red Emergency Stop button at the platform the red Emergency Stop button at the platform and ground controls is in the on position. and ground controls is in the on position.
  • Page 42 Section 3 • Repair Procedures September 2016 PLATFORM CONTROLS Primary boom extend/retract functions: Primary boom up/down functions: Note: If the calibration fault is already displayed at Note: If the calibration fault is already displayed at the ground box begin with step 6. the ground box begin with step 6. 1 Turn the key switch to the off position. Confirm 1 Turn the key switch to the off position. Confirm the red Emergency Stop button at the platform the red Emergency Stop button at the platform and ground controls is in the on position.
  • Page 43 September 2016 Section 3 • Repair Procedures PLATFORM CONTROLS How to Reset a Proportional Turntable rotate functions: Valve Coil Default Note: If the calibration fault is already displayed at the ground box begin with step 6. (software version 2.00 and above) 1 Turn the key switch to the off position. Confirm Note: Software version 2.00 requires the use of the red Emergency Stop button at the platform Web GPI to perform this procedure. and ground controls is in the on position.
  • Page 44 Section 3 • Repair Procedures September 2016 PLATFORM CONTROLS How to Set the Function 6 Slowly move the joystick off center in the opposite direction just until the machine Thresholds and Function Speeds function starts to move, then move the joystick very slowly towards the neutral or center Note: Before the threshold and default function position just before the machine function stops.
  • Page 45 September 2016 Section 3 • Repair Procedures PLATFORM CONTROLS Function speeds: 15 Once all the joystick controllers have been calibrated, push in the red Emergency Stop Note: Be sure the machine is in the stowed button at the platform controls to save the position and the boom is rotated between the circle settings in memory.
  • Page 46 Section 3 • Repair Procedures September 2016 PLATFORM CONTROLS 5 Press the plus button to increase the speed 2 Press and hold the enter button on the ground control panel while turning the key or press the minus button to decrease the speed.

  • Page 47: Platform Components

    September 2016 Section 3 • Repair Procedures Platform Components Platform Platform Leveling Cylinder How to Remove the Platform The platform leveling cylinder keeps the platform level through the entire range of boom motion. 1 Separate the foot switch quick disconnect plug. The platform is maintained level to the turntable.
  • Page 48 Section 3 • Repair Procedures September 2016 PLATFORM COMPONENTS 4 Tag, disconnect and plug the hydraulic hoses 9 Use a soft metal drift to remove the barrel-end from the platform leveling cylinder at the pivot pin. bulkhead fittings located inside the boom tube 10 Carefully pull the platform leveling cylinder out at the platform end and connect them together of the boom.

  • Page 49: Platform Rotator

    September 2016 Section 3 • Repair Procedures PLATFORM COMPONENTS 3 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on platform rotator Platform Rotator manifold. Cap the fittings on the manifold. The platform rotator is a hydraulically activated Bodily injury hazard. Spraying helical gear assembly used to rotate the platform hydraulic oil can penetrate and 160 degrees.

  • Page 50: Platform Level Sensor

    Section 3 • Repair Procedures September 2016 PLATFORM COMPONENTS 10 Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Platform Level Sensor Crushing hazard. The platform mounting weldment may become The platform level sensor is mounted to the side unbalanced and fall if it is not of the platform rotator.

  • Page 51: Platform Overload System

    September 2016 Section 3 • Repair Procedures PLATFORM COMPONENTS 8 Confirm that the number shown on the display is the same as that shown on the data sheet Platform Overload System supplied with the new platform level sensor. Result: If the number shown on the display The platform overload system is designed to is the same as that shown on the data sheet prevent the machine from continuing to operate supplied with the new platform level sensor, when the load in the platform exceeds maximum...
  • Page 52 Section 3 • Repair Procedures September 2016 PLATFORM COMPONENTS 2 Determine the maximum platform capacity. 6 Move the platform up and down by hand, so Refer to the machine serial plate. it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. 3 Remove all weight, tools and accessories from the platform.
  • Page 53 September 2016 Section 3 • Repair Procedures PLATFORM COMPONENTS 7 Move the platform up and down by hand, so 9 Test all machine functions from the platform it bounces approximately 2.5 to 5 cm / 1 to 2 controls. inches. Allow the platform to settle. Result: All platform control functions should not Result: The alarm should be off. The platform operate. overload indicator light should be off at the 10 Turn the key switch to ground control. platform controls and there should be no error message on the LCD display at the ground 11 Test all machine functions from the ground...

  • Page 54: Platform Overload Recovery Message (Software V3.14 And Later)

    Section 3 • Repair Procedures September 2016 3 Press the buttons on the ground controls in the following sequence: Platform Overload Recovery (plus)(minus)(minus)(plus). Message (software V3.14 and 4 Press the enter or previous button on the LCD later) screen until CLEAR OVERLOAD RECOVERY is displayed. If the ground controls LCD screen displays 5 Press the plus button or minus OVERLOAD RECOVERY, the emergency lowering button to select YES.

  • Page 55: Boom Components

    September 2016 Section 3 • Repair Procedures Boom Components S-100HD Models Number 1 Number 2 Number 3 S-120HD Models Number 0 Number 1 Number 2 Number 3 Part No. 1268495 S-100HD • S-120HD 3 - 25...

  • Page 56: Cable Track

    Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 4 Tag, disconnect and plug the two hydraulic hoses from the boom pull tube to the platform Cable Track manifold. Secure them to the cable track assembly. The cable track and boom cable tube guides Bodily injury hazard.
  • Page 57 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Repair the Boom 10 Remove the fasteners securing the side tube and horizontal cable track to the main cable Cable Track track tube located on the engine side of the tube.
  • Page 58 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 6 Remove the snap-on spacers from the replacement section of cable track. 7 Lift up the hoses and cables and carefully insert the new 3-link or 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched.

  • Page 59: Boom

    September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Remove the Boom Boom Bodily injury hazard. This procedure requires specific repair How to Shim the Boom skills, lifting equipment and a suitable workshop. Attempting 1 Measure each upper, side and lower wear pad. this procedure without these skills and tools could result in death Boom wear pad specifications...
  • Page 60 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 8 Place support blocks under the boom lift 15 Tag and disconnect the wiring connector from cylinder. the cable break limit switch. 9 Remove the pin retaining fastener from the 16 Tag, disconnect and plug the hydraulic hoses boom lift cylinder rod-end pivot pin.
  • Page 61 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS How to Disassemble the Boom, S-120HD Models Note: Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced. The primary boom extension cylinder can be removed without completely disassembling the boom. Refer to Repair Procedure, How to Remove the Primary Extension Cylinder.
  • Page 62 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 9 Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the pivot end of the boom. 10 Remove the pulley pivot pins, cable guards and pulleys. Note: When installing the pulleys, be sure that the side of the pulley with the taller flange is facing the center of the boom tube.
  • Page 63 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 24 Support and slide the primary boom extension 28 Remove the retaining fasteners from the limit cylinder out of the boom assembly while switch cover on the side of the number 0 boom guiding the cables out of the boom and place it tube at the platform end of the boom.
  • Page 64 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 34 Attach a lifting strap from an overhead crane to 39 Support and slide the number 2 boom tube out the number 3 boom tube at the platform end of of the number 1 boom tube. When the number the boom.
  • Page 65 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 42 Support the secondary boom extension cylinder 47 Attach a lifting strap from an overhead crane to with an overhead crane or other suitable lifting the number 1 boom tube at the platform end of device. the boom. 43 Remove the pin retaining fasteners from both 48 Support and slide the number 1 boom tube out the rod-end and barrel-end pivot pins.
  • Page 66 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 6 Tag, disconnect and plug the hydraulic hoses from the primary boom extension cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.
  • Page 67 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 12 Remove the cable break actuator mounting plate retaining fasteners. Remove the lower plate from the machine. 13 Remove the upper plate and actuator pivot pin. Do not remove the cable break limit switch from the mounting plate.
  • Page 68 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 22 Support and slide the primary boom extension 27 Carefully remove the cover with proximity and cylinder out of the boom assembly while limit switches from the number 1 boom tube at guiding the cables out of the boom and place it the platform end of the boom. on a structure capable of supporting it.
  • Page 69 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 33 Support and slide the number 3 boom tube out 37 Support and slide the number 2 boom tube out of the number 2 boom tube. When the number of the number 1 boom tube. When the number 3 boom tube is approximately halfway removed, 2 boom tube is approximately halfway removed, remove the bottom wear pads from the number remove the bottom wear pads from the number 2 boom tube at the platform end of the boom.

  • Page 70: Boom Lift Cylinder

    Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 5 Place support blocks under the boom lift cylinder. Boom Lift Cylinder 6 Remove the pin retaining fastener from the How to Remove the Boom boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.
  • Page 71 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 11 Remove the engine pivot plate retaining Crushing hazard. The boom lift fastener. Swing the engine pivot plate out away cylinder may become unbalanced from the machine. and fall if it is not properly supported when it is removed from the machine.

  • Page 72: Extension Cylinders

    Section 3 • Repair Procedures September 2016 BOOM COMPONENTS 3 Remove the access cover retaining fasteners from both sides of the boom. Remove the Extension Cylinders access covers. The primary boom extension cylinder is located 4 Secure the number 2 and number 3 boom inside the boom assembly and incorporates cables tubes together with a strap or chain to prevent and pulleys that are responsible for extending them from moving.
  • Page 73 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 8 S-120HD models: Remove the fasteners from 17 Push the cable break actuator and cables the inner cable track mounting bracket at the towards the platform end of the boom primary boom extension cylinder. approximately 18 inches / 46 cm. 9 S-120HD models: Lay the inner cable track 18 Remove the retaining fasteners from the red and hoses down and out of the way.
  • Page 74 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS How to Remove the Secondary 19 Remove the two cable adjustment bolts. Boom Extension Cylinder, 20 Remove the cable-end block mounting plate fasteners. Remove the cable-end block S-120HD Models mounting plate. Bodily injury hazard. This 21 Remove the trunnion pin retaining fasteners.
  • Page 75 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS 3 Tag, disconnect and plug the secondary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 76: Boom Extend/Retract Cables

    Section 3 • Repair Procedures September 2016 BOOM COMPONENTS Boom Extend/Retract Cables How to Adjust the Boom Extend/ Retract Cables Properly adjusted extend/retract cables are essential to safe machine operation. Failure to maintain proper adjustment of the cables could result in unsafe operating conditions and may cause component damage. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise.
  • Page 77 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS i extension cable coupling j cable retainer bracket k equal distance boom tube 1 l guide plate boom tube 2 Illustration 2 nylock nut h hex jam nut 10 At the platform end of the boom, tighten the hex jam nut (h) on the cable tension equalizer Illustration 3 bracket located underneath the number 1 boom...
  • Page 78 Section 3 • Repair Procedures September 2016 BOOM COMPONENTS How to Replace the Boom Extend/ 17 Extend the boom approximately 2 feet / 0.6 m. Retract Cables 18 Retract the boom. While retracting the boom, visually inspect the number 2 and number 3 Note: The cable pulleys must also be replaced boom tubes. when replacing the cables. Result: The number 2 should not move more 1 Remove the boom extension cylinder. Refer to than...
  • Page 79 September 2016 Section 3 • Repair Procedures BOOM COMPONENTS Boom retract cables: 20 Secure the number 2 and number 3 booms together at the platform end with a chain or 9 Remove the fasteners from the boom retract strap to prevent them from moving. cables at the platform end of the boom.

  • Page 80: Rpm Adjustment

    Section 3 • Repair Procedures September 2016 Engines How to Remove the Flex Plate RPM Adjustment 1 Disconnect the wiring plug at the electronic proportional controller located on the drive Refer to Maintenance Procedure, pump. Check and Adjust the Engine RPM. 2 Remove the hose clamp from the air cleaner hose at the air cleaner. Carefully disconnect the hose from the air cleaner.
  • Page 81 September 2016 Section 3 • Repair Procedures ENGINES How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. ® 2 Apply Loctite removable thread sealant to the mounting fasteners. Then torque the flex plate mounting bolts in sequence to: Cummins engines: 23 ft-lbs / 31.2 Nm. Deutz engines: 28 ft-lbs / 38 Nm. 3 Install the pump coupler onto the pump shaft with the set screw toward the pump.

  • Page 82: Oil Pressure And Coolant Temperature Sending Units

    Section 3 • Repair Procedures September 2016 ENGINES Oil Pressure and Coolant Oil Pressure and Temperature Temperature Sending Units - Sending Units - Deutz Models Cummins Models The engine oil temperature sending unit is an electrical device. If the engine oil temperature The coolant temperature sending unit is an reaches 275° F / 135° C, the ECM will shut the electrical device.

  • Page 83: Ground Controls

    September 2016 Section 3 • Repair Procedures Ground Controls The ground control box (TCON) is the communication and operations center for the Circuit Boards machine. The ground control box contains two key switches. The key switch towards the top How to Remove the LCD Display of the control box is for selection of ground or platform controls. The key switch at the bottom Screen Circuit Board of the control box is the Service Bypass key switch.

  • Page 84: Membrane Decal

    Section 3 • Repair Procedures September 2016 GROUND CONTROLS 7 Locate the ECM circuit board mounted to the inside of the platform control box. Membrane Decal Electrocution/burn hazard. Contact with electrically charged circuits The membrane decal is a special decal that could result in death or serious consists of a decal with an electronic membrane injury.

  • Page 85: Control Relays

    September 2016 Section 3 • Repair Procedures GROUND CONTROLS 5 Carefully remove the membrane decal from the control box lid while guiding the ribbon cables Control Relays out of the control box lid. 6 Remove any decal adhesive from the control Relays used for single function switching are single box lid with a mild solvent. pole double throw (SPDT) relays. Note: Do not allow any solvent to come in contact How to Test a Single Pole Double with the LCD display screen.
  • Page 86 Section 3 • Repair Procedures September 2016 GROUND CONTROLS 3 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination. Test Desired result 85 to 95 Ω terminal 85 to 86 terminal 87 to 87a & 30 no continuity...

  • Page 87: Limit Switches

    September 2016 Section 3 • Repair Procedures Limit Switches S-100HD Models S-120HD Models Part No. 1268495 S-100HD • S-120HD 3 - 57...
  • Page 88 Section 3 • Repair Procedures September 2016 LIMIT SWITCHES 3 Activate the limit switch. Connect the leads from an ohmmeter or continuity tester to the Deutsch Limit Switches connector terminals in the combination listed below and check for continuity. How to Test the Limit Switches terminal 1 to 2 no continuity (infinite Ω) There are 2 types of limit switches: Mechanical (roller...
  • Page 89 September 2016 Section 3 • Repair Procedures LIMIT SWITCHES 2 Activate the limit switch. Connect the leads from 3 Place a piece of ferrous metal (steel, iron, etc.) an ohmmeter or continuity tester to the Deutsch in front of the target area so it is no more than connector terminals in the combination listed inch / 12.7 mm away from the target area of below and check for continuity.
  • Page 90 Section 3 • Repair Procedures September 2016 LIMIT SWITCHES 5 Disconnect the Deutsch connector from the 14 S-100HD models: Raise the boom to 52.5 68 degree proximity switch (LSB14AO) and degrees. connect an ohmmeter or continuity tester to 15 Loosen the mounting fasteners from the 53 terminals 3 and 4 of the deutsch connector.

  • Page 91: Limit Switch And Level Sensor Locations

    September 2016 Section 3 • Repair Procedures LIMIT SWITCHES Limit Switch and Level Sensor Locations Part No. 1268495 S-100HD • S-120HD 3 - 61...

  • Page 92: Limit Switch Functions

    Section 3 • Repair Procedures September 2016 LIMIT SWITCHES Located under the drive chassis end cover at the center of the square end (blue): LSAX1RO, Limit Switch Functions LSAX1EO, LSAX1ES Located under the drive chassis end cover at LSAX1RO: Operational Limit Switch, Front Axle, the center of the round end (yellow): LSAX2RO, Retract. This switch activates when the axle is LSAX2EO, LSAX2ES fully retracted, activating axle retracted LED and Located in the center of the swing chassis: LS- shutting off power to axle retract coils after two seconds. Located on the hydraulic tank tray: LSAX2RO: Operational Limit Switch, Rear Axle, Turntable Level Sensor Retract. This switch activates when the axle is...
  • Page 93 September 2016 Section 3 • Repair Procedures LIMIT SWITCHES LSB6S: Safety Limit Switch, Cable Tension. Cuts LSB3RO: Operational Limit Switch, 3’ Extend. power to the extend directional valve if extend This switch activates anytime the boom is extend- cables are out of adjustment or one breaks. ed beyond 3 feet. If axles are not extended, boom extend is disabled and the extend axle LED and LSB1DO: Operational Limit Switch, 10 Angle. icon will flash as long as boom extend is operat- This switch activates anytime the boom is raised ed. If axles are extended at this point, the motors above 10 . If axles are not extended, boom up is are shifted to low and drive speed is limited to disabled and the extend axle LED and icon will...
  • Page 94 Section 3 • Repair Procedures September 2016 LIMIT SWITCHES LSB2RS: Safety Limit Switch, 101’ Extend. This switch cuts power to boom extend, boom down and engine fuel solenoid when it is mechanically activated at 101 feet, if boom angle is less than LSB2RO: Operational Limit Switch, 100’ Retract. This switch is activated anytime boom length is 100’...

  • Page 95: Hydraulic Pumps

    September 2016 Section 3 • Repair Procedures Hydraulic Pumps 2 Tag, disconnect and plug the hydraulic hoses from the function pumps. Cap the fittings on the Function Pumps pumps. Bodily injury hazard. Spraying There are three hydraulic pumps connected to hydraulic oil can penetrate and the engine. There is one variable displacement burn skin.

  • Page 96: Drive Pump

    Section 3 • Repair Procedures September 2016 HYDRAULIC PUMPS 3 Close the two hydraulic tank valves located at the hydraulic tank. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment.
  • Page 97 September 2016 Section 3 • Repair Procedures HYDRAULIC PUMPS 7 Remove the drive pump from the machine. Cummins models: Component damage hazard. 2 Remove the engine pivot plate retaining Be sure to open the two hydraulic fastener. Swing the engine pivot plate out away tank valves and prime the pump from the machine to access the fuel injection after installing the pump.
  • Page 98 Section 3 • Repair Procedures September 2016 HYDRAULIC PUMPS 5 Deutz models: Disconnect the engine wiring 6 Have another person crank the engine with the harness from the fuel shutoff solenoid at the starter motor for 15 seconds, wait 15 seconds, injector pump.

  • Page 99: Auxiliary Pump

    September 2016 Section 3 • Repair Procedures HYDRAULIC PUMPS 4 Activate any function using auxiliary power. Auxiliary Pump Result: If the pressure gauge reads 2500 psi / 172 bar, immediately stop. The pump is good. How to Test the Auxiliary Pump Result: If pressure fails to reach 2500 psi / 172 bar, the internal relief valve setting is The auxiliary pump is a 2-section, gear-type pump. incorrect or the pump is bad and will need to be Pump number 1 is the pump section closest to serviced or replaced.
  • Page 100 Section 3 • Repair Procedures September 2016 This page intentionally left blank. 3 - 70 S-100HD • S-120HD Part No. 1268495...

  • Page 101: Function Manifold Components, S-100Hd Models

    September 2016 Section 3 • Repair Procedures Manifolds 10-1 Function Manifold Components, S-100HD Models 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 ..FD ..Boom up/down ..........30-35 in-lbs / 3-4 Nm Solenoid Valve, 3 position 4 way ..FC ..Turntable rotate control, left/right ....25-27 ft-lbs / 34-37 Nm Proportional Solenoid Valve ....
  • Page 102 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 72 S-100HD • S-120HD Part No. 1268495...
  • Page 103 September 2016 Section 3 • Repair Procedures MANIFOLDS Function Manifold Components, S-100HD Models, continued 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 ....25-27 ft-lbs / 34-37 Nm Counterbalance Valve, 3200 psi / 220.6 bar ......FH ..Primary lift, load holding ......30-35 ft-lbs / 38-41 Nm Orifice Plug, 0.040 inch / 1.016 mm ...
  • Page 104 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 74 S-100HD • S-120HD Part No. 1268495...

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

    September 2016 Section 3 • Repair Procedures MANIFOLDS 10-2 How to Adjust the Boom Extend Valve Adjustments - Function Relief Valve Manifold, S-100HD Models Note: Perform this procedure with the boom in the stowed position. How to Adjust the Function 1 Connect a 0 to 3000 psi / 0 to 207 bar pressure Manifold Relief Valve gauge to the test port on the function manifold. Note: Perform this procedure with the boom in the 2 Start the engine from the ground controls.

  • Page 106: Proportional Valves - Function Manifold

    Section 3 • Repair Procedures September 2016 MANIFOLDS 10-3 Proportional Valves - Function Manifold Note: When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity, the proportional valve cartridge or coil will need to be calibrated. Refer to Repair Procedure, How to Calibrate a Joystick.

  • Page 107: Function Manifold Components, S-120Hd Models

    September 2016 Section 3 • Repair Procedures MANIFOLDS 10-4 Function Manifold Components, S-120HD Models 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 ..BD ..Boom up/down ........30-35 in-lbs / 3-4 Nm Solenoid Valve, 2 position 3 way ..AA ..Auxiliary drive/steer selector ....25-27 ft-lbs / 34-37 Nm Check Valve, 5 psi / 0.34 bar .....
  • Page 108 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 78 S-100HD • S-120HD Part No. 1268495...
  • Page 109 September 2016 Section 3 • Repair Procedures MANIFOLDS Function Manifold Components, S-120HD Models, continued 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 ..BI ...Turntable, primary lift and boom retract pressure limit ..... 12-14 ft-lbs / 16.3-19 Nm Check Valve ........AG ..Blocks flow from auxiliary pump, port 2A to pump 1 ......
  • Page 110 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 80 S-100HD • S-120HD Part No. 1268495...

  • Page 111: Valve Adjustments - Function Manifold, S-120Hd Models

    September 2016 Section 3 • Repair Procedures MANIFOLDS 10-5 How to Adjust the Boom Extend Valve Adjustments - Function Relief Valve Manifold, S-120HD Models Perform this procedure with the boom in the stowed position. How to Adjust the Function 1 Connect a 0 to 3000 psi / 0 to 207 bar pressure Manifold Relief Valve gauge to the test port on the function manifold.

  • Page 112: Proportional Valves - Function Manifold

    Section 3 • Repair Procedures September 2016 MANIFOLDS 10-6 Proportional Valves - Function Manifold Note: When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity, the proportional valve cartridge or coil will need to be calibrated. Refer to Repair Procedure, How to Calibrate a Joystick Controller.
  • Page 113 September 2016 Section 3 • Repair Procedures MANIFOLDS 10-07 Platform Manifold Components 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........GF ..Platform rotate circuit Check valve........
  • Page 114 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 84 S-100HD • S-120HD Part No. 1268495...

  • Page 115: Proportional Valves - Platform Manifolds

    September 2016 Section 3 • Repair Procedures MANIFOLDS 10-08 Proportional Valves - Platform Manifolds Note: When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity, the proportional valve cartridge or coil will need to be calibrated. Refer to Repair Procedure, How to Calibrate a Joystick.

  • Page 116: Platform Rotate Counterbalance Valve Manifold Components

    Section 3 • Repair Procedures September 2016 MANIFOLDS 10-09 Platform Rotate Counterbalance Valve Manifold Components Index Schematic Description 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 3 - 86 S-100HD • S-120HD Part No.

  • Page 117: Turntable Rotation Manifold Components

    September 2016 Section 3 • Repair Procedures MANIFOLDS 10-10 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor. Index Schematic Description Item Function Torque Counterbalance valve ......A ....Turntable rotate left ........37-44 ft-lbs / 50-60 Nm Counterbalance valve ......B ....Turntable rotate right ........37-44 ft-lbs / 50-60 Nm Shuttle valve, 2 position 3 way ...

  • Page 118: Steer And Axle Extend/Retract Manifold Components

    Section 3 • Repair Procedures September 2016 MANIFOLDS 10-11 Steer and Axle Extend/Retract Manifold Components The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end of the machine. Index Schematic Description Item Function Torque Relief Valve, 3000 psi / 207 bar ..HJ ..Steering pressure limit....19-21 ft-lbs / 25.8-28.6 Nm Solenoid Valve, 3 position 5 way ..EA ..Right front steer cylinder....24-26 ft-lbs / 32.5-35.3 Nm Solenoid Valve, 3 position 5 way ..
  • Page 119 September 2016 Section 3 • Repair Procedures MANIFOLDS Part No. 1268495 S-100HD • S-120HD 3 - 89...

  • Page 120: Valve Adjustments - Steer And Axle Extend/Retract Manifold

    Section 3 • Repair Procedures September 2016 MANIFOLDS 10-12 How to Adjust the Axle Extend Valve Adjustments - Steer and Relief Valve Axle Extend/Retract Manifold Note: Perform this procedure with the axles retracted, the boom in the stowed position and the How to Adjust the Steer and Axle machine on a paved surface.
  • Page 121 September 2016 Section 3 • Repair Procedures MANIFOLDS 10-13 Traction Manifold, 2WD The 2WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. Index Schematic Description Item Function Torque Check valve, 5 psi / 0.34 bar ..... DH ...Drive motor anti-cavitation ....30-35 ft-lbs / 41-47 Nm Check valve, 5 psi / 0.34 bar .....
  • Page 122 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 92 S-100HD • S-120HD Part No. 1268495...
  • Page 123 September 2016 Section 3 • Repair Procedures MANIFOLDS 10-14 Traction Manifold, 4WD The drive manifold is mounted inside the drive chassis at the circle end of the machine. The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. ndex Schematic Description...
  • Page 124 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 94 S-100HD • S-120HD Part No. 1268495...
  • Page 125 September 2016 Section 3 • Repair Procedures MANIFOLDS Traction Manifold, 4WD, continued The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. Index Schematic Description Item Function Torque Bi-directional/Flow Control Valve, 2 gpm / 7.6 L/min ....... DI ...Equalizes pressure on both sides of divider/combiner valve FQ ..30-35 ft-lbs / 40.7-47.5 Nm Bi-directional/Flow Control Valve, 2 gpm / 7.6 L/min .......
  • Page 126 Section 3 • Repair Procedures September 2016 MANIFOLDS 3 - 96 S-100HD • S-120HD Part No. 1268495...

  • Page 127: Valve Adjustments - Traction Manifold

    September 2016 Section 3 • Repair Procedures MANIFOLDS 10-15 10-16 Valve Adjustments - Valve Coils Traction Manifold How to Test a Coil How to Adjust the Charge A properly functioning coil provides an Pressure Relief Valve electromagnetic force which operates the solenoid valve. Critical to normal operation is continuity 1 Connect a 0 to 600 psi / 0 to 41 bar pressure within the coil. Zero resistance or infinite...
  • Page 128 Section 3 • Repair Procedures September 2016 MANIFOLDS Valve Coil Resistance How to Test a Coil Diode Specification Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional Note: The following coil resistance specifications valves and those coils with a metal case. Properly are at an ambient temperature of 68°F / 20°C. As functioning coil diodes protect the electrical circuit valve coil resistance is sensitive to changes in by suppressing voltage spikes.
  • Page 129 September 2016 Section 3 • Repair Procedures MANIFOLDS 3 Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. 4 Connect the negative lead to the other terminal on the coil. Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading.

  • Page 130: Fuel And Hydraulic Tanks

    Section 3 • Repair Procedures September 2016 Fuel and Hydraulic Tanks 11-1 4 Using an approved hand-operated pump, drain the fuel tank into a suitable container. Refer to Fuel Tank specifications, Machine Specifications. How to Remove the Fuel Tank Explosion and fire hazard. When transferring fuel, connect a grounding wire between the Explosion and fire hazard.

  • Page 131: Hydraulic Tank

    September 2016 Section 3 • Repair Procedures FUEL AND HYDRAULIC TANKS 11-2 2 Close the two hydraulic shutoff valves located at the hydraulic tank. Hydraulic Tank The primary functions of the hydraulic tank are to cool, clean and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a filter condition indicator. How to Remove the open closed Hydraulic Tank...
  • Page 132 Section 3 • Repair Procedures September 2016 FUEL AND HYDRAULIC TANKS 4 Remove the ground controls support bracket 12 Remove the hydraulic tank from the machine. retaining fasteners. Remove the ground Crushing hazard. The hydraulic controls assembly from the machine. tank could become unbalanced and fall if it is not properly Component damage hazard.

  • Page 133: Turntable Rotation Components

    September 2016 Section 3 • Repair Procedures Turntable Rotation Components 12-1 3 Tag, disconnect and plug the hydraulic hoses from the manifold that is mounted to the motor. Turntable Rotation Hydraulic Bodily injury hazard. Spraying Motor and Drive Hub hydraulic oil can penetrate and burn skin.
  • Page 134 Section 3 • Repair Procedures September 2016 TURNTABLE ROTATION COMPONENTS How to Remove the Turntable 4 Attach a lifting strap from an overhead crane or other suitable lifting device to the drive hub. Rotation Drive Hub 5 Remove the drive hub mounting bolts and 1 Secure the turntable from rotating with the remove the drive hub from the machine.
  • Page 135 September 2016 Section 3 • Repair Procedures TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is adjustable to control the gap between the rotation motor gear and the turntable bearing. Note: Be sure to check the backlash with the machine on a flat level surface. 1 Secure the turntable from rotating with the turntable rotation lock pin.

  • Page 136: Axle Components

    Section 3 • Repair Procedures September 2016 Axle Components 13-1 How to Measure the Tire Steer Sensors Alignment 1 Start the engine from the platform controls. The steer sensor measures steer angle and communicates that information to the ground 2 Press down the foot switch and push the engine controls ECM. The steer sensor on the ground idle select button until the engine switches to controls side of the machine at the square end acts...

  • Page 137: Yoke And Hub

    September 2016 Section 3 • Repair Procedures AXLE COMPONENTS How to Adjust a Steer Sensor 13-2 Yoke and Hub 1 Locate the steer sensor on top of the yoke pivot pin. How to Remove the Yoke 2 Loosen the steer sensor cover retaining and Hub fasteners.
  • Page 138 Section 3 • Repair Procedures September 2016 AXLE COMPONENTS 3 Mark the mounting position of the steer sensor 6 Mark the mounting position of the steer sensor cover on the yoke. activator pin mounted to the top of the yoke pivot pin. Note: It is very important that the steer sensor is installed in the exact position it was in prior 7 Remove the steer sensor activator pin retaining...

  • Page 139: Drive Motor

    September 2016 Section 3 • Repair Procedures AXLE COMPONENTS 13-3 16 Remove the pin retaining fasteners from the upper and lower yoke pivot pins. Drive Motor 17 Support the yoke/drive hub assembly with a lifting jack. Secure the yoke/drive hub assembly How to Remove a Drive Motor to the lifting jack. Component damage hazard.

  • Page 140: Drive Hub

    Section 3 • Repair Procedures September 2016 AXLE COMPONENTS 13-4 5 Block the wheels at the opposite end of the machine. Drive Hub 6 Raise the machine approximately 6 inches / 15 cm and place blocks under the How to Remove a Drive Hub chassis for support.

  • Page 141: Steering Cylinders

    September 2016 Section 3 • Repair Procedures AXLE COMPONENTS 13-5 5 Remove the pin retaining fasteners from the steer cylinder pivot pins. Steering Cylinders 6 Support the steer cylinder with a suitable lifting device. How to Remove a Steering Cylinder 7 Place a rod through each steer cylinder pivot pin and twist to remove the pins.

  • Page 142: Hub And Bearings, 2Wd Models

    Section 3 • Repair Procedures September 2016 AXLE COMPONENTS 13-6 How to Install the Hub and Hub and Bearings, 2WD Models Bearings, 2WD Models Note: When replacing a wheel bearing, both the How to Remove the inner and outer bearings including the pressed-in Hub and Bearings, 2WD Models races must be replaced.

  • Page 143: Extendable Axles

    September 2016 Section 3 • Repair Procedures AXLE COMPONENTS 13-7 Top and bottom wear pads: Extendable Axles 6 Center a lifting jack of ample capacity under the axle that needs to be shimmed. Do not raise the machine. The extendable axles are used to widen the foot print of the drive chassis for stability. 7 Block the wheels at the opposite end of the machine. How to Shim an Extendable Axle 8 Raise the machine just until the weight of the Note: Measure each wear pad. Replace the wear machine is relieved off of the axle. Do not raise pad if it is less than 7/16 inch / 11 mm thick.
  • Page 144 Section 3 • Repair Procedures September 2016 AXLE COMPONENTS How to Remove an Inner Axle 8 Remove the pin retaining fasteners from the axle stop pin. Use a slide hammer to remove Note: When removing a hose assembly or fitting, the pin. the O-ring on the fitting and/or hose end must be 9 Remove the access cover fasteners from replaced and then torqued to specification during the end of the inner axle to access the axle installation. extension cylinder clevis pin. Remove the Refer to Specifications, Hydraulic Hose and Fitting cover.
  • Page 145 September 2016 Section 3 • Repair Procedures AXLE COMPONENTS How to Remove the Axle 7 Attach a lifting strap from an overhead crane to the end of the axle extension cylinder. Extension Cylinder Note: Attach the lifting strap to the end of the 1 Remove a yoke and hub assembly. Refer to cylinder that has the inner axle removed. Repair Procedure, How to Remove the Yoke 8 Remove the cotter pin from the axle extension and Hub. cylinder clevis pin on the remaining inner axle.
  • Page 146 Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-100HD and S-120HD Operator’s Manual. Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.
  • Page 147 Section 4 • Diagnostic Codes September 2016 CONTROL SYSTEM FAULT CODES Fault Diagnostics - Control System How to Read Control System Fault Codes Note: Initial fault testing occurs at power-up. Faults are abnormal conditions that exist due to component failure or System misuse. CPU, memory, LCD, LED, limited joystick and limited operator switch testing is done on power-up.

  • Page 148: Diagnostic Codes

    September 2016 Section 4 • Diagnostic Codes DIAGNOSTIC CODES Error Source Error Type Effects Recovery Actions Normal function except threshold for Calibrate Thresholds one or the other direction is zero, Dis- Not calibrated play message on LCD Self-clearing Initiate one second beep of audible Just calibrated (transient) warning device...
  • Page 149 Section 4 • Diagnostic Codes September 2016 DIAGNOSTIC CODES Error Source Error Type Effects Recovery Actions Value at 5.0 V Power up controller with Value Too High Limited Speed and Direction frozen at problem zero and neutral, Alarm sounds corrected Value Too Low Value at 0 V Primary Ext/Ret Joystick...
  • Page 150 September 2016 Section 4 • Diagnostic Codes DIAGNOSTIC CODES Error Source Error Type Effects Recovery Actions Display message on LCD and allow Perform auto calibrate Primary Up/Down Speed operation at default speed Not calibrated precedure Perform auto calibrate Not calibrated Display message on LCD and allow Primary Extend/Retract Speed precedure...
  • Page 151 Section 4 • Diagnostic Codes September 2016 DIAGNOSTIC CODES Error Source Error Type Effects Recovery Actions Primary Boom Lock-Out Valve #1 Power up controller with Limited Speed and Direction frozen at Fault Check problem corrected zero and neutral, Alarm sounds Primary Boom Lock-Out Valve #2 Platform Overload Fault Check...
  • Page 152 September 2016 Section 4 • Diagnostic Codes DIAGNOSTIC CODES Error Source Error Type Effects Recovery Actions Value at 5.0 V Power up controller with Limited Speed and Direction frozen Value Too High problem at zero and neutral, Alarm sounds corrected Value Too Low Value at 0 V Propel Joystick...
  • Page 153 Section 4 • Diagnostic Codes September 2016 DIAGNOSTIC CODES Error Source Error Type Effects Recovery Actions Value at 5.0 V Power up controller with Value Too High Limited Speed and Direction frozen problem at zero and neutral, Alarm sounds Value Too Low corrected SteeringJoystick Value at 0 V...
  • Page 154 September 2016 Section 4 • Diagnostic Codes CONTROL SYSTEM FAULT CODES P_38-Propel P_39-Turntable P_10-Primary P_11-Primary P_9A-Primary P_9B- (P13-17 TCON) Rotate (P13-19 Boom Extend Up (P12-09 Down (P12-06 Ignition/Fuel TCON) (P12-08 TCON) TCON) TCON) (P12-07 TCON) P_22-Jib Jib P_22R - Primary P_12 - Axle Lvl Pwr Up/Down FC...
  • Page 155 Section 4 • Diagnostic Codes September 2016 CONTROL SYSTEM FAULT CODES Fault Source and Type will display as: Fault Source Source Type Description " ID XXX_xx FAULT " SCON Controller Area Network Primary Boom Angle Zone Where XXX is the one to three digit Fault Source and xx is Primary Boom Length Switches Cross-Check the two digit Fault Type.
  • Page 156 September 2016 Section 4 • Diagnostic Codes CONTROL SYSTEM FAULT CODES Fault Source Fault Source Description Description Turntable Level Sensor X-Direction Enable Output Power P7R Turntable Level Sensor Y-Direction Primary Down Power P9A Boom Length Sensor Cross-Check (SCON) IGN/Fuel Power P9B Boom Safety Envelope (SCON) Primary Extend Power P10 Turntable Controller - Platform Controller...
  • Page 157 Section 4 • Diagnostic Codes September 2016 CONTROL SYSTEM FAULT CODES Fault Source Description Brake Valve Motor Shift Valve Chassis Tilt Sensors Cross-Check (SCON) Jib Bellcrank Level Sensor Jib Bellcrank Level Flow Valve AUX Relay Platform Level Toggle Switch Platform Rotate Toggle Switch Platform Level Flow Valve Platform Rotate Valve Boom Length Sensor...
  • Page 158 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier 1022 Actuator error EGR-Valve; signal KWP = Keyword Protocol range check high SPN FMI KWP Description 1224...
  • Page 159 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier Sensor error ambient air press; KWP = Keyword Protocol signal range check high SPN FMI KWP Description Sensor error ambient air press;...
  • Page 160 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier High low fuel temperature; KWP = Keyword Protocol warning threshold exceeded SPN FMI KWP Description High low fuel temperature;...
  • Page 161 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal SPN FMI KWP Description range check high...
  • Page 162 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier Starter relay high side; short KWP = Keyword Protocol circuit to battery SPN FMI KWP Description Starter relay low side;...
  • Page 163 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP = Keyword Protocol upstream turbine; shut off SPN FMI KWP Description threshold exceeded...
  • Page 164 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number SPN FMI KWP Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error KWP = Keyword Protocol of short circuit to ground SPN FMI KWP Description measurement cyl.
  • Page 165 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523008 2 Timeout error in Manipulation KWP = Keyword Protocol control FMI KWP Description 523009 9 Pressure Relief Valve (PRV) 4766...
  • Page 166 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 12 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 12 Internal ECU monitoring 523470 7...
  • Page 167 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523615 3 Metering unit (Fuel-System); KWP = Keyword Protocol short circuit to battery low side FMI KWP Description 523615 4 Metering unit (Fuel-System);...
  • Page 168 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523897 13 Check of missing injector KWP = Keyword Protocol adjustment value programming FMI KWP Description (IMA) injector 3 (in firing order) 523768 9...
  • Page 169 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523936 12 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame FMI KWP Description EEC3VOL2;...
  • Page 170 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 2 1259 Amount of air is not plausible to KWP = Keyword Protocol pumb speed FMI KWP Description 524016 2...
  • Page 171 Section 4 • Diagnostic Codes September 2016 DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524108 9 1669 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame FMI KWP Description ComEGRTVActr 524035 12 1341 Injector diagnostics;...
  • Page 172 September 2016 Section 4 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol FMI KWP Description 524120 9 1682 Timeout Error of CAN-Receive-Frame ComRxSCRHtDiag 524121 9 1683 Timeout Error of CAN-Receive-Frame ComRxTrbChActr...
  • Page 173 Section 4 • Diagnostic Codes September 2016 PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Exhaust Gas Recirculation Valve Position: Voltage Value Position Sensor- Test Above Normal Engine Exhaust Gas Recirculation Valve Position: Voltage Value Position Sensor- Test Be- low Normal...
  • Page 174 September 2016 Section 4 • Diagnostic Codes PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure: Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure: Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test...
  • Page 175 Section 4 • Diagnostic Codes September 2016 PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Air Inlet Temperature Sensor: Voltage Above Engine Temperature Sensor Open or Short Normal Circuit - Test Engine Air Inlet Temperature Sensor: Voltage Below...
  • Page 176 September 2016 Section 4 • Diagnostic Codes PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Injector Cylinder #02: Current Below Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02: Current Above Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02: Data Drifted High Injector Data Incorrect- Test...
  • Page 177 Section 4 • Diagnostic Codes September 2016 PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 1076 Engine Fuel Injection Pump Fuel Control Value: Solenoid Value - Test Erratic, Intermittent, or Incorrect 1076 Engine Fuel Injection Pump Fuel Control Value: Solenoid Value - Test...
  • Page 178 September 2016 Section 4 • Diagnostic Codes PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 2791 Engine Exhuast Gas Recirculation (EGR) Value Motorized Value - Test Control: Current Below Normal 2791 Engine Exhuast Gas Recirculation (EGR) Value Motorized Value - Test...
  • Page 179 Section 4 • Diagnostic Codes September 2016 PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3219 After treatment #1 Intake Gas Sensor at Temperature: Oxygen Level - Test High - least severe (1) 3219 After treatment #1 Intake Gas Sensor at Temperature:...
  • Page 180 September 2016 Section 4 • Diagnostic Codes PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3702 Diesel Particulate Filter Active Regeneration Inhibited Indicator Lamp Circuit - Test Status: Current Above Normal 4765 After treatment #1 Diesel Oxidation Catalyst Intake Gas Engine Temperature Sensor Open or...
  • Page 181 Section 4 • Diagnostic Codes September 2016 DIAGNOSTIC CODES Control System Fault Codes Using the TCON LCD Note: Take care when using this method to avoid How to Clear Boom Safety resetting threshold defaults. Switch Faults 1 With the key switch off, press and hold the button and turn the key switch to the on Note: Beginning with software release 3.0, the boom envelope switches will latch and faults...

  • Page 182: Software

    September 2016 Section 4 • Diagnostic Codes Software SOFTWARE About This Section This section explains various parts of the machine software operating system and how to access some of the adjustable parameters of the control system. Web GPI Observe and Obey: The software system used on the machine is called Web GPI.
  • Page 183 September 2016 Section 5 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious Observe and Obey: injury. Remove all rings, watches and other jewelry.

  • Page 184: Circuit Numbering

    Section 5 • Schematics September 2016 Wire Circuit Legend Circuit numbering Circuit suffix 1 Circuit numbers consist of three parts: the Definition Suffix circuit prefix, circuit number and circuit suffix. AC Generator The circuit prefix indicates the type of circuit. Alternator Field The circuit number describes the function Angle...
  • Page 185 September 2016 Section 5 • Schematics WIRE CIRCUIT LEGEND Definition Suffix Definition Suffix Function Enable Pressure Comp Enable Ground Control Pressure Sender Ground Pressure Switches Horn Primary Boom Angle Sensor High RPM Primary Boom Down Hydraulic Generator Primary Boom Ext/Ret Lockout Valve Ignition Primary Boom Extend Jib Bellcrank Down...

  • Page 186: Wire Color Legend

    Section 5 • Schematics September 2016 WIRE CIRCUIT LEGEND Wire Coloring Definition Suffix Secondary Boom Lockout Valve (Extend) 1 All cylinder extension colors are solid and all Secondary Boom Lockout Valve (Riser Down) SLD retract functions are striped black. When using Sensor black wire, the stripe shall be white.
  • Page 187 September 2016 Section 5 • Schematics WIRE CIRCUIT LEGEND Color, Circuit #, and Primary function Color, Circuit #, and Primary function Primary boom up drive WH/BK 31 Reverse/EDC-B RD/BK 2 Primary boom down drive WH/RD 32 Brake RD/WH 3 Primary boom up/dwn FC Start proportional valve drive BK/WH 34...
  • Page 188 Section 5 • Schematics September 2016 WIRE CIRCUIT LEGEND Color, Circuit #, and Primary function Color, Circuit #, and Primary function OR/BK 64 Power for operational switches J1708 - (low) BL/WH 65 Low fuel indication WH/RD 100 Outrigger lowered Drive enable WH/BK 101 Outrigger raised Secondary boom not stowed...
  • Page 189 September 2016 Section 5 • Schematics WIRE CIRCUIT LEGEND Color, Circuit #, and Primary function Color, Circuit #, and Primary function RD/BK 129 Descent alarm BL/WH 163 Pri extend/retract signal WH/RD 130 Travel alarm RD/WH 164 Pri up/down signal Motion alarm WH/RD 165 TT Rotate signal Platform load input...

  • Page 190: Limit Switches

    Section 5 • Schematics September 2016 Limit Switches Types of Limit Switches Limit Switch Numbering There are two types of limit switches, which are LSAX1RO Front axle retract proximity found in various locations throughout the machine: LSAX2RO Rear axle retract proximity mechanical-type operational or safety switches LSAX1EO Front axle extend proximity...
  • Page 191 September 2016 Section 5 • Schematics LIMIT SWITCHES S-100HD Models S-120HD Models Part No. 1268495 S-100HD • S-120HD 5 - 9...

  • Page 192: Relay Layout

    Section 5 • Schematics September 2016 Relay Layout Fuel solenoid relay (Deutz models only). Oil cooler relay. Engine cold start relay. Starter relay. Horn relay. Flashing beacon relay. CR17 relay (K7) - powers C35RPM circuit (Hi/low solenoid). CR16 relay (K8) - powers C34SA circuit (Engine cold start).

  • Page 193: Drive Chassis Controller Pin Legend

    September 2016 Section 5 • Schematics Drive Chassis Controller Pin Legend DCON DCON DRIVE CHASSIS DRIVE CHASSIS CONTROLLER CONTROLLER 1 = GND-DCON - BR 1 = VLVRET - BR 2 = P21DCON - WH 2 = V61AXRT - GR 3 = P53LS - GR 3 = V60AXEX - GR/WH 4 = (UNUSED) 4 = V29MS - RD/WH...

  • Page 194: Platform Controller Pin Legend

    Section 5 • Schematics September 2016 Platform Controller Pin Legend PCON PCON PLATFORM PLATFORM CONTROLLER CONTROLLER 1 = VLVRET - BR 1 = GNDPCON - BR 2 = (UNUSED) 2 = P52PCON - WH 3 = C17PRL - GR 3 = (UNUSED) 4 = C18PRR - GR/BK 4 = S56PRV - RD/WH 5 = (UNUSED)

  • Page 195: Turntable Controller Pin Legend

    September 2016 Section 5 • Schematics Turntable Controller Pin Legend TCON TCON TCON TCON TURNTABLE TURNTABLE TURNTABLE TURNTABLE CONTROLLER CONTROLLER CONTROLLER CONTROLLER 1 = (UNUSED) 1 = VLVRET4 - BR (S-120HD MODELS) (S-100HD MODELS) 2 = R35RPM - BK/RD 2 = C03PBF - RD/WH 1 = GNDDCON - BR 1 = GNDDCON - BR 3 = C21IGN - WH...
  • Page 196 Section 5 • Schematics September 2016 Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models Deutz TD2.9 Models CR39 CR77A CR77A CR17 CR15 CR28 CR77B CR77B CR41 Number Component Description C 39 Engine Shutdown C 77A Engine Alt Relay C 17 Hydraulic Oil Cooler / Fan Relay C 28...
  • Page 197 September 2016 Section 5 • Schematics Engine Relay and Fuse Panel Legend - Perkins 854F Models Perkins 854F-34T Models CR77A CR17 CR81 CR41 CR77B Number Component Description C 77A Engine Alt Hydraulic Oil Cooler Fan Relay C 17 C 77B PCE 2 Fuse 30A ECU Power Fuse 20A Key Switch Power...
  • Page 198 Section 5 • Schematics September 2016 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 Genie Machine Function(s) Telematics Use Case System Power...

  • Page 199: Electrical Symbols Legend

    September 2016 Section 5 • Schematics Electrical Symbols Legend Part No. 1268495 S-100HD • S-120HD 5 - 17...

  • Page 200: Hydraulic Symbols Legend

    Section 5 • Schematics September 2016 Hydraulic Symbols Legend 5 - 18 S-100HD • S-120HD Part No. 1268495...
  • Page 201 Section 5 • Schematics September 2016 Electrical Schematic, View 1 S-100HD Models 5 - 19 5 - 20...
  • Page 202 Section 5 • Schematics September 2016 Electrical Schematic, View 1 S-100HD Models AXLE RETRACT AXLE EXTEND MOTOR SPEED VLVRET-BRN P2-01 VALVE RTN1 V61AXRT-GR P2-02 AXLE RETRACT BRAKE V60AXEX-GR/WH P2-03 AXLE EXTEND V29MS-RD/WH P2-04 MOTOR SPEED P2-05 P2-06 P2-07 P2-08 RR STEER RIGHT P2-09 RR STEER LEFT P2-10...
  • Page 203 September 2016 Section 5 • Schematics Electrical Schematic, View 2 S-100HD Models VLVRET-BR P1-01 VLV RTN P1-02 PLAT ROT CCW C17PRL-GR P1-03 ON/OFF VLV3_A PLAT ROT CW C18PRR-GR/BK P1-04 ON/OFF VLV3_B P1-05 PROP VLV2_A P1-06 PROP VLV2_B PLAT LEVEL UP C14PLU-OR P1-07 PROP VLV1_A...
  • Page 204 September 2016 Section 5 • Schematics Electrical Schematic, View 2 S-100HD Models 5 - 21 5 - 22...
  • Page 205 Section 5 • Schematics September 2016 Electrical Schematic, View 3 S-100HD Models 5 - 23 5 - 24...
  • Page 206 Section 5 • Schematics September 2016 Electrical Schematic, View 3 S-100HD Models P1-01 GNDPCON-BR PCON GND P52PCON-WH P1-02 PCON POWER C46HN-WH P1-03 HORN RELAY COIL C47OUT-WH/BK P1-04 OUT PWR ENBL LT BL P23PCON-BK P1-05 PWR-PCON ESTOP FUSE S56PRV-RD/WH P1-06 YL/WH P1-07 P_22 GN/WH...
  • Page 207 September 2016 Section 5 • Schematics Electrical Schematic, View4 S-100HD Models 8 WAY 8 WAY P53LS-WH/BK P53LS-WH/BK P54ENG-BK/WH LSB2RS 101' SJ2-BK/RD SJ1-WH/RD S2PLD2-GR/BK GNDDCON-BR P2-01 DCON ECU GND C69PBE-BK P21DCON-RD P2-02 DCON ECU PWR 3-10A LSB2RO P53LS-WH/BK P2-03 P_6R1 100' P54ENG-BK/WH P2-04 P_6R2...
  • Page 208 September 2016 Section 5 • Schematics Electrical Schematic, View4 S-100HD Models 5 - 25 5 - 26...
  • Page 209 Section 5 • Schematics September 2016 Electrical Schematic, View 5 S-100HD Models 5 - 27 5 - 28...
  • Page 210 Section 5 • Schematics September 2016 Electrical Schematic, View 5 S-100HD Deutz Engine Models 4.5 DEGREE TURNTABLE TILT SENSOR J144-7 J144-5 DEUTZ ENGINE OPTION J144-3 5 - 28 S-100HD • S-120HD Part No. 1268495...
  • Page 211 September 2016 Section 5 • Schematics Electrical Schematic, View 6 S-100HD Cummins Engine Models 4.5 DEGREE TURNTABLE TILT SENSOR J144-7 J144-5 CUMMINS ENGINE OPTION J144-3 Part No. 1268495 S-100HD • S-120HD 5 - 29...
  • Page 212 September 2016 Section 5 • Schematics Electrical Schematic, View 6 S-100HD Models 5 - 29 5 - 30...
  • Page 213 Section 5 • Schematics September 2016 Electrical Schematic, View 7 S-100HD Models 5 - 31 5 - 32...
  • Page 214 Section 5 • Schematics September 2016 Electrical Schematic, View 7 S-100HD Models 5 DEUTZ ENGINE 6 CUMMINS ENGINE DETAIL E - TCON RELAY PARKING K1 POWERS CKT P22R OR CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE) K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD, VALVES AUX RELAY, BOOM EXT/RET, TURNTABLE ROTATE VLV.
  • Page 215 September 2016 Section 5 • Schematics Safety Circuit Schematic, S-100HD Models STAT P_15 IN 1 OUT 1 TCON/J2/23 TURNTABLE FLOW CONTROL ROTATE VALVE CR17 CR11 CR12 IN 2 OUT 2 (K2) (K3) (K4) NFET STAT IN 1 OUT 1 IN 2 OUT 2 TCON/J4/32 TO AUXILIARY RELAY...
  • Page 216 September 2016 Section 5 • Schematics Safety Circuit Schematic, S-100HD Models 5 - 33 5 - 34...
  • Page 217 Section 5 • Schematics September 2016 Electrical Schematic, View 1 S-120HD Models 5 - 35 5 - 36...
  • Page 218 Section 5 • Schematics September 2016 Electrical Schematic, View 1 S-120HD Models AXLE RETRACT AXLE EXTEND MOTOR SPEED VLVRET-BRN P2-01 VALVE RTN1 V61AXRT-GR P2-02 AXLE RETRACT BRAKE V60AXEX-GR/WH P2-03 AXLE EXTEND V29MS-RD/WH P2-04 MOTOR SPEED P2-05 P2-06 P2-07 P2-08 RR STEER RIGHT P2-09 RR STEER LEFT P2-10...
  • Page 219 September 2016 Section 5 • Schematics Electrical Schematic, View 2 S-120HD Models VLVRET -BR P1-01 VLV R TN P1-02 PLAT R OT CCW C17PRL-GR P1-03 ON/OFF VLV3_A PLAT R OT CW C18PRR-GR/B K P1-04 ON/OFF VLV3_B P1-05 PRO P V LV2_A P1-06 PRO P V LV2_B PLAT LEVEL UP...
  • Page 220 September 2016 Section 5 • Schematics Electrical Schematic, View 2 S-120HD Models 5 - 37 5 - 38...
  • Page 221 Section 5 • Schematics September 2016 Electrical Schematic, View 3 S-120HD Models 5 - 39 5 - 40...
  • Page 222 Section 5 • Schematics September 2016 Electrical Schematic, View 3 S-120HD Models GNDPCON-BR P1-01 PCON GND P52PCON-WH P1-02 PCON POWER C46HN-WH P1-03 HORN RELAY COIL P1-04 OUT PWR ENBL LT BL C47OUT-WH/BK P1-05 P23PCON-BK PWR-PCON ESTOP FUSE YL/WH S56PRV-RD/WH P1-06 P56PRV-RD P1-07 P_22...
  • Page 223 September 2016 Section 5 • Schematics Electrical Schematic, View 4 S-120HD Models 8 WAY 8 WAY P53LS-WH/BK P53LS-WH/BK P54ENG-BK/WH LSB2RS 101' SJ2-BK/RD SJ1-WH/RD S2PLD2-GR/BK DCON ECU GND GNDDCON-BR P2-01 C69PBE-BK P21DCON-RD P2-02 DCON ECU PWR 3-10A LSB2RO P53LS-WH/BK P2-03 P_6R1 100' P54ENG-BK/WH P2-04...
  • Page 224 September 2016 Section 5 • Schematics Electrical Schematic, View 4 S-120HD Models 5 - 41 5 - 42...
  • Page 225 Section 5 • Schematics September 2016 Electrical Schematic, View 5 S-120HD Models 5 - 43 5 - 44...
  • Page 226 Section 5 • Schematics September 2016 Electrical Schematic, View 5 S-120HD Deutz Engine Models 4.5 DEGREE TURNTABLE TILT SENSOR J144-7 J144-5 DEUTZ ENGINE OPTION J144-3 5 - 44 S-100HD • S-120HD Part No. 1268495...
  • Page 227 September 2016 Section 5 • Schematics Electrical Schematic, View 6 S-120HD Cummins Engine Models 4.5 DEGREE TURNTABLE TILT SENSOR J144-7 J144-5 CUMMINS ENGINE OPTION J144-3 Part No. 1268495 S-100HD • S-120HD 5 - 45...
  • Page 228 September 2016 Section 5 • Schematics Electrical Schematic, View 6 S-120HD Models 5 - 45 5 - 46...
  • Page 229 Section 5 • Schematics September 2016 Electrical Schematic, View 7 S-120HD Models 5 - 47 5 - 48...
  • Page 230 Section 5 • Schematics September 2016 Electrical Schematic, View 7 S-120HD Models 5 DEUTZ ENGINE 6 CUMMINS ENGINE DETAIL E - TCON RELAY PARKING K1 POWERS CKT P22R OR CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE) K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD, VALVES AUX RELAY, BOOM EXT/RET, TURNTABLE ROTATE VLV.
  • Page 231 September 2016 Section 5 • Schematics Safety Circuit Schematic, S-120HD Models P_15 STAT IN 1 OUT 1 TCON/J2/23 TURNTABLE FLOW CONTROL ROTATE VALVE CR17 CR11 CR12 IN 2 OUT 2 (K2) (K3) (K4) NFET STAT IN 1 OUT 1 CR16 IN 2 OUT 2 TCON/J4/32...
  • Page 232 September 2016 Section 5 • Schematics Safety Circuit Schematic, S-120HD Models 5 - 49 5 - 50...
  • Page 233 Section 5 • Schematics September 2016 Perkins 854F-34T Engine Electrical Schematic 5 - 51 5 - 52...
  • Page 234 Section 5 • Schematics September 2016 Perkins 854F-34T Engine Electrical Schematic 5 - 52 S-100HD • S-120HD Part No. 1268495...
  • Page 235 September 2016 Section 5 • Schematics Part No. 1268495 S-100HD • S-120HD 5 - 53...
  • Page 236 September 2016 Section 5 • Schematics Perkins 854F-34T Engine Electrical Harness 5 - 53 5 - 54...
  • Page 237 Section 5 • Schematics September 2016 Deutz TD2.9 Engine Electrical Schematic 5 - 55 5 - 56...
  • Page 238 Section 5 • Schematics September 2016 Deutz TD2.9 Engine Electrical Schematic 5 - 56 S-100HD • S-120HD Part No. 1268495...
  • Page 239 September 2016 Section 5 • Schematics Deutz TD2.9 Engine Electrical Harness Part No. 1268495 S-100HD • S-120HD 5 - 57...
  • Page 240 September 2016 Section 5 • Schematics Deutz TD2.9 Engine Electrical Harness 5 - 57 5 - 58...
  • Page 241 Section 5 • Schematics September 2016 Hydraulic Schematic, S-100HD Models 5 - 59 5 - 60...
  • Page 242 Section 5 • Schematics September 2016 Hydraulic Schematic, S-100HD Models, 2WD 2WS 5 - 60 S-100HD • S-120HD Part No. 1268495...
  • Page 243 September 2016 Section 5 • Schematics Hydraulic Schematic, S-100HD Models, 4WD 2WS Part No. 1268495 S-100HD • S-120HD 5 - 61...
  • Page 244 Section 5 • Schematics September 2016 Hydraulic Schematic, S-100HD Models, 4WD 4WS 5 - 62 S-100HD • S-120HD Part No. 1268495...
  • Page 245 September 2016 Section 5 • Schematics Hydraulic Schematic, S-120HD Models, 2WD 2WS Part No. 1268495 S-100HD • S-120HD 5 - 63...
  • Page 246 Section 5 • Schematics September 2016 Hydraulic Schematic, S-120HD Models, 4WD 2WS 5 - 64 S-100HD • S-120HD Part No. 1268495...
  • Page 247 September 2016 Section 5 • Schematics Hydraulic Schematic, S-120HD Models, 4WD 4WS Part No. 1268495 S-100HD • S-120HD 5 - 65...
  • Page 248 September 2016 Section 5 • Schematics Hydraulic Schematic, S-120HD Models 5 - 60 5 - 66...

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Genie s-120hd

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