Terex Genie S-120 Service Manual
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Terex Genie S-120 Service Manual

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Service Manual
S-100
S-105
S-120
S-125
Serial Number Range
from S100/105-136
to S10012/S10512-941
from S10011D-114
to S10015D-1000
from S10511D-133
to S10515D-982
from S120/125-404
to S12012/S12512-3399
from S12011D-113
to S12015D-1011
from S12511D-134
to S12515D-983
Part No. 102916
Rev F3
January 2019

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Summary of Contents for Terex Genie S-120

  • Page 1 Service Manual Serial Number Range from S100/105-136 S-100 to S10012/S10512-941 from S10011D-114 S-105 to S10015D-1000 from S10511D-133 to S10515D-982 S-120 from S120/125-404 to S12012/S12512-3399 from S12011D-113 S-125 to S12015D-1011 from S12511D-134 to S12515D-983 Part No. 102916 Rev F3 January 2019...
  • Page 2 Copyright © 2001 by Terex Corporation 102916 Rev F September 2015 Second Edition, Sixth Printing Genie is a registered trademark of Terex South Dakota, Inc.in the U.S.A and many other countries. S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 3: Introduction

    This machine complies with: Model year ANSI A92.5 CAN B.354.4 Facility code (used only for model manufactured in multiple facilities) Terex South Dakota 500 Oak Wood Road PO Box 1150 Watertown, SD 57201 Serial label (located under cover) Serial number stamped on chassis Part No.
  • Page 4 January 2016 This page intentionally left blank. S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 5: 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. 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 January 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

    January 2016 Table of Contents Introduction Important Information ....................ii Serial Number Information ................... ii Serial Number Legend ....................iii Section 1 Safety Rules General Safety Rules ....................v Section 2 Specifications 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...
  • Page 8 January 2016 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures Introduction ......................3 - 1 Pre-delivery Preparation ..................3 - 3 Maintenance Inspection Report ................3 - 5 Checklist A Procedures Inspect the Manuals and Decals ..............3 - 7 Perform Pre-operation Inspection ..............3 - 8 Perform Function Tests .................3 - 8 Perform Engine Maintenance - Perkins Models ..........3 - 9 Perform Engine Maintenance - Deutz Models ..........3 - 9...
  • Page 9 January 2016 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist B Procedures Check the Exhaust System .................3 - 25 Inspect the Tires, Wheels and Lug Nut Torque ...........3 - 26 B-10 Check the Dirve Hub Oil Level and Fastener Torque ........3 - 26 B-11 Confirm the Proper Brake Configuration .............3 - 28 B-12 Check and Adjust the Engine RPM .............3 - 29 B-13 Test the Key Switches .................3 - 32...
  • Page 10 January 2016 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist D Procedures Check the Boom Wear Pads ...............3 - 51 Check the Extendable Axle Wear Pads ............3 - 52 Check the Free-wheel Configuration ............3 - 53 Check the Turntable Rotation Bearing Bolts ..........3 - 54 Check the Turntable Rotation Gear Backlash ..........3 - 55 Replace the Drive Hub Oil ................3 - 57 Inspect for Turntable Bearing Wear ............3 - 59...
  • Page 11 January 2016 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ......................4 - 1 Display Module......................4 - 2 Platform Controls Circuit Boards ....................4 - 7 Membrane Decal ...................4 - 8 Joystick Controllers ..................4 - 9 Platform Components Platform .......................4 - 16 Platform Leveling Cylinder ................4 - 16 Platform Rotator ..................4 - 18 Platform Level Sensor .................4 - 21...
  • Page 12 January 2016 TABLE OF CONTENTS Section 4 Repair Procedures, continued Turntable Covers Turntable Covers ..................4 - 54 Engines RPM Adjustment ..................4 - 56 Flex Plate ....................4 - 56 Oil Pressure and Coolant Temperature Sending Units, Cummins and Perkins Models ..............4 - 58 Oil Pressure and Temperature Sending Units, Deutz Models .....4 - 58 Ground Controls Circuit Boards ....................4 - 59...
  • Page 13 January 2016 TABLE OF CONTENTS Section 4 Repair Procedures, continued 10-5 Function Manifold Components, S-120 and S-125 Models (before serial number 431) ................4 - 87 10-6 Function Manifold Components, S-120 and S-125 Models (from serial number 431 to 574) ..............4 - 91 10-7 Function Manifold Components, S-120 and S-125 Models (after serial number 574) ................4 - 95 10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models .....4 - 99...
  • Page 14 January 2016 TABLE OF CONTENTS Section 4 Repair Procedures, continued Axle Components 13-1 Steer Sensors ....................4 - 133 13-2 Yoke and Hub ....................4 - 135 13-3 Drive Motor ....................4 - 137 13-4 Drive Hub ....................4 - 138 13-5 Steering Cylinders ..................4 - 139 13-6 Extendable Axles ..................4 - 140 Section 5 Diagnostic Codes...
  • Page 15 January 2016 TABLE OF CONTENTS Section 6 Schematics Hydraulic Symbols Legend ...................6 - 19 Safety Circuit Schematic ..................6 - 21 Engine Options- Perkins and Cummins (S-100/105 before serial number 219) (S-120/125 before serial number 933) ............6 - 23 Engine Options- Perkins (S-100/105 from serial number 219 to 247) (S-120/125 from serial number 933 to 984) ..........6 - 25 Engine Options- Perkins...
  • Page 16 January 2016 TABLE OF CONTENTS Section 6 Schematics,continued Deutz TD2.9 Engine Electrical Harness ..............6 - 47 Hydraulic Schematic - 12 kW Generator (welder option) ........6 - 49 Hydraulic Schematic, S-100 • S-105 (serial number 136) ..................6 - 51 Hydraulic Schematic, S-100 • S-105 (from serial number 137 to 290) ..............6 - 53 Hydraulic Schematic, S-100 •...

  • Page 17: Specifications

    January 2016 Section 2 • Specifications Specifications Machine Specifications, Turning radius, inside, 13 ft 2 in 13 ft 2 in axles retracted 4.01 m 4.01 m S-120 and S-125 Models Turning radius, outside, 18 ft 10 in 18 ft 10 in axles extended 5.74 m 5.74 m...
  • Page 18 Section 2 • Specifications January 2016 SPECIFICATIONS Performance Specifications, Fluid capacities Hydraulic tank 55 gallons S-120 and S-125 Models 208 liters Drive speeds Hydraulic system 80 gallons (including tank) 303 liters High drive speed, stowed 8.0 - 8.4 sec 36 ft / 11 m Fuel tank 40 gallons Low drive speed, stowed 14.4 - 16.4 sec...
  • Page 19 January 2016 Section 2 • Specifications SPECIFICATIONS Machine Specifications, Boom extend vertical, 0 to 120 ft / 0 to 36.6 m 170 to 190 seconds S-100 and S-105 Models Boom retract vertical, 120 ft to 0 / 36.6 m to 0 170 to 190 seconds Stowed dimensions S-100...
  • Page 20 Section 2 • Specifications January 2016 SPECIFICATIONS Turning radius, outside, 19 ft 10 in 19 ft 10 in Fluid capacities axles extended 6.05 m 6.05 m Hydraulic tank 55 gallons Turning radius, inside, 9 ft 9 ft 208 liters axles extended 2.74 m 2.74 m Hydraulic system...
  • Page 21 January 2016 Section 2 • Specifications SPECIFICATIONS Performance Specifications, Boom extend, boom fully raised S-100 and S-105 Models 0 to 100 ft / 0 to 30.5 m 120 to 140 seconds Drive speeds Boom retract, boom fully raised 100 ft to 0 / 30.5 m to 0 120 to 140 seconds High drive speed, stowed 8.0 - 8.4 sec...

  • Page 22: Hydraulic Specifications

    Section 2 • Specifications January 2016 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 23 January 2016 Section 2 • Specifications SPECIFICATIONS Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...

  • Page 24: Hydraulic Component Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Petro-Canada Environ MV 46 Hydraulic Component Fluid Properties Specifications Drive pump ISO Grade Viscosity index Type: bi-directional variable displacement piston pump Kinematic Viscosity Displacement 0 to 2.8 cu in cSt @ 200°F / 100°C 0 to 46 cc cSt @ 104°F / 40°C 44.4...
  • Page 25 January 2016 Section 2 • Specifications SPECIFICATIONS Rear Section Steer/Axle manifold Displacement 0 to 1.1 cu in Axle extend relief pressure 1800 psi 0 to 18 cc 124 bar Drive manifold Flow rate @ 2350 rpm, maximum 11.2 gpm 42.4 L/min Hot oil relief pressure: Pressure, maximum continuous 3350 psi...
  • Page 26 Section 2 • Specifications January 2016 SPECIFICATIONS Hydraulic filters High pressure filter Beta 3 ≥ 200 High pressure filter 102 psi bypass pressure 7 bar Beta 3 ≥ 200 Medium pressure filter Medium pressure filter 25 psi bypass pressure 1.7 bar Hydraulic tank 10 micron with return filter...
  • Page 27 January 2016 Section 2 • Specifications SPECIFICATIONS Deutz Engine F4L 913 Injection system Injection pump make IMSA Displacement 249.3 cu in Injection pump pressure 8702 psi 4.086 liters 600 bar Number of cylinders Injector opening pressure 3626 psi Bore and stroke 4.02 x 4.92 inches 250 bar 102 x 125 mm...

  • Page 28: Deutz Engine Bf4L 2011 Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Deutz BF4L 2011 Engine Oil temperature switch Torque 8-18 ft-lbs Displacement 189.6 cu in 11-24 Nm 3.1 liters Oil temperature switch point 275°F Number of cylinders 135°C Bore and stroke 3.7 x 4.409 inches Oil pressure switch 94 x 112 mm Torque...
  • Page 29 January 2016 Section 2 • Specifications SPECIFICATIONS Deutz TD2011L04i Engine Oil temperature switch Installation torque 8-18 ft-lbs Displacement 220.9 cu in 11-24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C Bore and stroke 3.78 x 4.92 inches Oil pressure switch 96 x 125 mm Installation torque...

  • Page 30: Deutz Engine Td 2.9 Specifications

    Section 2 • Specifications January 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 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 31 January 2016 Section 2 • Specifications SPECIFICATIONS Perkins 1104D-44T Oil temperature switch Installation torque 8-18 ft-lbs Displacement 268.5 cu in 11-24 Nm 4.4 liters Pressure switch point 8 psi Number of cylinders 0.55 bar Bore and stroke 4.13 x 5 inches Oil Sensor Settings 105 x 127 mm 0 psi...
  • Page 32 Section 2 • Specifications January 2016 SPECIFICATIONS Perkins 854F-34T Perkins 1104D-44T Engine coolant Displacement 207 cu in Capacity 9.5 quarts 3.4 liters (engine only) 9 liters Number of cylinders Coolant temperature switch Bore and stroke 3.89 x 4.33 inches Installation torque 8-18 ft-lbs 99 x 110 mm 11-24 Nm...
  • Page 33 January 2016 Section 2 • Specifications SPECIFICATIONS 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 34: Perkins Engine 1004-42 Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Perkins Engine 1004-42 Injection system Injection pump make Zexel Displacement 258 cu in Injector opening pressure 2204 psi 4.23 liters 152 bar Number of cylinders Fuel requirement Bore & stroke 4.06 x 5 inches For fuel requirements, refer to the engine Operator's 103.1 x 127 mm Manual on your machine.

  • Page 35: Perkins Engine 1104C-44 Specifications

    January 2016 Section 2 • Specifications SPECIFICATIONS Perkins 1104C-44 Engine Lubrication system Oil pressure, hot 40 to 60 psi Displacement 268.5 cu in (at 2000 rpm) 2.8 to 4.1 bar 4.4 liters Oil capacity 7.3 quarts Number of cylinders (including filter) 6.9 liters Bore and stroke 4.13 x 5 inches...

  • Page 36: Perkins Engine 804D-33T Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Perkins 804D-33T Engine Battery - Engine starting Type 12V, Group 31 Displacement 203 cu in Quantity 3.33 liters Cold cranking ampere 1000A Reserve capacity @ 25A rate 175 minutes Number of cylinders Battery - Control system Bore and stroke 3.7 x 4.72 inches 94 x 120 mm...
  • Page 37 January 2016 Section 2 • Specifications SPECIFICATIONS Oil viscosity requirements Starter motor Below 86°F / 30°C 5W-30 Current draw, normal load 200A -4°F to 104°F / -20°C to 40°C 10W-30 Cranking speed 250 rpm Above 14°F / -10°C 15W-40 Engine coolant Units ship with 15W-40.

  • Page 38: Cummins Engine B3.3T Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Cummins B3.3T Engine Fuel injection system Injection pump make Zexel Displacement 199 cu in Injection pressure 12,000 psi 3.26 liters 827 bar Number of cylinders Fuel requirement Bore and stroke 3.74 x 4.53 inches For fuel requirements, refer to the engine Operator's 95 x 115 mm Manual on your machine.

  • Page 39: Cummins Engine B3.9L Specifications

    January 2016 Section 2 • Specifications SPECIFICATIONS Cummins B3.9L Engine Injection system Injection pump make Bosch Displacement 238 cu in Injection pump pressure 5500 psi 3.9 liters 379.2 bar Number of cylinders Injector opening pressure 3480 psi Bore and stroke 4.02 x 4.72 inches 240 bar 102 x 120 mm...

  • Page 40: Cummins Engine B4.5L Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Cummins B4.5L Engine Fuel injection system Injection pump make Delphi Displacement 275 cu in Injection pump pressure 3480 to 3680 psi 4.5 liters 240 to 254 bar Number of cylinders Injector opening pressure 3480 psi Bore and stroke 4.02 x 5.42 inches...

  • Page 41: Machine Torque Specifications

    January 2016 Section 2 • Specifications 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 42: Hydraulic Hose And Fitting Torque Specifications

    Section 2 • Specifications January 2016 SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal- SAE Dash size Torque fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to 14 ft-lbs / 19 Nm specification when they are removed and installed...
  • Page 43 January 2016 Section 2 • Specifications SPECIFICATIONS Torque Procedure JIC 37° fittings 1 Align the tube flare (hex nut) against the nose Seal-Lok fittings of the fitting body (body hex fitting) and tighten 1 Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight, replaced anytime the seal has been broken.
  • Page 44 Section 2 • Specifications January 2016 SPECIFICATIONS 3 Working clockwise on the body hex fitting, make 4 Tighten the hex nut until the mark on the hex a second mark with a permanent ink marker to nut is aligned with the second mark on the body indicate the proper tightening position.
  • Page 45 January 2016 Section 2 • Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED LUBED...
  • Page 46 Section 2 • Specifications January 2016 SPECIFICATIONS This page intentionally left blank. 2 - 30 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 47: Scheduled Maintenance Procedures

    January 2016 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Maintenance inspections shall be completed Safety alert symbol—used to alert by a person trained and qualified on the personnel to potential personal...
  • Page 48 Section 3 • Scheduled Maintenance Procedures January 2016 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used The pre-delivery preparation report contains in this manual to help communicate the intent checklists for each type of scheduled inspection. of the instructions.

  • Page 49: Pre-Delivery Preparation

    500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (44) 1476-584333 (605) 882-4000 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. Rev D...
  • Page 50 Section 3 • Scheduled Maintenance Procedures January 2016 This page intentionally left blank. 3 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 51: Maintenance Inspection Report

    January 2016 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R Checklist B Y N R A-1 Inspect the manuals B-1 Batteries Serial number and decals B-2 Electrical wiring A-2 Pre-operation B-3 Oil cooler and fins - Date inspection Deutz models...
  • Page 52 Section 3 • Scheduled Maintenance Procedures January 2016 MAINTENANCE INSPECTION REPORT Model Checklist C Y N R Checklist E Y N R C-1 Engine maintenance - E-1 Replace hydraulic oil Serial number Deutz models E-2 Engine maintenance - C-2 Engine maintenance - Cummins models Date Cummins models...

  • Page 53: Checklist A Procedures

    January 2016 Section 3 • Scheduled Maintenance Procedures Checklist A Procedures 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie requires that this procedure be performed daily.

  • Page 54: Perform Pre-Operation Inspection

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Genie requires that this procedure be performed Genie requires that this procedure be performed daily. daily. Completing a pre-operation inspection is essential Completing the function tests is essential to safe to safe machine operation.

  • Page 55: Perform Engine Maintenance - Perkins Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Perkins Models Deutz Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 8 hours or daily, whichever be performed every 8 hours or daily, whichever comes first.

  • Page 56: Perform Engine Maintenance - Cummins Models

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST A PROCEDURES Perform Engine Maintenance - Check the Hydraulic Filter Cummins Models Condition Indicators Engine specifications require that this procedure Genie requires that this procedure be performed be performed daily or every 8 hours, whichever daily.
  • Page 57 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Tank return filter Medium and high pressure filters Note: The tank return filter indicator needle may Note: The medium and high pressure filters are operate in the red area when hydraulic oil is below mounted to the engine side bulkhead.

  • Page 58: Perform 30 Day Service

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST A PROCEDURES Perform 30 Day Service Perform Engine Maintenance - Perkins Models The 30 day maintenance procedure is a one time sequence of procedures to be performed after Engine specifications require that this procedure the first 30 days or 40 hours of usage.

  • Page 59: Perform Engine Maintenance - Deutz Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-10 To access the engine: Perform Engine Maintenance - 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine Deutz Models tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable.

  • Page 60: Grease The Turntable Rotation Bearing And Rotate Gear

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST A PROCEDURES A-11 To access the engine: Grease the Turntable Rotation 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine Bearing and Rotate Gear tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable.

  • Page 61: Grease The Extendable Axles

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-12 A-13 Grease the Extendable Axles Replace the Drive Hub Oil Genie specifications require that this procedure be Genie specifications require that this one-time performed every 100 hours of operation. Perform procedure be performed after the first 150 hours of this procedure more often if dusty conditions exist.
  • Page 62 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST A PROCEDURES Turntable Rotate Drive Hub: 5 Remove the plug from the side of the drive hub. Drain the oil from the hub into a suitable Note: When removing a hose assembly or fitting, container.
  • Page 63 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES This page intentionally left blank. Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 17...

  • Page 64: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures January 2016 Checklist B Procedures 3 Be sure that the battery retainers and cable connections are tight. Inspect the Batteries 4 Fully charge the batteries. Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize.

  • Page 65: Inspect The Electrical Wiring

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as Inspect the Electrical Wiring follows: • Add 0.004 to the reading of each cell for every 10°...
  • Page 66 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES 4 Install the bolt that was just removed into the 12 Start the engine from the ground controls and anchor hole to secure the engine pivot plate raise the boom above the turntable covers. from moving.

  • Page 67: Check The Engine Oil Cooler And Cooling Fins - Deutz Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES material. Check the Engine Oil Cooler and Cooling and blower fins Cooling Fins - Deutz Models (does 5 Inspect the fan blower fins for physical damage. not include TD 2.9 models) 6 Clean the fan blower fins of debris and foreign material.

  • Page 68: Inspect The Engine Air Filter

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES 2 Release the latches from the end cap of the air filter canister. Remove the end cap. Inspect the Engine Air Filter 3 Remove the filter element. 4 Clean the inside of the canister and the canister end cap with a damp cloth.
  • Page 69 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Perform Hydraulic Oil Analysis Perform Engine Maintenance - Deutz Models Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Engine specifications require that this procedure first.
  • Page 70 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES To access the engine: Perform Engine Maintenance - 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine Cummins Models tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable.

  • Page 71: Check The Exhaust System

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Check the Exhaust System Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the exhaust system is essential to engine pivot plate anchor hole good engine performance and service life.

  • Page 72: Inspect The Tires, Wheels And Lug Nut Torque

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES B-10 Inspect the Tires, Wheels Check the Drive Hub Oil Level and Lug Nut Torque and Fastener Torque Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.
  • Page 73 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Turntable Rotate Drive Hub: 1 Remove the fixed turntable cover at the ground controls side of the machine. 2 Remove the power to platform plug panel upper retaining fasteners and loosen the lower retaining fasteners.

  • Page 74: Confirm The Proper Brake Configuration

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES B-11 2 Be sure the free-wheel valve on the drive pump is closed (clockwise). Confirm the Proper Note: The free-wheel valve is located on the drive Brake Configuration pump. Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

  • Page 75: Check And Adjust The Engine Rpm

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-12 Deutz models: Check and Adjust the 1 Start the engine from the ground controls. Engine RPM 2 Push one of the LCD screen buttons shown until engine rpm is displayed. Result: Refer to Specifications, Deutz Engine Specification.
  • Page 76 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES 4 Adjust the low idle adjustment screw until low 2 Locate the engine pivot plate anchor hole at the idle is 1500 rpm. Tighten the locknut. pivot end of the engine pivot plate. 5 Push and hold the function enable/high speed 3 Install the bolt that was just removed into the button.
  • Page 77 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Skip to step 7 if the low idle rpm is correct. If the high idle is correct, disregard adjustment step 8. 6 Loosen the low idle lock nut. Turn the low idle adjustment screw clockwise to increase the 8 Perkins models: Loosen the yoke lock nut.

  • Page 78: Test The Key Switches

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES B-13 STOP Test the Key Switches 00000 Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential to safe machine operation.

  • Page 79: Test The Ground Control Override

    January 2016 Section 3 • Scheduled Maintenance Procedures B-14 10 Attempt to raise the primary boom. Test the Ground Control Override Result: The boom should not raise. Note: The primary boom will not raise until the Genie requires that this procedure be performed axles are fully extended.

  • Page 80: Test The Platform Self-Leveling

    Section 3 • Scheduled Maintenance Procedures January 2016 B-15 5 Push and hold a function enable/speed select button and fully raise the boom. Test the Platform Self-leveling Result: The platform should remain level at Genie requires that this procedure be performed all times to within ±2 degrees.

  • Page 81: Test The Safety Envelope And Circuits

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-16 7 Pull out the red Emergency Stop button to the on position and restart the engine. Test the Safety Envelope and 8 Disconnect the 68° proximity switch LSB14AO Circuits and install a wire jumper between pin 3 and pin 4 of the Deutsch connector.
  • Page 82 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES S-100/105 models before SN 806: 20 Measure the angle of the boom. S-120/125 models before SN 2710: Result: The angle of the boom should be greater than 65°. 12 Proceed to step 15. 21 Using auxiliary power, raise the boom until the S-100/105 Models after SN 805: boom angle is greater than 68°.
  • Page 83 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 32 Activate the function enable/high RPM button 38 Select , then press the button. and lower the boom to 50°. 39 Press the button until appears. exit Result: The engine should stop and the boom down function should be disabled.
  • Page 84 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES 44 Using auxiliary power, retract the boom until the 54 Place the arm removed in step 53 back on boom is extended to less than 75 feet / 22.9 m. the LSB6S switch 180°...
  • Page 85 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 56 Allow the switch to return to its neutral position, 62 Place a metal washer over the target area of then rotate the head of the switch 45° counter the axle extend proximity switch LSAX1EO and clockwise and activate the function enable/high place a metal washer over the target area of...
  • Page 86 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES 64 Activate the function enable/high RPM button 67 Activate the function enable/high RPM button and attempt to raise the boom. and attempt to extend the boom. Result: The boom should not raise to more Result: The boom should not extend to more than 11°.

  • Page 87: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-17 2 Check for proper venting. Inspect the Fuel and Hydraulic Result: Air passes through the fuel tank cap. Procced to step 4. Tank Cap Venting Systems Result: If air does not pass through the cap, clean or replace the cap.

  • Page 88: Test The Engine Idle Select Operation

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES B-18 6 Turn the key switch to platform controls. Test the Engine Idle Select 7 At the platform controls, press the engine idle select button until high idle (rabbit symbol) is Operation selected.

  • Page 89: Test The Drive Brakes

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-19 B-20 Test the Drive Brakes Test the Drive Speed - Stowed Position Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed first.

  • Page 90: Test The Drive Speed - Raised Or Extended Position

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST B PROCEDURES B-21 7 Continue at full speed and note the time when the machine reference point crosses the finish Test the Drive Speed - line. Refer to Section Specifications, Machine Raised or Extended Position Specification.

  • Page 91: Inspect The Boom Extend/Retract Cables

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-22 3 Visually inspect the cables and components through both inspection holes for the following: Inspect the Boom Extend/Retract • Frayed or broken wire strands Cables • Kinks or crushed cables •...

  • Page 92: Checklist C Procedures

    Section 3 • Scheduled Maintenance Procedures January 2016 Checklist C Procedures Perform Engine Maintenance - Perform Engine Maintenance - Deutz Models Cummins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 500 hours. be performed every 500 hours or 6 months, whichever comes first.

  • Page 93: Perform Engine Maintenance - Perkins Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Perkins Models Perkins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 500 hours. be performed every 500 hours or annually.

  • Page 94: Replace The Engine Air Filter Element

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST C PROCEDURES Replace the Engine Air Filter Grease the Platform Overload Element Mechanism (if equipped) Engine specifications require that this procedure Genie specifications require that this procedure be be performed every 500 hours or 6 months, performed every 500 hours or 6 months, whichever whichever comes first.

  • Page 95: Test The Platform Overload System (If Equipped)

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 4 Using a suitable lifting device, place an appropriate test weight equal to that of the Test the Platform Overload maximum platform capacity in one of the System (if equipped) locations shown.
  • Page 96 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST C PROCEDURES 11 Lift the test weights off the platform floor using a suitable lifting device. Result: The platform overload indicator light and alarm should turn off at both the ground and platform controls.

  • Page 97: Checklist D Procedures

    January 2016 Section 3 • Scheduled Maintenance Procedures Checklist D Procedures 6 Remove the boom end cover retaining fasteners at the pivot end of the boom. Remove Check the Boom Wear Pads the boom end cover from the machine. Genie specifications require that this procedure 7 Remove the boom side inspection cover be performed every 1000 hours or annually, retaining fasteners from the boom at the pivot...

  • Page 98: Check The Extendable Axle Wear Pads

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST D PROCEDURES 3 Replace any wear pad if it is less than specification. If a wear pad is not less than Check the Extendable Axle specification, shim as necessary to obtain Wear Pads minimum clearance and no drag.

  • Page 99: Check The Free-Wheel Configuration

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 5 Manually rotate each wheel at the square-end of the machine. Check the Free-wheel Result: Each wheel at the square-end of the Configuration machine should rotate with minimum effort. 6 Re-engage the drive hubs by turning over the drive hub disconnect caps.

  • Page 100: Check The Turntable Rotation Bearing Bolts

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST D PROCEDURES 12 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each Check the Turntable Rotation wheel to check for engagement. Lift the Bearing Bolts machine and remove the blocks. Lower the machine.

  • Page 101: Check The Turntable Rotation Gear Backlash

    January 2016 Section 3 • Scheduled Maintenance Procedures 3 Be sure that each turntable rotation bearing mounting bolt above the turntable is torqued Check the Turntable Rotation in sequence. Refer to Specifications, Machine Gear Backlash Torque Specifications. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
  • Page 102 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST D PROCEDURES 3 Using a feeler guage, measure the gap 5 Apply approximately 20 lbs / 89 N of side force between the swing hub pinion gear and the to the platform, moving the rotator to the left as turntable rotation bearing at the center tooth.

  • Page 103: Replace The Drive Hub Oil

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 4 Fill the hub with oil from either plug hole until the oil level is even with the bottom of both plug Replace the Drive Hub Oil holes. Install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs.
  • Page 104 Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST D PROCEDURES 7 Fill the drive hub with oil from the side hole until the oil level is even with the bottom of the hole. Apply pipe thread sealant to the plug. Install the plug.

  • Page 105: Inspect For Turntable Bearing Wear

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life.

  • Page 106: Perform Engine Maintenance - Deutz Models

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST D PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Deutz Models Perkins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 1000 hours or annually, be performed every 1000 hours.

  • Page 107: Perform Engine Maintenance - Perkins Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES D-10 D-11 Perform Engine Maintenance - Perform Engine Maintenance - Perkins Models Cummins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 1500 hours. be performed every 1000 hours or annually, whichever comes first.

  • Page 108: Replace The Hydraulic Filter Elements

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST D PROCEDURES D-12 3 Remove each filter with an oil filter wrench. Replace the Hydraulic Filter 4 Apply a thin layer of clean oil to the new oil filter gaskets. Elements 5 Install the new hydraulic return filter element and tighten it securely by hand.
  • Page 109 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES Medium and High Pressure Hydraulic Filters: 4 Remove the filter element from the housing. 5 Inspect the housing seal and replace it if Burn hazard. Beware of hot oil. necessary.

  • Page 110: Checklist E Procedures

    Section 3 • Scheduled Maintenance Procedures January 2016 Checklist E Procedures 2 Close the two hydraulic shut-off valves located at the hydraulic tank. Test or Replace the Hydraulic Oil Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component Genie specifications require that this procedure be damage will occur.
  • Page 111 January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES 10 Remove the hydraulic tank breather filter from 24 Install the two suction hoses and the supply the tank. hose for the auxiliary power unit onto the machine. 11 Remove the hydraulic tank strap retaining 25 Install the case drain hose onto the return filter fasteners and remove the hydraulic tank straps head.

  • Page 112: Perform Engine Maintenance - Cummins Models

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST E PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Cummins Models Perkins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 2000 hours or 2 years, be performed every 2000 hours.

  • Page 113: Perform Engine Maintenance - Deutz Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Deutz Models Perkins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 2 years. be performed every 3000 hours.

  • Page 114: Perform Engine Maintenance - Deutz Models

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST E PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Deutz Models Perkins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 3000 hours. be performed every 4000 hours.

  • Page 115: Perform Engine Maintenance - Deutz Models

    January 2016 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES Perform Engine Maintenance - Perform Engine Maintenance - Deutz Models Perkins Models Engine specifications require that this procedure Engine specifications require that this procedure be performed every 6000 hours. be performed every 12000 hours or 6 years, whichever come first.

  • Page 116: Replace The Boom Extend/Retract Cables

    Section 3 • Scheduled Maintenance Procedures January 2016 CHECKLIST E PROCEDURES E-10 Replace the Boom Extend/Retract Cables Genie specifications require that this procedure be performed every 10 years. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube on the S-100 and S-105, and the numbers 2 and 3 boom tubes on the S-120 and S-125.

  • Page 117: Repair Procedures

    Genie S-105 Operator’s Manual and the which, if not avoided, will result in Genie S-120 & Genie S-125 Operator’s Manual. death or serious injury. Be sure that all necessary tools and parts are Used to indicate the presence of available and ready for use.

  • Page 118: Display Module

    Section 4 • Repair Procedures January 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 119 January 2016 Section 4 • Repair Procedures DISPLAY MODULE Screen or Procedure Description Range or Selection Menu Drive With key switch Drive output max forward 100% max and 10% min, 100 % (default) , press and Functions Drive output max reverse 100% max and 10% min, hold the button and turn 90% (default) the key switch to 120% max and 50% min, Elevated drive (>75 ft / 24 m) % position.
  • Page 120 Section 4 • Repair Procedures January 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 hold the 2600 max and 100 min, Ramp ramp deceleration % button and turn...
  • Page 121 January 2016 Section 4 • Repair Procedures DISPLAY MODULE Screen or Procedure Description Range or Selection Menu Default With key switch Reset drive functions , press and Reset Reset boom function speeds hold the button and turn the key switch to Reset lift function ramps position.

  • Page 122: Platform Controls

    Section 4 • Repair Procedures January 2016 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 123: Circuit Boards

    January 2016 Section 4 • Repair Procedures PLATFORM CONTROLS 7 Locate the ECM circuit board mounted to the inside of the platform control box. Circuit Boards Electrocution/burn hazard. Contact with electrically charged circuits Note: When an ECM circuit board is replaced, the could result in death or serious joystick controllers will need to be calibrated. See injury. Remove all rings, watches 1-3, How to Calibrate a Joystick Controller. and other jewelry.

  • Page 124: Membrane Decal

    Section 4 • Repair Procedures January 2016 PLATFORM CONTROLS REV B 3 Locate the membrane circuit board mounted to the inside of the platform control box lid. Membrane Decal Electrocution/burn hazard. Contact with electrically charged circuits How to Replace the Membrane could result in death or serious Decal injury. Remove all rings, watches and other jewelry.
  • Page 125 January 2016 Section 4 • Repair Procedures REV B 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 126 Section 4 • Repair Procedures January 2016 PLATFORM CONTROLS REV B 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 127 January 2016 Section 4 • Repair Procedures REV B 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 128 Section 4 • Repair Procedures January 2016 PLATFORM CONTROLS REV B 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. Note: Use this procedure for any software version 1 Turn the key switch to the off position. Confirm other than 2.00. For software version 2.00 refer to the red Emergency Stop button at the platform the following procedure.
  • Page 129 January 2016 Section 4 • Repair Procedures REV B PLATFORM CONTROLS How to Reset a Proportional How to Set the Function Valve Coil Default Thresholds and Function Speeds (software version 2.00) Note: Before the threshold and default function speeds can be set, the boom function proportional Note: Software version 2.00 requires the use of valve coil defaults must be set first.
  • Page 130 Section 4 • Repair Procedures January 2016 PLATFORM CONTROLS REV B 7 While holding the joystick in position, press the Boom extend/retract functions: Raise the boom until the low-speed drive function is engine start button at the platform controls enabled. Move the joystick full stroke in the to set the joystick controller threshold.
  • Page 131 January 2016 Section 4 • Repair Procedures REV B PLATFORM CONTROLS ground control panel while turning the key 2 Press and hold the enter button on the ground control panel while turning the key switch to ground controls. Hold the enter switch to ground controls.

  • Page 132: Platform Components

    Section 4 • Repair Procedures January 2016 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 133 January 2016 Section 4 • Repair Procedures PLATFORM COMPONENTS 4 Tag, disconnect and plug the hydraulic hoses 8 Use a soft metal drift to remove the rod-end from the platform leveling cylinder at the pivot pin. bulkhead fittings located inside the boom tube Crushing hazard. The platform at the platform end and connect them together (S-100 and S-120 models) or using a connector. Cap the bulkhead fittings on jib boom (S-105 and S-125...

  • Page 134: Platform Rotator

    Section 4 • Repair Procedures January 2016 PLATFORM COMPONENTS How to Bleed the Platform Leveling Cylinder Platform Rotator Note: Do not start the engine. Use auxiliary power The platform rotator is a hydraulically activated for all machine functions in this procedure. helical gear assembly used to rotate the platform 160 degrees.
  • Page 135 January 2016 Section 4 • Repair Procedures PLATFORM COMPONENTS 3 Tag, disconnect and plug the hydraulic hoses 8 Support the platform mounting weldment, but from the "V1" and "V2" ports on platform rotator do not apply any lifting pressure. manifold. Cap the fittings on the manifold. 9 Remove the eight mounting bolts from the platform mounting weldment.
  • Page 136 Section 4 • Repair Procedures January 2016 PLATFORM COMPONENTS S-105 and S-125 models: 2 Connect a clear hose to the top bleed valve. Place the other end of the hose in a container 12 Remove the pin retaining fasteners from the jib to collect any drainage. Secure the container to boom and jib boom leveling arms to platform the boom.

  • Page 137: Platform Level Sensor

    January 2016 Section 4 • Repair Procedures PLATFORM COMPONENTS 4 Hold the platform rotate left button until the platform is fully rotated. Continue holding the Platform Level Sensor button until air stops coming out of the bleed valve. Close the bleed valve. The platform level sensor is mounted to the side Crushing hazard. Keep clear of of the platform rotator.

  • Page 138: Platform Overload System

    Section 4 • Repair Procedures January 2016 PLATFORM COMPONENTS 9 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 139 January 2016 Section 4 • Repair Procedures 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 140 Section 4 • Repair Procedures January 2016 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.

  • Page 141: Platform Overload Recovery Message(Software V3.14 And Later)

    January 2016 Section 4 • Repair Procedures PLATFORM COMPONENTS 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 142 Section 4 • Repair Procedures January 2016 Jib Boom Components, S-105 / S-125 Models 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. Spraying hydraulic oil can penetrate and How to Remove the Jib Boom burn skin.

  • Page 143: Jib Boom Components, S-105 And S-125 Models

    January 2016 Section 4 • Repair Procedures JIB BOOM COMPONENTS, S-105 AND S-125 MODELS 12 Remove the pin retaining fasteners from the 18 Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. Do not platform leveling cylinder rod-end pivot pin. remove the pin. 19 Use a soft metal drift to remove the platform 13 Slide both of the jib boom leveling arms off of leveling cylinder rod-end pivot pin.
  • Page 144 Section 4 • Repair Procedures January 2016 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. Spraying hydraulic oil can penetrate and How to Remove the Jib Boom burn skin.

  • Page 145: Boom Components

    January 2016 Section 4 • Repair Procedures Boom Components S-100 and S-105 Models Pivot end Number 1 Platform end Number 2 Number 3 S-120 and S-125 Models Pivot end Platform end Number 0 Number 1 Number 2 Number 3 Part No. 102916 S-100 •...

  • Page 146: Cable Track

    Section 4 • Repair Procedures January 2016 BOOM COMPONENTS 4 Tag and disconnect the black electrical connector from the bottom of the control box. Cable Track 5 Remove the platform-end boom cable tube mounting fasteners at the engine side of the The cable track and boom cable tube guides machine.
  • Page 147 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 13 Remove the cable track roller guide mounting If not removing the boom from the machine, fasteners from the ground controls side of the proceed to step 19. machine at the platform end. 18 Tag, disconnect and plug the primary extension 14 Remove the roller guide from the cable cylinder hydraulic hoses on the side of the...
  • Page 148 Section 4 • Repair Procedures January 2016 BOOM COMPONENTS If not removing the boom from the machine, 28 Attach a lifting strap from an overhead crane to proceed to step 25. each end of the cable track assembly. Carefully lift the assembly from the boom and set it on a 24 Pull the hydraulic hoses from the boom cable structure capable of supporting it.

  • Page 149: Boom

    January 2016 Section 4 • Repair Procedures BOOM COMPONENTS After serial number 880 (S-120/125) and 209 (S-100/105): Boom Use part number 102214 which includes a 3-link section of cable track. How to Shim the Boom 1 Visually inspect the cable track and determine which section needs to be replaced.
  • Page 150 Section 4 • Repair Procedures January 2016 BOOM COMPONENTS How to Remove the Boom 8 Remove the boom storage area cover retaining fasteners. Remove the cover from the machine. Bodily injury hazard. This 9 Place support blocks under the boom lift procedure requires specific repair cylinder.
  • Page 151 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS How to Disassemble the Boom, 16 Tag and disconnect the wiring connector from the cable break limit switch. S-120 and S-125 Models 17 Tag, disconnect and plug the hydraulic hoses Note: Complete disassembly of the boom is only from the primary boom extension cylinder. Cap necessary if the outer or inner boom tubes must the fittings on the cylinder.
  • Page 152 Section 4 • Repair Procedures January 2016 BOOM COMPONENTS 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. 11 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. 12 Remove the cotter pin and clevis pin from both cables.
  • Page 153 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 24 Support and slide the primary boom extension cylinder out of the boom assembly while guiding the cables out of the boom and place it on a structure capable of supporting it. Crushing hazard. The primary boom extension cylinder may become unbalanced and fall when it is removed from the boom if it is not properly supported and attached to the overhead crane.
  • Page 154 Section 4 • Repair Procedures January 2016 BOOM COMPONENTS 28 Remove the retaining fasteners from the limit 34 Attach a lifting strap from an overhead crane to switch cover on the side of the number 0 boom the number 3 boom tube at the platform end of tube at the platform end of the boom.
  • Page 155 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 39 Support and slide the number 2 boom tube out 42 Support the secondary boom extension cylinder of the number 1 boom tube. When the number with an overhead crane or other suitable lifting 2 boom tube is approximately halfway removed, device. remove the bottom wear pads from the number 43 Remove the pin retaining fasteners from both 1 boom tube at the platform end of the boom.
  • Page 156 Section 4 • Repair Procedures January 2016 BOOM COMPONENTS How to Disassemble the Boom, 46 Remove and label the top and side wear pads from the number 0 boom tube at the platform S-100 and S-105 Models end of the boom. Do not remove the bottom wear pads.
  • Page 157 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 10 Remove the cotter pin and clevis pin from both cables. Note: When installing a clevis pin, always replace the cotter pin with a new one. 11 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin. 12 Remove the cable break actuator mounting plate retaining fasteners.
  • Page 158 Section 4 • Repair Procedures January 2016 BOOM COMPONENTS 23 Remove the retaining fasteners from the limit switch cover on top of the number 2 boom tube at the platform end of the machine. 24 Carefully remove the cover with proximity and limit switches from the top of the number 2 boom tube at the platform end of the boom.
  • Page 159 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 30 Remove and label the top and side wear pads 34 Remove and label the top and side wear pads of the number 3 boom tube at the pivot end from the number 2 boom tube at the pivot end of the boom.

  • Page 160: Boom Lift Cylinder

    Section 4 • Repair Procedures January 2016 BOOM COMPONENTS 5 Place support blocks under the boom lift cylinder. Boom Lift Cylinder 6 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a How to Remove the Boom soft metal drift to remove the pin.
  • Page 161 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 11 Remove the engine pivot plate retaining 17 With the boom lift cylinder being supported by fastener. Swing the engine pivot plate out away the overhead crane, pull the boom lift cylinder from the machine.

  • Page 162: Extension Cylinders

    Section 4 • Repair Procedures January 2016 BOOM COMPONENTS 3 Remove the access cover retaining fasteners from both sides of the boom. Remove the Extension Cylinders access covers. 4 Secure the number 2 and number 3 boom The primary boom extension cylinder is located tubes together with a strap or chain to prevent inside the boom assembly and incorporates cables them from moving.
  • Page 163 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS 8 S-120 and S-125 models: Remove the 17 Push the cable break actuator and cables fasteners from the inner cable track mounting towards the platform end of the boom bracket at the primary boom extension cylinder. approximately 18 inches / 46 cm. 9 S-120 and S-125 models: Lay the inner cable 18 Remove the retaining fasteners from the red track and hoses down and out of the way.
  • Page 164 Section 4 • Repair Procedures January 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-120 and S-125 Models mounting plate. Bodily injury hazard.
  • Page 165 January 2016 Section 4 • 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 166: Boom Extend/Retract Cables

    Section 4 • Repair Procedures January 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 167 January 2016 Section 4 • Repair Procedures BOOM COMPONENTS i extension cable coupling j cable retainer bracket k equal distance l guide plate Illustration 2 boom tube 1 10 At the platform end of the boom, tighten the boom tube 2 hex jam nut (h) on the cable tension equalizer nylock nut bracket located underneath the number 1 boom h hex jam nut tube (Illustration 3). Tighten the hex jam nut...
  • Page 168 Section 4 • Repair Procedures January 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. See 4-4, than...
  • Page 169 January 2016 Section 4 • 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 170: Turntable Covers

    Section 4 • Repair Procedures January 2016 Turntable Covers 4 Mark the location of the hinges on the bulkhead to ensure proper cover alignment during Turntable Covers installation. 5 Remove the cover hinge to bulkhead retaining In addition to the standard hinged turntable covers, fasteners.
  • Page 171 January 2016 Section 4 • Repair Procedures TURNTABLE COMPONENTS How to Remove a Fixed Turntable Cover 1 Ground controls side: Remove the top retaining fasteners from the power to platform plug panel and loosen the bottom retaining fasteners. Do not disconnect the wiring. 2 Support the cover with a suitable lifting device.

  • Page 172: Engines

    Section 4 • Repair Procedures January 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 173 January 2016 Section 4 • 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 and Perkins engines: 28 ft-lbs / 38 Nm. 3 Install the pump coupler onto the pump shaft with the set screw toward the pump.

  • Page 174: Oil Pressure And Coolant Temperature Sending Units, Cummins And Perkins Models

    Section 4 • Repair Procedures January 2016 ENGINES Oil Pressure and Coolant Oil Pressure and Temperature Temperature Sending Units - Sending Units - Deutz Models Cummins and Perkins 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 175: Ground Controls

    January 2016 Section 4 • 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 176: Membrane Decal

    Section 4 • Repair Procedures January 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 177: Control Relays

    January 2016 Section 4 • 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 178 Section 4 • Repair Procedures January 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 &...

  • Page 179: Limit Switches

    January 2016 Section 4 • Repair Procedures Limit Switches 120 ft / 36.6 m 110 ft / 33.5 m LSB14AO LSB9AS 100 ft / 30.5 m LSB2RO 102 ft (31.1 m) 90 ft / 27.4 m LSB4EO LSB2RS 100 ft 101 ft (30.5 m) (30.8 m)
  • Page 180 Section 4 • Repair Procedures January 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 181 January 2016 Section 4 • 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 182 Section 4 • Repair Procedures January 2016 LIMIT SWITCHES S-120 and S-125 models: All models: 3 Raise boom until the protractor reads 67.5 14 S-100 and S-105 models: Raise the boom to degrees. 52.5 degrees. 4 Loosen the mounting fasteners from the 68 15 Loosen the mounting fasteners from the 53 degree proximity switch (LSB14AO).

  • Page 183: Limit Switch And Level Sensor Locations

    January 2016 Section 4 • Repair Procedures LIMIT SWITCHES Limit Switch and Level Sensor Locations LSB3RO LSB3EO LSB4EO LSB3RS LSB9AS LSB4ES LSB8AS LSB1DO LSB7DS LSB13AO LSB14AO LSB19LO LSB6S LSB2RO LSB19LO LSB2RS PLATFORM LSAX2ES TURNTABLE LSAX1EO LEVEL LSAX1ES LSAX2RO LEVEL SENSOR LSAX1RO SENSOR LSAX2EO LST1O...

  • Page 184: Limit Switch Functions

    Section 4 • Repair Procedures January 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 185 January 2016 Section 4 • 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 186 Section 4 • Repair Procedures January 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 187: Hydraulic Pumps

    January 2016 Section 4 • 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 188: Drive Pump

    Section 4 • Repair Procedures January 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 189 January 2016 Section 4 • Repair Procedures HYDRAULIC PUMPS 7 Remove the drive pump from the machine. Cummins and Perkins models: 2 Remove the engine pivot plate retaining Component damage hazard. 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 190 Section 4 • Repair Procedures January 2016 HYDRAULIC PUMPS 5 Deutz models: Disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump. Perkins models fuel shutoff solenoid 6 Have another person crank the engine with the starter motor for 15 seconds, wait 15 seconds, Deutz models then crank the engine an additional 15 seconds fuel shutoff solenoid...

  • Page 191: Auxiliary Pump

    January 2016 Section 4 • 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 192 Section 4 • Repair Procedures January 2016 HYDRAULIC PUMPS How to Remove the Auxiliary Pump 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.

  • Page 193: Function Manifold Components, S-100 And S-105 Models (Serial Number 136)

    January 2016 Section 4 • Repair Procedures Manifolds 10-1 Function Manifold Components, S-100 and S-105 Models (to serial number 136) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Relief valve, 1800 psi / 124.1 bar ..FA ..Boom extend pressure limit ......18-20 ft-lbs / 24-27 Nm Proportional solenoid valve ....
  • Page 194 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 78 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 195 January 2016 Section 4 • Repair Procedures MANIFOLDS Function Manifold Components, S-100 and S-105 Models, continued (to serial number 136) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Orifice - plug, 0.040 inch / 1.02 mm......FK ..Differential sensing dampening Check valve........FL ...Load sensing circuit, turntable rotate ........12-14 ft-lbs / 16-19 Nm Diagnostic Nipple ..........Testing Check valve........
  • Page 196 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 80 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 197: Function Manifold Components, S-100 And S-105 Models (After Serial Number 136)

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-2 Function Manifold Components, S-100 and S-105 Models (from serial number 137) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Solenoid Valve Assembly, 3 position 4 way, DO3, 12V DC ..FD ..Boom up/down ..........30-35 in-lbs / 3-4 Nm Solenoid Valve, 3 position 4 way ..
  • Page 198 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 82 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 199 January 2016 Section 4 • Repair Procedures MANIFOLDS Function Manifold Components, S-100 and S-105 Models, continued (from serial number 137) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Relief Valve, 2600 psi / 179.3 bar ..FI ....Turntable, primary lift and boom retract pressure limit ....
  • Page 200 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 84 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 201: Valve Adjustments - Function Manifold, S-100 And S-105 Models

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-3 How to Adjust the Boom Extend Valve Adjustments - Function Relief Valve Manifold, S-100 and S-105 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 202: Proportional Valves - Function Manifold

    Section 4 • Repair Procedures January 2016 MANIFOLDS 10-4 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. See Repair Procedure, How to Calibrate a Joystick.

  • Page 203: Function Manifold Components, S-120 And S-125 Models (Before Serial Number 431)

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-5 Function Manifold Components, S-120 and S-125 Models (to serial number 430) 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 ..BA ..Boom extend pressure limit ....18-20 ft-lbs / 24-27 Nm Proportional solenoid valve ....
  • Page 204 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 88 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 205 January 2016 Section 4 • Repair Procedures MANIFOLDS Function Manifold Components, S-120 and S-125 Models, continued (to serial number 430) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Diagnostic nipple ..........Testing Check valve........BL ..Load sensing circuit, turntable rotate ........12-14 ft-lbs / 16-19 Nm Check valve........
  • Page 206 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 90 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 207: Function Manifold Components, S-120 And S-125 Models (From Serial Number 431 To 574)

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-6 Function Manifold Components, S-120 and S-125 Models (from serial number 431 to 574) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque DO3 Valve, 3 position 4 way, ..... BD ..Boom up/down ........30-35 in-lbs / 3-4 Nm Solenoid Valve, 3 position 4 way ..
  • Page 208 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 92 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 209 January 2016 Section 4 • Repair Procedures MANIFOLDS Function Manifold Components, S-120 and S-125 Models, continued (from serial number 431 to 574) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Item Function Torque Counterbalance Valve, 3200 psi / 220.6 bar ......BH ..Primary lift, load holding ....30-35 ft-lbs / 41-47 Nm Orifice Plug, 0.040 inch / 1.016 mm ...
  • Page 210 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 94 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 211: Function Manifold Components, S-120 And S-125 Models (After Serial Number 574)

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-7 Function Manifold Components, S-120 and S-125 Models (from serial number 575) 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 ..
  • Page 212 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 96 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 213 January 2016 Section 4 • Repair Procedures MANIFOLDS Function Manifold Components, S-120 and S-125 Models, continued (from serial number 575) 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 .....
  • Page 214 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 98 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 215: Valve Adjustments - Function Manifold, S-120 And S-125 Models

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-8 How to Adjust the Boom Extend Valve Adjustments - Function Relief Valve Manifold, S-120 and S-125 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 216: Proportional Valves - Function Manifold

    Section 4 • Repair Procedures January 2016 MANIFOLDS valve pressure. 10-9 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. See 1-3, How to Calibrate a Joystick Controller.

  • Page 217: Platform Manifold Components, S-100 And S-120 Models

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-10 Platform Manifold Components, S-100 and S-120 Models The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Item Function Torque Proportional solenoid valve, 3 position 4 way ......... GH ..Platform level up/down ......18-20 ft-lbs / 24-27 Nm Check valve........
  • Page 218 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 102 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 219: Platform Manifold Components, S-105 And S-125 Models

    January 2016 Section 4 • Repair Procedures MANIFOLDS 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 220 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 104 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 221: Proportional Valves - Platform Manifolds

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-12 Proportional Valves - Platform 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. See 1-3, How to Calibrate a Joystick.

  • Page 222: Turntable Rotation Manifold Components

    Section 4 • Repair Procedures January 2016 MANIFOLDS 10-14 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 ......

  • Page 223: Steer And Axle Extend/Retract Manifold Components - View 1

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-15 Steer and Axle Extend/Retract Manifold Components - View 1 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 Solenoid Valve, 3 position 4 way ..EA ..Steering cylinder control, square end, right side ......18-20 ft-lbs / 24-27 Nm Solenoid Valve, 3 position 4 way ..
  • Page 224 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 108 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 225: Steer And Axle Extend/Retract Manifold Components - View 2

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-16 Steer and Axle Extend/Retract Manifold Components - View 2 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 Flow Regulator Valve, 2 gpm / 7.6 L/min ....... EE ..Steering cylinder speed ......18-20 ft-lbs / 25-27 Nm Flow Regulator Valve, 1.4 gpm / 5.3 L/min ......
  • Page 226 Section 4 • Repair Procedures January 2016 MANIFOLDS EH EK EJJ ENN 4 - 110 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 227 January 2016 Section 4 • Repair Procedures MANIFOLDS Steer and Axle Extend/Retract Manifold Components - View 2, continued 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 Check Valve ........EK ..Steering cylinder lock, square end, left side, extend/retract .......18-20 ft-lbs / 25-27 Nm Check Valve ........
  • Page 228 Section 4 • Repair Procedures January 2016 MANIFOLDS EH EK EJJ ENN 4 - 112 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 229: Valve Adjustments - Steer And Axle Extend/Retract Manifold

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-17 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 230 Section 4 • Repair Procedures January 2016 MANIFOLDS This page intentionally left blank. 4 - 114 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 231: Traction Manifold Components (S-100/105 Before Serial Number 291) (S-120/125 Before Serial Number 1195)

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-18 Traction Manifold Components (S-100/105- to serial number 290) (S-120/125- to serial number 1194) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index Schematic Description Item Function...
  • Page 232 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 116 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 233 January 2016 Section 4 • Repair Procedures MANIFOLDS Traction Manifold Components, continued (S-100/105- to serial number 290), (S-120/125- to serial number 1194) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index Schematic Description Item Function...
  • Page 234 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 118 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 235: Traction Manifold Components (S-100/105 After Serial Number 290) (S-120/125 After Serial Number 1194)

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-19 Traction Manifold Components (S-100/105- from serial number 291) (S-120/125- from serial number 1195) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index Schematic Description Item Function...
  • Page 236 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 120 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 237 January 2016 Section 4 • Repair Procedures MANIFOLDS Traction Manifold Components, continued (S-100/105- from serial number 291), (S-120/125- from serial number 1195) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index Schematic Description Item Function...
  • Page 238 Section 4 • Repair Procedures January 2016 MANIFOLDS 4 - 122 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 239: Valve Adjustments - Traction Manifold

    January 2016 Section 4 • Repair Procedures MANIFOLDS 10-20 10-21 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 240 Section 4 • Repair Procedures January 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 241 January 2016 Section 4 • 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 242: Fuel And Hydraulic Tanks

    Section 4 • Repair Procedures January 2016 Fuel and Hydraulic Tanks 11-1 5 Remove the fuel tank hold down strap retaining fasteners. Remove the straps from the fuel Fuel Tank tank. 6 Support and secure the fuel tank to an How to Remove the Fuel Tank appropriate lifting device.

  • Page 243: Hydraulic Tank

    January 2016 Section 4 • 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 244 Section 4 • Repair Procedures January 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 245: Turntable Rotation Components

    January 2016 Section 4 • 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 246 Section 4 • Repair Procedures January 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 247 January 2016 Section 4 • 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 248 Section 4 • Repair Procedures January 2016 TURNTABLE ROTATION COMPONENTS This page intentionally left blank. 4 - 132 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 249: Axle Components

    January 2016 Section 4 • Repair Procedures Axle Components 13-1 Measure the circle-end tires: Steer Sensors 3 Press the square-end steer mode button. 4 Measure the distance between the inside of The steer sensor measures steer angle and one circle-end tire and the chassis side plate on communicates that information to the ground both sides of the axle.
  • Page 250 Section 4 • Repair Procedures January 2016 AXLE COMPONENTS How to Adjust a Steer Sensor Measure the square-end tires: 6 Press the circle-end steer mode button. Square-end steer sensors: 7 Measure the distance between the inside of 1 At the platform controls, press the circle-end one square-end tire and the chassis side plate steer mode button.

  • Page 251: Yoke And Hub

    January 2016 Section 4 • Repair Procedures AXLE COMPONENTS 13-2 Circle-end steer sensors: Yoke and Hub 8 At the platform controls, press the square-end steer mode button. How to Remove the Yoke 9 Locate the steer sensor on top of the yoke pivot and Hub pin.
  • Page 252 Section 4 • Repair Procedures January 2016 AXLE COMPONENTS 3 Mark the mounting position of the steer sensor 7 Remove the steer sensor activator pin retaining cover on the yoke. fasteners. Remove the steer sensor activator pin from the machine. Note: It is very important that the steer sensor is installed in the exact position it was in prior Note: It is very important that the steer sensor to removal.

  • Page 253: Drive Motor

    January 2016 Section 4 • Repair Procedures AXLE COMPONENTS 13-3 17 Support the yoke/drive hub assembly with a lifting jack. Secure the yoke/drive hub assembly Drive Motor to the lifting jack. 18 Use a soft metal drift to remove both yoke pivot How to Remove a Drive Motor pins.

  • Page 254: Drive Hub

    Section 4 • Repair Procedures January 2016 AXLE COMPONENTS 13-4 8 Place a second lifting jack under the drive hub for support and secure the drive hub to the Drive Hub lifting jack. 9 Remove the drive hub mounting bolts that How to Remove a Drive Hub attach the drive hub to the yoke.

  • Page 255: Steering Cylinders

    January 2016 Section 4 • Repair Procedures AXLE COMPONENTS 13-5 7 Place a rod through each steer cylinder pivot pin and twist to remove the pins. Steering Cylinders How to Remove a Steering Cylinder Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 8 Remove the steering cylinder from the machine.

  • Page 256: Extendable Axles

    Section 4 • Repair Procedures January 2016 AXLE COMPONENTS 13-6 Top and bottom wear pads: Extendable Axles 3 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. 4 Block the wheels at the opposite end of the machine. How to Shim an Extendable Axle 5 Raise the machine just until the weight of the Note: Measure each wear pad. Replace the wear...
  • Page 257 January 2016 Section 4 • Repair Procedures 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 258 Section 4 • Repair Procedures January 2016 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. See 13-2, cylinder that has the inner axle removed. How to Remove the Yoke and Hub. 8 Remove the cotter pin from the axle extension 2 Remove the axle. See How to Remove an Inner cylinder clevis pin on the remaining inner axle.

  • Page 259: Diagnostic Codes

    January 2016 Section 5 • Diagnostic Codes Diagnostic Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-100, S-105, S-120, S-125 Operator’s Manual. Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.
  • Page 260 Section 5 • Diagnostic Codes January 2016 DIAGNOSTIC 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 261 January 2016 Section 5 • 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 262 Section 5 • Diagnostic Codes January 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 263 January 2016 Section 5 • 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 264 Section 5 • Diagnostic Codes January 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 265 January 2016 Section 5 • 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 266 Section 5 • Diagnostic Codes January 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 267: Control System Fault Codes

    January 2016 Section 5 • 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 268 Section 5 • Diagnostic Codes January 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 269 January 2016 Section 5 • 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 270 Section 5 • Diagnostic Codes January 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 271: Deutz Td 2.9 L4 Engine Fault Codes

    January 2016 Section 5 • Diagnostic Codes DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN FMI KWP Description SPN = Suspect Parameter Number FMI = Failure Mode Identifier 1022 Actuator error EGR-Valve; signal KWP = Keyword Protocol range check high SPN FMI KWP Description 1224...
  • Page 272 Section 5 • Diagnostic Codes January 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 273 January 2016 Section 5 • 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 274 Section 5 • Diagnostic Codes January 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 275 January 2016 Section 5 • 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 276 Section 5 • Diagnostic Codes January 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 277 January 2016 Section 5 • 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 278 Section 5 • Diagnostic Codes January 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 279 January 2016 Section 5 • 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 280 Section 5 • Diagnostic Codes January 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 281 January 2016 Section 5 • 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 282 Section 5 • Diagnostic Codes January 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 283 January 2016 Section 5 • 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 284 Section 5 • Diagnostic Codes January 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 285 January 2016 Section 5 • 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 286: Perkins 854F-34T Engine Fault Code

    Section 5 • Diagnostic Codes January 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 287 January 2016 Section 5 • 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 288 Section 5 • Diagnostic Codes January 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 289 January 2016 Section 5 • 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 290 Section 5 • Diagnostic Codes January 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 291 January 2016 Section 5 • 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 292 Section 5 • Diagnostic Codes January 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 293 January 2016 Section 5 • 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 294 Section 5 • Diagnostic Codes January 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 position.

  • Page 295: Software

    Read, understand and obey the safety rules and operating instructions in the Genie S-100 & Genie S-105 Operator’s Manual and the Genie S-120 & Genie S-125 Operator’s Manual. Be sure that all necessary tools and parts are available and ready for use.
  • Page 296 Section 5 • Diagnostic Codes January 2016 This page intentionally left blank. 5 - 38 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 297 January 2016 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Electrocution/burn hazard. Contact Observe and Obey: with electrically charged circuits could result in death or serious Troubleshooting and repair procedures shall be injury.

  • Page 298: Circuit Numbering

    Section 6 • Schematics January 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 299 January 2016 Section 6 • 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 300: Wire Color Legend

    Section 6 • Schematics January 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 301 January 2016 Section 6 • 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 302 Section 6 • Schematics January 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 303 January 2016 Section 6 • 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 304: Limit Switches

    Section 6 • Schematics January 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 305 January 2016 Section 6 • Schematics LIMIT SWITCHES 120 ft / 36.6 m 110 ft / 33.5 m LSB14AO LSB9AS 100 ft / 30.5 m LSB2RO 102 ft (31.1 m) 90 ft / 27.4 m LSB4EO LSB2RS 100 ft 101 ft (30.5 m) (30.8 m) 80 ft / 24.4 m...

  • Page 306: Relay Layout

    Section 6 • Schematics January 2016 Relay Layout Fuel solenoid relay (Deutz F4L913 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 307: Drive Chassis Controller Pin Legend

    January 2016 Section 6 • Schematics Drive Chassis Controller Pin Legend DCON DCON DRIVE CHASSIS DRIVE CHASSIS CONTROLLER CONTROLLER 1 = VLVRET - BR 1 = GND-DCON - BR 2 = V61AXRT - GR 2 = P21DCON - WH 3 = V60AXEX - GN/WH 3 = P53LS - GR 4 = V29MS - RD/WH 4 = (UNUSED)

  • Page 308: Platform Controller Pin Legend

    Section 6 • Schematics January 2016 Platform Controller Pin Legend BLACK 23 PIN PCON PCON CONNECTOR PLATFORM PLATFORM CONTROLLER CONTROLLER 1 = VLVRET - BR 1 = GNDPCON - BR WHITE 23 PIN 2 = (UNUSED) 2 = P52PCON - BL/RD CONNECTOR 3 = C17PRL - GR 3 = (UNUSED)

  • Page 309: Turntable Controller Pin Legend

    January 2016 Section 6 • Schematics Turntable Controller Pin Legend WHITE EMERGENCY STOP 35 PIN RAISE BOOM CONNECTOR RETRACT BOOM MACHINE NOT LEVEL PLATFORM NOT LEVEL EXTEND AXLE 61227 A WHITE PIN NUMBERING FOR 23 PIN 23 PIN CONNECTOR CONNECTORS AUXILIARY POWER WIRE LOOM HIGH SPEED...

  • Page 310: Engine Relay And Fuse Panel Legend

    Section 6 • Schematics January 2016 Engine Relay and Fuse Panel Legend - Deutz TD2011 and Perkins 1104D Models Deutz TD2011L04i and Perkins 1104D-44T Models CR17 CR77A CR28 CR28 CR15 CR77B CR41 Number Component Description CR77A PCE 1 C 28 Engine / Fule Relay C 17 Hydraulic O Cooler Fan Relay...

  • Page 311: Engine Relay And Fuse Panel Legend - Deutz Td2.9 Models

    January 2016 Section 6 • Schematics Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models Deutz TD2.9 Models CR17 CR39 CR77A CR77A 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 312: Engine Relay And Fuse Panel Legend - Perkins 854F Models

    Section 6 • Schematics January 2016 Engine Relay and Fuse Panel Legend - Perkins 854F Models Perkins 854F-34T Models CR17 CR77A CR81 CR77B CR41 Number Component Description C 77A Engine Alt C 17 Hydraulic Oil Cooler Fan Relay C 77B PCE 2 Fuse 30A ECU Power Fuse 20A Key Switch Power...

  • Page 313: Telematics Connector Pin Legend

    January 2016 Section 6 • Schematics Telematics Connector Pin Legend Genie installed Telematics connector is wried with an Active High digital input. Connector Pin Numbering Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector. Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power...

  • Page 314: Electrical Symbols Legend

    Section 6 • Schematics January 2016 Electrical Symbols Legend OPS1 N.C. Foot switch Circuit breaker with amperage Oil pressure switch Quick disconnect Power relay normally closed terminal T-circuits Emergency Stop connect Horn or alarm button normally closed Sending unit Toggle switch Connection no terminal Flashing beacon...

  • Page 315: Hydraulic Symbols Legend

    January 2016 Section 6 • Schematics Hydraulic Symbols Legend 25 psi (1.7 bar) Accumulator Differential Directional valve Filter with sensing valve pilot operated .035" bypass valve (0.89 mm) 2 position, 2 way relief setting Orifice with size Solenoid operated Shut off valve proportional valve Solenoid operated 3 position, Pump...
  • Page 316 Section 6 • Schematics January 2016 This page intentionally left blank. 6 - 20 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 317: Safety Circuit Schematic

    January 2016 Section 6 • Schematics Safety Circuit Schematic 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 IN 2 OUT 2 TCON/J4/32 TO AUXILIARY RELAY CR16...
  • Page 318 Section 6 • Schematics January 2016 Safety Circuit Schematic 6-21 6-22...

  • Page 319: Engine Options- Perkins And Cummins

    January 2016 Section 6 • Schematics Engine Options- Perkins and Cummins S-100/105 (to serial number 218) S-120/125 (to serial number 932) 6-24 6-23...
  • Page 320 Section 6 • Schematics January 2016 Engine Options- Perkins and Cummins S-100/105 (to serial number 218) S-120/125 (to serial number 932) J5 BLACK 4 PIN J3 WHITE 23 PIN POWER HARN ENGINE HARN C84TAY-GN/WH C83TAX-GN/WH P85TTSR-GR RET85TTSR-BR J32-ENG HARN C45GEN-GR/WH 1 BAT GND-BR P114BAT-RD J29 PWR HARN...

  • Page 321: (S-100/105 From Serial Number 219 To 247) (S-120/125 From Serial Number 933 To 984)

    January 2016 Section 6 • Schematics Engine Options- Perkins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) J5 BLACK 4 PIN J3 WHITE 23 PIN POWER HARN ENGINE HARN C84TAY-GN/BK C83TAX-GN/WH 0-20 DEGREE P85TTSR-GN SENSOR ALARM SET AT 4.5 DEGREES RET85TTSR-BR...
  • Page 322 Section 6 • Schematics January 2016 Engine Options- Perkins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) 6-25 6-26...

  • Page 323: (S-100/105 From Serial Number 248) (S-120/125 From Serial Number 985)

    January 2016 Section 6 • Schematics Engine Options- Perkins S-100/105 (from serial number 248) S-120/125 (from serial number 985) 6-28 6-27...
  • Page 324 Section 6 • Schematics January 2016 Engine Options- Perkins S-100/105 (from serial number 248) S-120/125 (from serial number 985) J5 BLACK 4 PIN J3 WHITE 23 PIN POWER HARN ENGINE HARN C84TAY-GN/BK C83TAX-GN/WH 0-20 DEGREE SENSOR ALARM SET P85TTSR-GN AT 4.5 DEGREES RET85TTSR-BR J32-ENG HARN C45GEN-GN/WH 1...

  • Page 325: Engine Options- Perkins

    January 2016 Section 6 • Schematics Engine Options- Perkins S-100/105/120/125 (from serial number 874) 6-30 6-29...
  • Page 326 Section 6 • Schematics January 2016 Engine Options- Perkins S-100/105/120/125 (from serial number 874) Number Component Description Horn Relay Engine Fule Relay Oil Cooler Start Relay Glow Plug Relay Speed Solenoid Fuse, 30A, Eng / Start / Fuel Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn B3PBAT Fused Power from B1...

  • Page 327: Engine Options- Cummins

    January 2016 Section 6 • Schematics Engine Options- Cummins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) CUMMINS B4.5 C80 ENGINE Part No. 102916 S-100 • S-105 • S-120 • S-125 6-31...

  • Page 328: Engine Options- Cummins

    Section 6 • Schematics January 2016 Engine Options- Cummins S-100/105 (from serial number 219 to 247) S-120/125 (from serial number 933 to 984) 6-31 6-32...

  • Page 329: (S-100/105 From Serial Number 248) (S-120/125 From Serial Number 985)

    January 2016 Section 6 • Schematics Engine Options- Cummins S-100/105 (from serial number 248) S-120/125 (from serial number 985) 6-34 6-33...
  • Page 330 Section 6 • Schematics January 2016 Engine Options- Cummins S-100/105 (from serial number 248) S-120/125 (from serial number 985) CUMMINS B4.5 C80 ENGINE CUMMINS B3.3T ENGINE CB7 ADDED S100- S/N 710 S125- S/N 2589 6-34 S-100 • S-105 • S-120 • S-125 Part No.

  • Page 331: Electrical Schematic - Generator Options

    January 2016 Section 6 • Schematics Electrical Schematic - Generator Options 6-36 6-35...
  • Page 332 Section 6 • Schematics January 2016 Electrical Schematic - Generator Options Hydraulic Generator Option Belt-Driven Generator Option 110 VAC REGULATOR 120VAC GENERATOR W/REGULATOR. 220 VAC REGULATOR 220VAC GENERATOR W/REGULATOR. 6-36 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 333: Electrical Schematic - 12 Kw Generator (Welder Option)

    January 2016 Section 6 • Schematics Electrical Schematic - 12 kW Generator (welder option) NEUTRAL BUSS BAR 12.5 KW HYDRAULIC GENERATOR NEMA 4 CONTROL BOX MODIFIED ENCLOSURE WIRING 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI 208 VAC OUTLET SX CONTROLLER SAUER #K23334 WHITE...

  • Page 334: Electrical Schematic (Es0427)

    Section 6 • Schematics January 2016 Electrical Schematic - 12 kW Generator (welder option) 6-37 6-38...

  • Page 335: Perkins 1104D-44T Engine Electrical Schematic

    January 2016 Section 6 • Schematics Perkins 1104D-44T Engine Electrical Schematic Part No. 102916 S-100 • S-105 • S-120 • S-125 6-39...
  • Page 336 Section 6 • Schematics January 2016 Perkins 1104D-44T Engine Electrical Schematic 6-39 6-40...

  • Page 337: Perkins 854F-34T Engine Electrical Schematic

    January 2016 Section 6 • Schematics Perkins 854F-34T Engine Electrical Schematic 6-42 6-41...
  • Page 338 Section 6 • Schematics January 2016 Perkins 854F-34T Engine Electrical Schematic 6-42 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 339: Perkins 854F-34T Engine Electrical Harness

    January 2016 Section 6 • Schematics Perkins 854F-34T Engine Electrical Harness Part No. 102916 S-100 • S-105 • S-120 • S-125 6-43...
  • Page 340 Section 6 • Schematics January 2016 Perkins 854F-34T Engine Harness 6-45 6-44...
  • Page 341 January 2016 Section 6 • Schematics Deutz TD2011L04i Engine Electrical Schematic 6-46 6-45...
  • Page 342 Section 6 • Schematics January 2016 Deutz TD2011L04i Engine Electrical Schematic 6-46 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 343: Deutz Td2.9 Engine Electrical Schematic

    January 2016 Section 6 • Schematics Deutz TD2.9 Engine Electrical Schematic 6-48 6-47...
  • Page 344 Section 6 • Schematics January 2016 Deutz TD2.9 Engine Electrical Schematic 6-48 S-100 • S-105 • S-120 • S-125 Part No. 102916...

  • Page 345: Deutz Td2.9 Engine Electrical Harness

    January 2016 Section 6 • Schematics Deutz TD2.9 Engine Electrical Harness Part No. 102916 S-100 • S-105 • S-120 • S-125 6-49...
  • Page 346 Section 6 • Schematics January 2016 Deutz TD2.9 Engine Electrical Harness 6-51 6-50...

  • Page 347: Hydraulic Schematic - 12 Kw Generator (Welder Option)

    January 2016 Section 6 • Schematics Hydraulic Schematic - 12 kW Generator (welder option) 3.5 GPM / 13.25L/min DRIVE PUMP OIL COOLER PMP B PMP A WELDER MANIFOLD 0.030 inch / 0.76 mm PRESSURE SWITCH 200 PSI / 13.8 BAR N.O.

  • Page 348: Hydraulic Schematic

    Section 6 • Schematics January 2016 Hydraulic Schematic - 12 kW Generator (welder option) 6-53 6-52...

  • Page 349: (Serial Number 136)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (serial number 136) 6-54 6-53...

  • Page 350: Hydraulic Schematic

    Section 6 • Schematics January 2016 Hydraulic Schematic, S-100 • S-105 Models (serial number 136) PLATFORM MANIFOLD S-105 3 gpm 3 gpm TURNTABLE ROTATE PRIMARY LIFT PRIMARY1 EXT. TEST DISTRIBUTION MANIFOLD 3GPM 11GPM/5GPM 18GPM/6GPM P3 OUT 0.030 3000 psi P1 IN P1 OUT 0.030 3.0 GPM...
  • Page 351 January 2016 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290) PLATFORM MANIFOLD Primary extension HIGH PRESS CB valve ratio S-105 FILTERS CHARGE FILTER changed to 'K' at 3 gpm 3 gpm Serial No.
  • Page 352 Section 6 • Schematics January 2016 Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290) 6-57 6-56...

  • Page 353: From Serial Number 291 To Serial Number 738)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738) 6-58 6-57...
  • Page 354 Section 6 • Schematics January 2016 Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738) PLATFORM MANIFOLD S-105 TURNTABLE ROTATE PRIMARY LIFT PRIMARY1 EXT. 3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM 3 gpm HIGH 3 gpm...

  • Page 355: From Serial Number 739)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-100 • S-105 Models (from serial number 739) PLATFORM MANIFOLD PRIMARY LIFT TURNTABLE ROTATE PRIMARY1 EXT. S-105 11 GPM / 5 GPM 3 GPM 18 GPM / 6 GPM 3 gpm 3 gpm HIGH PRESS TEST...
  • Page 356 Section 6 • Schematics January 2016 Hydraulic Schematic, S-100 • S-105 Models (from serial number 739) 6-61 6-60...

  • Page 357: (From Serial Number 404 To Serial Number 430)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430) 6-62 6-61...
  • Page 358 Section 6 • Schematics January 2016 Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430) PLATFORM MANIFOLD S-125 PRIMARY LIFT PRIMARY 2 EXT. TURNTABLE ROTATE PRIMARY 1 EXT. 3 gpm 3 gpm 3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM P3 OUT...

  • Page 359: (From Serial Number 431 To Serial Number 1194)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194) Primary extension CB valve ratio changed PLATFORM MANIFOLD to ‘K’ at Serial No. 562 HIGH S-125 PRESS TURNTABLE ROTATE PRIMARY 1 EXT. PRIMARY 2 EXT.
  • Page 360 Section 6 • Schematics January 2016 Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194) 6-65 6-64...

  • Page 361: (From Serial Number 1195 To Serial Number 2634)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634) 6-66 6-65...
  • Page 362 Section 6 • Schematics January 2016 Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634) PRIMARY 1 EXT. PRIMARY 2 EXT. PRIMARY LIFT TURNTABLE ROTATE PLATFORM MANIFOLD 11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM 3 GPM S-125...

  • Page 363: (From Serial Number 2635 To Serial Number 3145)

    January 2016 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to serial number 3145) TURNTABLE ROTATE PRIMARY LIFT PRIMARY 1 EXT. PRIMARY 2 (SECONDARY) EXT. 3 gpm 3 gpm 3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM TEST...

  • Page 364: Hydraulic Schematic

    Section 6 • Schematics January 2016 Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to serial number 3145) 6-69 6-68...
  • Page 365 January 2016 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921) 6-70 6-69...
  • Page 366 Section 6 • Schematics January 2016 Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921) 6-70 S-100 • S-105 • S-120 • S-125 Part No. 102916...
  • Page 367 January 2016 Section 6 • Schematics Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922) Part No. 102916 S-100 • S-105 • S-120 • S-125 6-71...
  • Page 368 Section 6 • Schematics January 2016 Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922) 6-73 6-72...
  • Page 369 WAS 10A BEFORE: S100/105- SN 159 HORN RELAY J2-BL/RD (before serial number 231) S120/125- SN 619 S56PRV-RD J1-BL/BK J4-GN/BK J3-OR/BL GNDDCON-BR FUEL Genie S-120/125 SOLENOID P21DCON-RD RELAY (before serial number 921) P57PBD-RD/WH ALTERNATOR C61AXRT-GN EXCT. Electrical Schematic P63LS-OR/RD P264 WAY BAT.
  • Page 370 RELAY Genie S-100/105 HORN S120- S/N 2589 RELAY J2-BL/RD S56PRV-RD J1-BL/BK J4-GN/BK J3-OR/BL (from s/n 231 to s/n 809) GNDDCON-BR Genie S-120/125 P21DCON-RD P57PBD-RD/WH LIMIT SWITCHES ALTERNATOR (from s/n 921 to s/n 2709) C61AXRT-GN EXCT. P63LS-OR/RD P264 WAY S-120/125 BAT.
  • Page 371 D81CAN- -GR GLOW PLUG RELAY RELAY Genie S-100/105 HORN RELAY J2-BL/RD S56PRV-RD (from serial number 810) J1-BL/BK J4-GR/BK J3-OR/BL GNDDCON-BR Genie S-120/125 P21DCON-RD (from serial number 2710) P57PBD-RD/WH ALTERNATOR C61AXRT-GR Electrical Schematic EXCT. P63LS-OR/RD P264 WAY C60AXEX-GR/WH BAT. BAT. HI/LO...
  • Page 372 Genie S-100(from serial number S10011D-114) HORN RELAY J2-BL/RD Genie S-105(from serial number S10511D-133) S56PRV-RD 10 A J1-BL/BK J4-GR/BK J3-OR/BL GNDDCON-BR Genie S-120(from serial number S12011D-113) Genie S-125(from serial number S12511D-134) P21DCON-RD P57PBD-RD/WH ALTERNATOR C61AXRT-GR Electrical Schematic EXCT. P63LS-OR/RD P264 WAY C60AXEX-GR/WH BAT.
  • Page 373 Genie S-100(from serial number S10014D-876) HORN RELAY J2-BL/RD Genie S-105(from serial number S10514D-877) S56PRV-RD 10 A J1-BL/BK J4-GR/BK J3-OR/BL GNDDCON-BR Genie S-120(from serial number S12014D-875) Genie S-125(from serial number S12514D-874) P21DCON-RD P57PBD-RD/WH ALTERNATOR C61AXRT-GR Electrical Schematic EXCT. P63LS-OR/RD P264 WAY C60AXEX-GR/WH BAT.

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