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Genie S-120
Terex Genie S-120 Manuals
Manuals and User Guides for Terex Genie S-120. We have
7
Terex Genie S-120 manuals available for free PDF download: Service Manual, Maintenance Manual, Replacement Instructions Manual, Operator's Manual, Operator's Manual Supplement
Terex Genie S-120 Service Manual (374 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 12 MB
Table of Contents
Introduction
3
Serial Number Legend
3
Safety Rules
5
Table of Contents
7
Specifications
17
Hydraulic Specifications
22
Hydraulic Component Specifications
24
Deutz Engine BF4L 2011 Specifications
28
Deutz Engine TD 2.9 Specifications
30
Perkins Engine 1004-42 Specifications
34
Perkins Engine 1104C-44 Specifications
35
Perkins Engine 804D-33T Specifications
36
Cummins Engine B3.3T Specifications
38
Cummins Engine B3.9L Specifications
39
Cummins Engine B4.5L Specifications
40
Machine Torque Specifications
41
Manifold Plug Torque Specifications
41
Hydraulic Hose and Fitting Torque Specifications
42
Scheduled Maintenance Procedures
47
Pre-Delivery Preparation
49
Maintenance Inspection Report
51
Checklist a Procedures
53
Inspect the Manuals and Decals
53
Perform Pre-Operation Inspection
54
Perform Function Tests
54
Perform Engine Maintenance - Perkins Models
55
Perform Engine Maintenance - Deutz Models
55
Perform Engine Maintenance - Cummins Models
56
Check the Hydraulic Filter Condition Indicators
56
Perform 30 Day Service
58
Perform Engine Maintenance - Perkins Models
58
Perform Engine Maintenance - Deutz Models
59
Grease the Turntable Rotation Bearing and Rotate Gear
60
Grease the Extendable Axles
61
Replace the Drive Hub Oil
61
Checklist B Procedures
64
Inspect the Batteries
64
Inspect the Electrical Wiring
65
Check the Engine Oil Cooler and Cooling Fins - Deutz Models
67
Inspect the Engine Air Filter
68
Checklist B Procedures
68
Check the Exhaust System
71
Inspect the Tires, Wheels and Lug Nut Torque
72
Check the Dirve Hub Oil Level and Fastener Torque
72
Confirm the Proper Brake Configuration
74
Check and Adjust the Engine RPM
75
Test the Key Switches
78
Test the Ground Control Override
79
Test the Platform Self-Leveling
80
Test the Safety Envelope and Circuits
81
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
87
Test the Engine Idle Select Operation
88
Test the Drive Brakes
89
Test the Drive Speed - Stowed Position
89
Test the Drive Speed - Raised or Extended Position
90
Inspect the Boom Extend/Retract Cables
91
Checklist C Procedures
92
Perform Engine Maintenance - Deutz Models
92
Perform Engine Maintenance - Cummins Models
92
Perform Engine Maintenance - Perkins Models
93
Replace the Engine Air Filter Element
94
Grease the Platform Overload Mechanism (if Equipped)
94
Test the Platform Overload System (if Equipped)
95
Checklist D Procedures
97
Check the Boom Wear Pads
97
Check the Extendable Axle Wear Pads
98
Check the Free-Wheel Configuration
99
Check the Turntable Rotation Bearing Bolts
100
Check the Turntable Rotation Gear Backlash
101
Replace the Drive Hub Oil
103
Inspect for Turntable Bearing Wear
105
Perform Engine Maintenance - Deutz Models
106
Perform Engine Maintenance - Perkins Models
106
Perform Engine Maintenance - Perkins Models
107
Perform Engine Maintenance - Cummins Models
107
Replace the Hydraulic Filter Elements
108
Checklist E Procedures
110
Test or Replace the Hydraulic Oil
110
Perform Engine Maintenance - Cummins Models
112
Perform Engine Maintenance - Perkins Models
112
Perform Engine Maintenance - Deutz Models
113
Perform Engine Maintenance - Perkins Models
113
Perform Engine Maintenance - Deutz Models
114
Perform Engine Maintenance - Perkins Models
114
Perform Engine Maintenance - Deutz Models
115
Perform Engine Maintenance - Perkins Models
115
Replace the Boom Extend/Retract Cables
116
Repair Procedures
117
Display Module
118
Platform Controls
122
Circuit Boards
123
Membrane Decal
124
Platform Components
132
Platform
132
Platform Leveling Cylinder
132
Platform Rotator
134
Platform Level Sensor
137
Platform Overload System
138
Platform Overload Recovery Message(Software V3.14 and Later)
141
Jib Boom Components, S-105 and S-125 Models
143
Boom Components
145
Cable Track
146
Boom
149
Boom Lift Cylinder
160
Extension Cylinders
162
Boom Extend/Retract Cables
166
Turntable Covers
170
Engines
172
RPM Adjustment
172
Flex Plate
172
Oil Pressure and Coolant Temperature Sending Units, Cummins and Perkins Models
174
Oil Pressure and Temperature Sending Units, Deutz Models
174
Ground Controls
175
Circuit Boards
175
Membrane Decal
176
Control Relays
177
Limit Switches
179
Limit Switch and Level Sensor Locations
183
Limit Switch Functions
184
Hydraulic Pumps
187
Function Pumps
187
Drive Pump
188
Auxiliary Pump
191
Function Manifold Components, S-100 and S-105 Models (Serial Number 136)
193
Function Manifold Components, S-100 and S-105 Models (after Serial Number 136)
197
Valve Adjustments - Function Manifold, S-100 and S-105 Models
201
Proportional Valves - Function Manifold
202
Function Manifold Components, S-120 and S-125 Models (before Serial Number 431)
203
Function Manifold Components, S-120 and S-125 Models (from Serial Number 431 to 574)
207
Function Manifold Components, S-120 and S-125 Models (after Serial Number 574)
211
Valve Adjustments - Function Manifold, S-120 and S-125 Models
215
Proportional Valves - Function Manifold
216
Platform Manifold Components, S-100 and S-120 Models
217
Platform Manifold Components, S-105 and S-125 Models
219
Proportional Valves - Platform Manifolds
221
Platform Rotate Counterbalance Valve Manifold Components
221
Turntable Rotation Manifold Components
222
Steer and Axle Extend/Retract Manifold Components - View 1
223
Steer and Axle Extend/Retract Manifold Components - View 2
225
Valve Adjustments - Steer and Axle Extend/Retract Manifold
229
Traction Manifold Components (S-100/105 before Serial Number 291) (S-120/125 before Serial Number 1195)
231
Traction Manifold Components (S-100/105 after Serial Number 290) (S-120/125 after Serial Number 1194)
235
Valve Adjustments - Traction Manifold
239
Valve Coils
239
Fuel and Hydraulic Tanks
242
Fuel Tank
242
Hydraulic Tank
243
Turntable Rotation Components
245
Turntable Rotation Hydraulic Motor and Drive Hub
245
Axle Components
249
Steer Sensors
249
Yoke and Hub
251
Drive Motor
253
Drive Hub
254
Steering Cylinders
255
Extendable Axles
256
Diagnostic Codes
259
Control System Fault Codes
267
Deutz TD 2.9 L4 Engine Fault Codes
271
Perkins 854F-34T Engine Fault Code
286
Software
295
Circuit Numbering
298
Wire Color Legend
300
Limit Switches
304
Relay Layout
306
Drive Chassis Controller Pin Legend
307
Platform Controller Pin Legend
308
Turntable Controller Pin Legend
309
Engine Relay and Fuse Panel Legend
310
Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models
311
Engine Relay and Fuse Panel Legend - Perkins 854F Models
312
Telematics Connector Pin Legend
313
Electrical Symbols Legend
314
Hydraulic Symbols Legend
315
Safety Circuit Schematic
317
Engine Options- Perkins and Cummins
319
Engine Options- Perkins
319
(S-100/105 from Serial Number 219 to 247) (S-120/125 from Serial Number 933 to 984)
321
Engine Options- Perkins
321
(S-100/105 from Serial Number 248) (S-120/125 from Serial Number 985)
323
Engine Options- Perkins
325
(S-100/105/120/125 from Serial Number 874)
325
Engine Options- Cummins
327
(S-100/105 from Serial Number 219 to 247) (S-120/125 from Serial Number 933 to 984)
327
Engine Options- Cummins
328
(S-100/105 from Serial Number 248) (S-120/125 from Serial Number 985)
329
Electrical Schematic - Generator Options
331
Electrical Schematic - 12 Kw Generator (Welder Option)
333
Electrical Schematic (ES105C, ES125G)
333
Electrical Schematic (ES0427)
334
Electrical Schematic (ES0509)
334
Perkins 1104D-44T Engine Electrical Schematic
335
Perkins 854F-34T Engine Electrical Schematic
337
Perkins 854F-34T Engine Electrical Harness
339
Deutz TD2.9 Engine Electrical Schematic
343
Deutz TD2.9 Engine Electrical Harness
345
Hydraulic Schematic - 12 Kw Generator (Welder Option)
347
Hydraulic Schematic
348
(Serial Number 136)
349
Hydraulic Schematic
349
Hydraulic Schematic
350
From Serial Number 291 to Serial Number 738)
353
Hydraulic Schematic
353
From Serial Number 739)
355
Hydraulic Schematic
355
(From Serial Number 404 to Serial Number 430)
357
Hydraulic Schematic
357
(From Serial Number 431 to Serial Number 1194)
359
Hydraulic Schematic
359
(From Serial Number 1195 to Serial Number 2634)
361
Hydraulic Schematic
361
(From Serial Number 2635 to Serial Number 3145)
363
Hydraulic Schematic
363
Hydraulic Schematic
364
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Terex Genie S-120 Maintenance Manual (198 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 8 MB
Table of Contents
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
5
Find Additional Manuals for Your Model
5
Revision History
6
Safety Rules
8
Table of Contents
10
Performance Specifications
17
Function Speeds - S-100, S-105 and S-100HD
17
Function Speeds - S-120, S-125 and S-120HD
18
Function Speeds - All Other Models
19
Drive Speeds
25
Torque Specifications
29
Tires and Wheels
29
Trax Torque Specifications
31
Engine Specifications
32
Engine Operator and Maintenance Manuals
32
Deutz Engine Models
33
Perkins Engine Models
34
Ford Engine Models
36
Kubota Engine Models
37
GM Engine Models
38
Continental Engine Models
38
Cummins Engine Models
39
Hydraulic Specifications
40
Hydraulic Relief Valves
40
Hydraulic and Drive Hub Fluid Capacities
43
Hydraulic Oil Specifications
45
Hydraulic Hose and Fitting Torque Specifications
48
Torque Procedure
49
Maintenance Procedures
51
Introduction
51
Maintenance Schedule
53
Pre-Delivery Preparation Report
54
Scheduled Maintenance Inspection Report - Quarterly or Frequent
55
Scheduled Maintenance Inspection Report - Annual
56
Programmed Maintenance Inspection Report - Booms
57
Commissioning Procedures
58
Perform 50 Hour Service
58
Perform Engine Maintenance - 50 Hours
58
Perform 150 Hour Service
59
Quarterly Maintenance Procedures
60
Check for Open Bulletins and Owner Registration
60
Battery Inspection
61
Inspect the Electrical Wiring
63
Inspect the Electrical Contactors - DC / Bi-Energy Models
64
Check the Exhaust System
65
Inspect the Tires, Wheels and Lug Nut Torque
66
Check the Generator Belts and Pulleys, Bi-Energy Models
66
Check the Oscillate Directional Valve Linkage (if Equipped)
68
Visual Inspection of the Hydraulic Oil
68
Inspect the Hydraulic Filters
69
Check and Adjust the Engine RPM
70
Test the Ground Control Override
76
Test the Alarm Package (if Equipped)
76
Test the Emergency Power System
77
Test the Engine Idle Select - Engine Models
78
Test the Fuel Select Operation - Gasoline/Lpg Models
79
Inspect the Calibration Decal - ALC1000 Models
81
Test the Recovery Mode System - ALC-1000 Models
82
Test the Platform Self-Leveling
83
Confirm the Proper Brake Configuration
84
Test the Drive Brakes
84
Test the Drive Speed - Stowed Position
85
Test the Drive Speed - Raised or Extended Position
85
Test the Drive Speed - Raised and Extended, ALC1000 Models
86
Test the Turntable Level Sensor
88
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
88
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
90
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
92
Test the Primary Boom Angle Sensor
95
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
95
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70
100
Test the Primary Boom Angle Sensor - Z-80/60
104
Test the Safety Envelope and Circuits - Z-80/60
105
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000
107
Test the Safety Envelope and Circuits
109
And S-125
109
Test the Aircraft Protection System (if Equipped)
115
Test the Operator Protection Alarm (if Equipped)
117
Inspect the Boom Extend/Retract Cables - All Models
117
Test the Recovery Mode System - ALC600 Models
119
Test the Turntable Level Sensor - ALC600 Models
120
Test the Primary Boom Angle Sensor - ALC600 Models
122
Annual Maintenance Procedures
124
Grease the Turntable Rotation Bearing and Rotate Gear
124
Check the Turntable Rotation Bearing Bolts
125
Inspect for Turntable Bearing Wear
127
Check the Extendable Axle - S-100, S-105, S-120 and S-125
128
Perform Maintenance- Jib Rotate Bearing
129
Test the Bypass/Recovery Key Switch - ALC1000 Models
130
Grease the Platform Overload Mechanism (if Equipped)
133
Test the Platform Overload System - (if Equipped)
133
Test the Platform Overload System - ALC1000 Models
135
Test the Platform Load Sense System - S-60 HC
137
S-60/65, S-80/85 and S-80J Models
138
Inspect the Boom Extend/Retract Cables and Sheaves
139
Inspect the Boom Extend/Retract Cables and Sheaves
141
S-100, S-105, S-120, S-125, SX-105XC and SX-125XC
141
Inspect the Boom Extend and Retract Cables and Sheaves -
143
Check the Drive Hub Oil Level and Fastener Torque
146
Test the Dual Capacity and Platform Overload System - SX-105XC, SX-125XC and SX-135XC
150
Test the Dual Capacity and Platform Overload System - Z-45XC Models
152
Test the Dual Capacity and Platform Overload System - S-40XC, S-45XC, S-60HF, S-65HF, S-60XC from S60XCH-45001, S-65XC, S-80HF, S-85HF, S-80XC, S-85XC
154
Test the Platform Overload System - S-40HF, S-45HF, S-60J
156
S-80J, Z-45HF, Z-45 DC/FE from Z45EM-101
156
Perform Engine Maintenance
158
Programmed Maintenance Procedures
159
P0-1 Check the Track Tension and Fastener Torque, Trax Models
159
XC, S-65 XC, Z-62 Models
159
P0-2 Check the Track Tension and Fastener Torque, Trax Models - S-40, S-45, S-40 XC, S-45 XC Models
160
P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125
162
P0-4 Continental Engine Maintenance - under 1000 Hours
163
P0-5 Cummins Engine Maintenance - under 1000 Hours
164
P0-6 Deutz Engine Maintenance - under 1000 Hours
165
P0-7 Ford Engine Maintenance - under 1000 Hours
166
P0-8 Kubota Engine Maintenance - under 1000 Hours
167
P0-9 Perkins Engine Maintenance - under 1000 Hours
169
P0-10 GM .998L Engine Maintenance - under 1000 Hours
170
P0-11 GM 3.0L Engine Maintenance - under 1000 Hours
171
P1-1 Perform Engine Maintenance - 1000 Hours
172
P1-2 Replace the Drive Hub Oil
174
P1-3 Perform Engine Maintenance - 1500 Hours
177
P2-1 Perform Engine Maintenance - 2000 Hours
177
P2-2 Test or Replace the Hydraulic Oil
179
P2-3 Replace the Hydraulic Filters
180
P2-4 Check the Free-Wheel Configuration
182
P2-5 Check the Boom Wear Pads
184
P2-6 Check the Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD and S-120HD
187
P2-7 Check the Turntable Rotation Gear Backlash
187
P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models, Except S-60, S-65, Z-60 DC/FE and Z-62
188
P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models
190
DC/FE and Z-62
190
Terex Genie S-120 Maintenance Manual (185 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 4 MB
Table of Contents
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
5
Find Additional Manuals for Your Model
5
Revision History
6
Safety Rules
8
Table of Contents
10
Performance Specifications
17
Function Speeds - S-100, S-105 and S-100HD
17
Function Speeds - S-120, S-125 and S-120HD
18
Function Speeds - All Other Models
19
Drive Speeds
25
Torque Specifications
29
Tires and Wheels
29
Trax Torque Specifications
31
Engine Specifications
32
Engine Operator and Maintenance Manuals
32
Deutz Engine Models
33
Perkins Engine Models
34
Ford Engine Models
36
Kubota Engine Models
37
GM Engine Models
38
Continental Engine Models
38
Cummins Engine Models
39
Hydraulic Specifications
40
Hydraulic Relief Valves
40
Hydraulic and Drive Hub Fluid Capacities
43
Hydraulic Oil Specifications
45
Hydraulic Hose and Fitting Torque Specifications
48
Torque Procedure
49
Maintenance Procedures
51
Introduction
51
Maintenance Schedule
53
Pre-Delivery Preparation Report
54
Scheduled Maintenance Inspection Report - Quarterly or Frequent
55
Scheduled Maintenance Inspection Report - Annual
56
Programmed Maintenance Inspection Report - Booms
57
Commissioning Procedures
58
Perform 50 Hour Service
58
Perform Engine Maintenance - 50 Hours
58
Perform 150 Hour Service
59
Quarterly Maintenance Procedures
60
Check for Open Bulletins and Owner Registration
60
Battery Inspection
61
Inspect the Electrical Wiring
63
Inspect the Electrical Contactors - DC / Bi-Energy Models
64
Check the Exhaust System
65
Inspect the Tires, Wheels and Lug Nut Torque
66
Check the Generator Belts and Pulleys, Bi-Energy Models
66
Check the Oscillate Directional Valve Linkage (if Equipped)
68
Visual Inspection of the Hydraulic Oil
68
Inspect the Hydraulic Filters
69
Check and Adjust the Engine RPM
70
Test the Ground Control Override
76
Test the Alarm Package (if Equipped)
76
Test the Emergency Power System
77
Test the Engine Idle Select - Engine Models
78
Test the Fuel Select Operation - Gasoline/Lpg Models
79
Inspect the Calibration Decal - ALC1000 Models
81
Test the Recovery Mode System - ALC-1000 Models
82
Test the Platform Self-Leveling
83
Confirm the Proper Brake Configuration
84
Test the Drive Brakes
84
Test the Drive Speed - Stowed Position
85
Test the Drive Speed - Raised or Extended Position
85
Test the Drive Speed - Raised and Extended, ALC1000 Models
86
Test the Turntable Level Sensor
88
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
88
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
90
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
92
Test the Primary Boom Angle Sensor
95
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
95
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70
100
Test the Primary Boom Angle Sensor - Z-80/60
104
Test the Safety Envelope and Circuits - Z-80/60
105
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000
107
Test the Safety Envelope and Circuits
109
And S-125
109
Test the Aircraft Protection System (if Equipped)
115
Test the Operator Protection Alarm (if Equipped)
117
Inspect the Boom Extend/Retract Cables - All Models
117
Test the Recovery Mode System - ALC600 Models
118
Test the Turntable Level Sensor - ALC600 Models
119
Test the Primary Boom Angle Sensor - ALC600 Models
122
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Terex Genie S-120 Replacement Instructions Manual (90 pages)
Battery Separator
Brand:
Terex
| Category:
Water Filtration Systems
| Size: 1 MB
Table of Contents
Safety Notice
2
Tools Required
5
Observe and Obey
9
Before Starting Installation
9
Parts Order Form
14
Erforderliche Werkzeuge
24
Aviso de Seguridad
31
Herramientas Necesarias
35
Antes de Comenzar la Instalación
39
Avis de Sécurité
46
Outillage Requis
50
Avant de Commencer L'installation
54
Outils Nécessaires
54
Avviso DI Sicurezza
61
Attrezzi Necessari
65
Benodigd Gereedschap
80
Terex Genie S-120 Operator's Manual (71 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 2 MB
Table of Contents
Table of Contents
2
Introduction
3
Symbol and Hazard Pictorials Definitions
5
General Safety
7
Personal Safety
10
Work Area Safety
11
Legend
22
Controls
23
Inspections
31
Operating Instructions
47
Transport and Lifting Instructions
59
Maintenance
62
Specifications
65
Terex Genie S-120 Operator's Manual (68 pages)
Brand:
Terex
| Category:
Lifting Systems
| Size: 2 MB
Table of Contents
Table of Contents
2
Introduction
3
Symbol and Hazard Pictorials Definitions
5
General Safety
7
Personal Safety
10
Work Area Safety
11
Legend
21
Controls
22
Inspections
30
Operating Instructions
44
Transport and Lifting Instructions
56
Maintenance
59
Specifications
62
Terex Genie S-120 Operator's Manual Supplement (17 pages)
Lift Tools Access Deck
Brand:
Terex
| Category:
Boom Lifts
| Size: 0 MB
Table of Contents
Symbol and Hazard Pictorials Definitions
9
Pre-Operation Inspection
9
Annual Inspection
11
Installation Instructions
12
Observe and Obey
12
Before Starting Installation
12
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