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Genie S-100 S-105 S-120 S-125 Service Manual 102916 – PDF DOWNLOAD
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Genie S-100 S-105 S-120 S-125 Service Manual 102916 – PDF DOWNLOAD
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Description
Genie S-100 S-105 S-120 S-125 Service Manual 102916 – PDF DOWNLOAD
Language : English
Pages : 374
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-100 S-105 S-120 S-125 Service Manual 102916 – PDF DOWNLOAD
Front Cover ................................................................................................................................................................................................................. 1 Introduction ................................................................................................................................................................................................................ 2 Find a Manual for this Model ................................................................................................................................................................................................ 2 Serial Number Legend ........................................................................................................................................................................................................ 3 Safety Rules ................................................................................................................................................................................................................ 5 Table of Contents ........................................................................................................................................................................................................... 7 Specifications .............................................................................................................................................................................................................. 17 Machine Specifications, S-120 and S-125 Models........................................................................................................................................................................... 17 Performance Specifications, S-120 and S-125 Models ...................................................................................................................................................................... 18 Machine Specifications, S-100 and S-105 Models .......................................................................................................................................................................... 19 Performance Specifications, S-100 and S-105 Models ...................................................................................................................................................................... 21 Hydraulic Specifications ................................................................................................................................................................................................ 22 Hydraulic Component Specifications ...................................................................................................................................................................................... 24 Deutz Engine F4L 913 .................................................................................................................................................................................................... 27 Deutz Engine BF4L 2011................................................................................................................................................................................................... 28 Deutz Engine TD2011L04i.................................................................................................................................................................................................. 29 Deutz Engine TD 2.9...................................................................................................................................................................................................... 30 Perkins Engine 1104D-44T................................................................................................................................................................................................. 31 Perkins Engine 854F-34T.................................................................................................................................................................................................. 32 Perkins Engine 1004-42 .................................................................................................................................................................................................. 34 Perkins Engine 1104C-44 ................................................................................................................................................................................................. 35 Perkins Engine 804D-33T ................................................................................................................................................................................................. 36 Cummins Engine B3.3T .................................................................................................................................................................................................... 38 Cummins Engine B3.9L .................................................................................................................................................................................................... 39 Cummins Engine B4.5L .................................................................................................................................................................................................... 40 Machine Torque Specifications ........................................................................................................................................................................................... 41 Hydraulic Hose and Fitting Torque Specifications ........................................................................................................................................................................ 42 SAE and Metric Torque Charts ............................................................................................................................................................................................ 45 Scheduled Maintenance Procedures ............................................................................................................................................................................................ 47 Pre-Delivery Preparation Form............................................................................................................................................................................................ 49 Maintenance Inspection Report ........................................................................................................................................................................................... 51 Checklist A Procedures .................................................................................................................................................................................................. 53 A-1 Inspect the Manuals and Decals .................................................................................................................................................................................. 53 A-2 Perform Pre-operation Inspection ................................................................................................................................................................................ 54 A-3 Perform Function Tests .......................................................................................................................................................................................... 54 A-4 Perform Engine Maintenance - Perkins Models ..................................................................................................................................................................... 55 A-5 Perform Engine Maintenance - Deutz Models ....................................................................................................................................................................... 55 A-6 Perform Engine Maintenance - Cummins Models ..................................................................................................................................................................... 56 A-7 Check the Hydraulic Filter Condition Indicators ................................................................................................................................................................. 56 A-8 Perform 30 Day Service .......................................................................................................................................................................................... 58 A-9 Perform Engine Maintenance - Perkins Models ..................................................................................................................................................................... 58 A-10 Perform Engine Maintenance - Deutz Models ...................................................................................................................................................................... 59 A-11 Grease the Turntable Rotation Bearing and Rotate Gear .......................................................................................................................................................... 60 A-12 Grease the Extendable Axles .................................................................................................................................................................................... 61 A-13 Replace the Drive Hub Oil ...................................................................................................................................................................................... 61 Checklist B Procedures .................................................................................................................................................................................................. 64 B-1 Inspect the Batteries ........................................................................................................................................................................................... 64 B-2 Inspect the Electrical Wiring ................................................................................................................................................................................... 65 B-3 Check the Engine Oil Cooler and Cooling Fins - Deutz Models (does not include TD 2.9 modesl) .................................................................................................................... 67 B-4 Inspect the Engine Air Filter ................................................................................................................................................................................... 68 B-5 Hydraulic Oil Analysis .......................................................................................................................................................................................... 69 B-6 Perform Engine Maintenance - Deutz Models ....................................................................................................................................................................... 69 B-7 Perform Engine Maintenance - Cummins Models ..................................................................................................................................................................... 70 B-8 Check the Exhaust System ........................................................................................................................................................................................ 71 B-9 Inspect the Tires, Wheels and Lug Nut Torque .................................................................................................................................................................... 72 B-10 Check the Drive Hub Oil Level and Fastener Torque .............................................................................................................................................................. 72 B-11 Confirm the Proper Brake Configuration ......................................................................................................................................................................... 74 B-12 Check and Adjust the Engine RPM ................................................................................................................................................................................ 75 B-13 Test the Key Switches .......................................................................................................................................................................................... 78 B-14 Test the Ground Control Override ............................................................................................................................................................................... 79 B-15 Test the Platform Self-leveling ................................................................................................................................................................................ 80 B-16 Test the Safety Envelope and Circuits .......................................................................................................................................................................... 81 B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ........................................................................................................................................................ 87 B-18 Test the Engine Idle Select Operation .......................................................................................................................................................................... 88 B-19 Test the Drive Brakes .......................................................................................................................................................................................... 89 B-20 Test the Drive Speed - Stowed Position ......................................................................................................................................................................... 89 B-21 Test the Drive Speed - Raised or Extended Position ............................................................................................................................................................. 90 B-22 Inspect the Boom Extend/Retract Cables ......................................................................................................................................................................... 91 Checklist C Procedures .................................................................................................................................................................................................. 92 C-1 Perform engine Maintenance - Deutz Models ....................................................................................................................................................................... 92 C-2 Perform Engine Maintenance - Cummins Models ..................................................................................................................................................................... 92 C-3 Perform Engine Maintenance - Perkins Models ..................................................................................................................................................................... 93 C-4 Perform Engine Maintenance - Perkins Models...................................................................................................................................................................... 93 C-5 Replace the Engine Air Filter Element ........................................................................................................................................................................... 94 C-6 Grease the Platform Overload Mechanism (if equipped) ............................................................................................................................................................ 94 C-7 Test the Platform Overload System (if equipped) ................................................................................................................................................................. 95 Checklist D Procedures .................................................................................................................................................................................................. 97 D-1 Check the Boom Wear Pads ........................................................................................................................................................................................ 97 D-2 Check the Extendable Axle Wera Pads ............................................................................................................................................................................. 98 D-3 Check the Free-wheel Configuration .............................................................................................................................................................................. 99 D-4 Check the Turntable Rotation Bearing Bolts ......................................................................................................................................................................100 D-5 Check the Turntable Rotation Gear Backlash ......................................................................................................................................................................101 D-6 Replace the Drive Hub Oil .......................................................................................................................................................................................103 D-7 Inspect for Turntable Bearing Wear...............................................................................................................................................................................105 D-8 Perform Engine Maintenance - Deutz Models.......................................................................................................................................................................106 D-9 Perform Engine Maintenance - Perkins Models .....................................................................................................................................................................106 D-10 Perform Engine Maintenance - Perkins Models ....................................................................................................................................................................107 D-11 Perform Engine Maintenance - Cummins Models ....................................................................................................................................................................107 D-12 Replace the Hydraulic Filter Elements ..........................................................................................................................................................................108 Checklist E Procedures ..................................................................................................................................................................................................110 E-1 Test or Replace the Hydraulic Oil ...............................................................................................................................................................................110 E-2 Perform Engine Maintenance - Cummins Models .....................................................................................................................................................................112 E-3 Perform Engine Maintenanc - Perkins Models ......................................................................................................................................................................112 E-4 Perform engine Maintenance - Deutz Models .......................................................................................................................................................................113 E-5 Perform Engine Maintenance - Perkins Models .....................................................................................................................................................................113 E-6 Perform Engine Maintenance - Deutz Models .......................................................................................................................................................................114 E-7 Perform Engine Miantenance - Perkins Models .....................................................................................................................................................................114 E-8 Perfom Engine Maintenance - Deutz Models ........................................................................................................................................................................115 E-9 Perform Engine Maintenance - Perkins Models .....................................................................................................................................................................115 E-10 Replace the Boom Extend/Retract Cables .........................................................................................................................................................................116 Repair Procedures ...........................................................................................................................................................................................................117 Display Module ..........................................................................................................................................................................................................118 Platform Controls .......................................................................................................................................................................................................122 1-1 Circuit Boards ..................................................................................................................................................................................................123 1-2 Membrane Decal...................................................................................................................................................................................................124 1-3 Joysticks........................................................................................................................................................................................................125 How to Calibrate a Joystick......................................................................................................................................................................................125 Drive Functions..............................................................................................................................................................................................126 Steer Functions..............................................................................................................................................................................................126 Primary Boom Extend/Retract..................................................................................................................................................................................127 Primary Boom Up/Down.........................................................................................................................................................................................127 Turntable Rotate.............................................................................................................................................................................................128 How to Reset a Proportional Valve Coil Default...................................................................................................................................................................128 How to Reset a Proportional Valve Coil Default (software version 2.00)...........................................................................................................................................129 How to Set the Function Thresholds and Function Speeds...........................................................................................................................................................129 How to Adjust the Function Speeds ...............................................................................................................................................................................130 How to Adjust the Function Ramp Rate Setting.....................................................................................................................................................................131 Platfrom Components .....................................................................................................................................................................................................132 2-1 Platform.........................................................................................................................................................................................................132 2-2 Platform Leveling Cylinder.......................................................................................................................................................................................132 How to Bleed the Platform Leveling Cylinder......................................................................................................................................................................134 2-3 Platform Rotator.................................................................................................................................................................................................134 How to Bleed the Platform Rotator................................................................................................................................................................................136 2-4 Platform Level Sensor............................................................................................................................................................................................137 2-5 Platform Overload System.........................................................................................................................................................................................138 2-6 Platform Overload Recovery Message (software V3.14 and later)....................................................................................................................................................141 Jib Boom Components, S-105/S-125 Models..................................................................................................................................................................................142 3-1 Jib Boom.........................................................................................................................................................................................................142 3-2 Jib Boom Lift Cylinder...........................................................................................................................................................................................144 Boom Components..........................................................................................................................................................................................................145 4-1 Cable Track......................................................................................................................................................................................................146 4-2 Boom.............................................................................................................................................................................................................149 How to Remove the Boom...........................................................................................................................................................................................150 How to Disassemble the Boom, S-120 and S-125 Models..............................................................................................................................................................151 How to Disassemble the Boom, S-100 and S-105 Models..............................................................................................................................................................156 4-3 Boom Lift Cylinder...............................................................................................................................................................................................160 4-4 Extension Cylinders..............................................................................................................................................................................................162 How to Remove the Primary Boom Extension Cylinder................................................................................................................................................................162 How to Remove the Secondary Boom Extension Cylinder, S-120 and S-125 Models......................................................................................................................................164 4-5 Boom Extend/Retract Cables.......................................................................................................................................................................................166 How to Adjust the Boom Extend/Retract Cables.....................................................................................................................................................................166 How to Replace the Boom Extend/Retract Cables....................................................................................................................................................................168 Turntable Covers.........................................................................................................................................................................................................170 5-1 Turntable Covers.....................................................................................................................................................................................................170 Engines..................................................................................................................................................................................................................172 6-1 RPM Adjustment...................................................................................................................................................................................................172 6-2 Flex Plate.......................................................................................................................................................................................................172 6-3 Oil Pressure and Coolant Temperature Sending Units - Cummins and Perkins Models..................................................................................................................................174 6-4 Oil Pressure and Temperature Sending Units - Deutz Models........................................................................................................................................................174 Ground Controls..........................................................................................................................................................................................................175 7-1 Circuit Boards...................................................................................................................................................................................................175 7-2 Membrane Decal...................................................................................................................................................................................................176 7-3 Control Relays...................................................................................................................................................................................................177 Limit Switches...........................................................................................................................................................................................................179 8-1 Limit Switches...................................................................................................................................................................................................180 8-2 Limit Switch and Level Sensor Locations..........................................................................................................................................................................183 8-3 Limit Switch Functions...........................................................................................................................................................................................184 Hydraulic Pumps..........................................................................................................................................................................................................187 9-1 Function Pumps...................................................................................................................................................................................................187 9-2 Drive Pump.......................................................................................................................................................................................................188 9-3 Auxiliary Pump...................................................................................................................................................................................................191 Manifolds................................................................................................................................................................................................................193 10-1 Function Manifold Components, S-100 and S-105 Models (to serial number 136).....................................................................................................................................193 10-2 Function Manifold Components, S-100 and S-105 Models (from serial number 137)...................................................................................................................................197 10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models...................................................................................................................................................201 10-4 Proportional Valves - Function Manifold.........................................................................................................................................................................202 10-5 Function Manifold Components, S-102 and s-125 Models (to serial number 430).....................................................................................................................................203 10-6 Function Manifold Components, S-120 and s-125 Models (from serial number 431 to 574)............................................................................................................................207 10-7 Function Manifold Components, S-120 and S-125 Models (from serial number 575)...................................................................................................................................211 10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models...................................................................................................................................................215 10-9 Proportional Valve - FunctionManifold...........................................................................................................................................................................216 10-10 Platform Manifold Components, S-100 and S-120 Models...........................................................................................................................................................217 10-11 Platform Manifold Components, S-105 and S-125 Models...........................................................................................................................................................219 10-12 Proportional Valves - Platform Manifold........................................................................................................................................................................221 10-13 Platform Rotate Counterbalance Valve Manifold Components.......................................................................................................................................................221 10-14 Turntable Rotation Manifold Components.........................................................................................................................................................................222 10-15 Steer and Axle Extend/retract Manifold Components - View 1.....................................................................................................................................................223 10-16 Steer and Axle Extend/Retract Manifold Components - View 2.....................................................................................................................................................225 10-17 Valve Adjustments - Steer and Axle Extend/Retract Manifold.....................................................................................................................................................229 10-18 Traction Manifold Components (S-100/105 to serial number 290) (S-120/125 to serial number 1194)................................................................................................................231 10-19 Traction Manifold Components (S-100/105 from serial number 291) (S-102/125 from serial number 1195)............................................................................................................235 10-20 Valve Adjustments - Traction Manifold..........................................................................................................................................................................239 10-21 Valve Coils....................................................................................................................................................................................................239 Fuel and Hydraulic Tanks.................................................................................................................................................................................................242 11-1 Fuel Tank.......................................................................................................................................................................................................242 11-2 Hydraulic Tank..................................................................................................................................................................................................243 Turntable Rotation Components............................................................................................................................................................................................245 12-1 Turntable Rotation Hydraulic Motor and Drive Hub................................................................................................................................................................245 Axle Components..........................................................................................................................................................................................................249 13-1 Steer Sensors...................................................................................................................................................................................................249 13-2 Yoke and Hub....................................................................................................................................................................................................251 13-3 Drive Motor.....................................................................................................................................................................................................253 13-4 Drive Hub.......................................................................................................................................................................................................254 13-5 Steer Cylinders.................................................................................................................................................................................................255 13-6 Extendable Axles................................................................................................................................................................................................256 Diagnostic Codes.............................................................................................................................................................................................................259 Fault Diagnostics - Control System.......................................................................................................................................................................................260 Diagnostic Code Charts...............................................................................................................................................................................................261 Control System Fault Codes...........................................................................................................................................................................................267 Deutz TD 2.9 L4 Engine Fault Codes...................................................................................................................................................................................271 Perkins 854F-34T Engine Fault Codes..................................................................................................................................................................................286 How to Clear Boom Safety Switch Faults...............................................................................................................................................................................294 Software.................................................................................................................................................................................................................295 Schematics Section...........................................................................................................................................................................................................297 Legends..................................................................................................................................................................................................................297 Wire Circuit Legend..................................................................................................................................................................................................298 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 - Deutz TD2011 and Perkins 1104D Models...........................................................................................................................................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 Schematics...............................................................................................................................................................................................................317 Safety Circuit Schematic.............................................................................................................................................................................................317 Electrical Schematics................................................................................................................................................................................................317 Engine Options - Perkins and Cummins (S-100/105 to serial number 218) (S-120/125 to serial number 932)...........................................................................................................320 Engine Option - Perkins (S-100/105 from serial number 219 to 247) (S-120/125 from serial number 933 to 984)......................................................................................................321 Engine Option - Perkins (S100/105 from serial number 248) (S120/125 from serial number 985)......................................................................................................................324 Engine Relay Layout - Perkins (from serial number 874)...........................................................................................................................................................325 Engine Option - Cummins (S100/105 from serial number 219 to 247) (S120/125 from serial number 933 to 984)........................................................................................................327 Engine Option - Cummins (S100/105 from serial number 248) (S120/125 from serial number 985)......................................................................................................................330 Electrical Schematic - Generator Options.........................................................................................................................................................................332 Electrical Schematic - 12kW Generator (welder option)............................................................................................................................................................333 Perkins 1104D-44T Engine Electrical Schematic....................................................................................................................................................................335 Perkins 854F-34T Engine Electrical Schematic.....................................................................................................................................................................338 Perkins 854F-34T Engine Electrical Harness.......................................................................................................................................................................339 Deutz TD2011L04i Engine Electrical Schematic.....................................................................................................................................................................342 Deutz TD2.9 Engine Electrical Schematic..........................................................................................................................................................................344 Deutz TD2.9 Engine Electrical Harness............................................................................................................................................................................345 Hydraulic Schematics.................................................................................................................................................................................................317 Hydraulic Schematic - 12 kW Generator (welder option)............................................................................................................................................................345 Hydraulic Schematic, S-100 • S-105 Models (serial number 136)....................................................................................................................................................350 Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to 290)........................................................................................................................................351 Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to 738)........................................................................................................................................354 Hydraulic Schematic, S-100 • S-105 Models (from serial number 739)...............................................................................................................................................355 Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to 430)........................................................................................................................................358 Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to 1194).......................................................................................................................................359 Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to 2634)......................................................................................................................................362 Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to 3145)......................................................................................................................................363 Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921)...............................................................................................................................366 Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922).......................................................................................................................................367 Large Electrical Schematics..........................................................................................................................................................................................367 Electrical Schematic with Deutz Engine Option (S-100/105 to serial number 230) (S-120/125 to serial number 920)..................................................................................................369 Electrical Schematic with Deutz Engine Option (S-100/105 from serial number 231 to 809) (S-120/125 from serial number 921 to 2709)...............................................................................370 Electrical Schematic with Deutz Engine Option (S-100/105 from serial number 810) (S-120/125 from serial number 2710).............................................................................................371 Electrical Schematic with Deutz Engine Option (S-100 from S10011D-114 to S10014D-875) (S-105 from S10511D-133 to S10514D-876) (S-120 from S12011D-113 to S12014D-874) (S-125 from S12511D-134 to S12514D-873)....372 Electrical Schematic with Deutz Engine Option (S-100 from S10014D-876) (S-105 from S10514D-877) (S-120 from S12014D-875) (S-125 ffrom S12514D-874)...............................................................373 Back Cover...................................................................................................................................................................................................................374
S.S 05/24
