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Genie S-100 S-105 S-120 S-125 Service & Repair Manual 1268494 – PDF DOWNLOAD
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Genie S-100 S-105 S-120 S-125 Service & Repair Manual 1268494 – PDF DOWNLOAD
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Description
Genie S-100 S-105 S-120 S-125 Service & Repair Manual 1268494 – PDF DOWNLOAD
Language : English
Pages : 302
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-100 S-105 S-120 S-125 Service & Repair Manual 1268494 – PDF DOWNLOAD
Front Cover ................................................................................................................................................................................................................. 1 Important Information ....................................................................................................................................................................................................... 2 Find a Manual for this Model ................................................................................................................................................................................................ 2 Revision History ............................................................................................................................................................................................................ 3 Serial Number Legend ........................................................................................................................................................................................................ 4 General Safety Rules ........................................................................................................................................................................................................ 5 Table of Contents ........................................................................................................................................................................................................... 7 Specifications .............................................................................................................................................................................................................. 15 Machine Specifications, S-120 and S-125 Models .......................................................................................................................................................................... 15 Performance Specifications, S-120 and S-125 Models ...................................................................................................................................................................... 16 Machine Specifications, S-100 and S-10 5 Models.......................................................................................................................................................................... 17 Performance Specifications, S-100 and S-10 5 Models...................................................................................................................................................................... 19 Hydraulic Specifications ................................................................................................................................................................................................ 20 Hydraulic Components Specifications .................................................................................................................................................................................... 22 Deutz Engine F4L 913 Specifications...................................................................................................................................................................................... 25 Deutz Engine BF4L 2011 Specifications.................................................................................................................................................................................... 26 Deutz Engine TD2011L04i Specifications .................................................................................................................................................................................. 27 Deutz Engine TD 2.9 Specifications ...................................................................................................................................................................................... 28 Perkins Engine 1104D-44T Specifications ................................................................................................................................................................................. 29 Perkins Engine 854F-34T Specifications ................................................................................................................................................................................. 30 Perkins Engine 1004-42 Specifications ................................................................................................................................................................................... 32 Perkins Engine 1104C-44 Specifications .................................................................................................................................................................................. 33 Perkins Engine 804D-33T Specifications .................................................................................................................................................................................. 34 Cummins Engine B3.3T Specifications ..................................................................................................................................................................................... 36 Cummins Engine B3.9L Specifications ..................................................................................................................................................................................... 37 Cummins Engine B4.5L Specifications ..................................................................................................................................................................................... 38 Machine Torque Specifications............................................................................................................................................................................................ 39 Manifold Plug Torque Specifications ..................................................................................................................................................................................... 39 Hydraulic Hose and FittingTorque Specifications.......................................................................................................................................................................... 40 SAE and Metric Fasteners Torque Charts .................................................................................................................................................................................. 43 Repair Procedures ........................................................................................................................................................................................................... 45 Introduction ............................................................................................................................................................................................................ 45 Display Module........................................................................................................................................................................................................... 46 Platform Controls........................................................................................................................................................................................................ 50 1-1 Circuit Boards.................................................................................................................................................................................................. 51 1-2 Membrane Decal .................................................................................................................................................................................................. 52 1-3 Joysticks....................................................................................................................................................................................................... 53 Platform Components ..................................................................................................................................................................................................... 60 2-1 Platform........................................................................................................................................................................................................ 60 2-2 Platform Leveling Cylinder...................................................................................................................................................................................... 60 2-3 Platform Rotator................................................................................................................................................................................................ 62 2-4 Platform Level Sensor........................................................................................................................................................................................... 65 2-5 Platform Overload System........................................................................................................................................................................................ 66 2-6 Platform Overload Recovery Message (software V3.14 and later)................................................................................................................................................... 69 Jib Boom Components, S-105 / S-125 Models................................................................................................................................................................................ 70 3-1 Jib Boom,S-105 and S-125 Models................................................................................................................................................................................. 70 3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models.................................................................................................................................................................. 72 Boom Components ......................................................................................................................................................................................................... 73 4-1 Cable Track..................................................................................................................................................................................................... 74 4-2 Boom............................................................................................................................................................................................................ 77 4-3 Boom Lift Cylinder.............................................................................................................................................................................................. 88 4-4 Extension Cylinders............................................................................................................................................................................................. 90 4-5 Boom Extend/Retract Cables...................................................................................................................................................................................... 94 Turntable Covers......................................................................................................................................................................................................... 98 5-1 Turntable Covers................................................................................................................................................................................................ 98 Engines..................................................................................................................................................................................................................100 6-1 RPM Adjustment..................................................................................................................................................................................................100 6-2 Flex Plate......................................................................................................................................................................................................100 6-3 Oil Pressure and Coolant Temperature Sending Units - Cummins and Perkins Models.................................................................................................................................102 6-4 Oil Pressure and Temperature Sending Units - Deutz Models.......................................................................................................................................................102 Ground Controls..........................................................................................................................................................................................................103 7-1 Circuit Boards..................................................................................................................................................................................................103 7-2 Membrane Decal..................................................................................................................................................................................................104 7-3 Control Relays..................................................................................................................................................................................................105 Limit Switches ..........................................................................................................................................................................................................108 8-1 Limit Switches..................................................................................................................................................................................................108 8-2 Limit Switch and Level Sensor Locations.........................................................................................................................................................................111 8-3 Limit Switch Functions..........................................................................................................................................................................................112 Hydraulic Pumps..........................................................................................................................................................................................................115 9-1 Function Pumps..................................................................................................................................................................................................115 9-2 Drive Pump......................................................................................................................................................................................................116 9-3 Auxiliary Pump..................................................................................................................................................................................................119 Manifolds................................................................................................................................................................................................................121 10-1 Function Manifold Components, S-100 and S-105 Models (to serial number 136)....................................................................................................................................121 10-2 Function Manifold Components, S-100 and S-105 Models (from serial number 137)..................................................................................................................................125 10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models..................................................................................................................................................129 10-4 Proportional Valves - Function Manifold........................................................................................................................................................................130 10-5 Function Manifold Components, S-120 and S-125 Models (to serial number 430)....................................................................................................................................131 10-6 Function Manifold Components, S-120 and S-125 Models (from serial number 431 to 574)...........................................................................................................................135 10-7 Function Manifold Components, S-120 and S-125 Models (from serial number 575)..................................................................................................................................139 10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models..................................................................................................................................................143 10-9 Proportional Valves - Function Manifold........................................................................................................................................................................144 10-10 Platform Manifold Components, S-100 and S-120 Models..........................................................................................................................................................145 10-11 Platform Manifold Components, S-105 and S-125 Models..........................................................................................................................................................147 10-12 Proportional Valves -Platform Manifold........................................................................................................................................................................149 10-13 Platform Rotate Counterbalance Valve Manifold Components......................................................................................................................................................149 10-14 Turntable Rotation Manifold Components........................................................................................................................................................................150 10-15 Steer and Axle Extend/Retract Manifold Components - View 1....................................................................................................................................................151 10-16 Steer and Axle Extend/Retract Manifold Components - View 2....................................................................................................................................................153 10-17 Valve Adjustments - Steer andAxle Extend/Retract Manifold.....................................................................................................................................................157 10-18 Traction Manifold Components (S-100/105- to serial number 290) (S-120/125- to serial number 1194).............................................................................................................159 10-19 Traction Manifold Components (S-100/105- from serial number 291) (S-120/125- from serial number 1195).........................................................................................................163 10-20 Valve Adjustments -Traction Manifold..........................................................................................................................................................................167 10-21 Valve Coils...................................................................................................................................................................................................167 Fuel and Hydraulic Tanks.................................................................................................................................................................................................170 11-1 Fuel Tank......................................................................................................................................................................................................170 11-2 Hydraulic Tank.................................................................................................................................................................................................171 Turntable Rotation Components............................................................................................................................................................................................173 12-1 Turntable Rotation Hydraulic Motor and Drive Hub...............................................................................................................................................................173 Axle Components..........................................................................................................................................................................................................177 13-1 Steer Sensors..................................................................................................................................................................................................177 13-2 Yoke and Hub...................................................................................................................................................................................................179 13-3 Drive Motor....................................................................................................................................................................................................181 13-4 Drive Hub......................................................................................................................................................................................................182 13-5 Steering Cylinders.............................................................................................................................................................................................183 13-6 Extendable Axles...............................................................................................................................................................................................184 Diagnostic Codes ............................................................................................................................................................................................................187 Introduction ............................................................................................................................................................................................................187 Diagnostic Code Chart ...................................................................................................................................................................................................189 Control System Fault Codes ..............................................................................................................................................................................................195 Deutz TD 2.9 L4 Engine Fault Codes ......................................................................................................................................................................................199 Perkins 854F-34T Engine Fault Code ......................................................................................................................................................................................214 Software.................................................................................................................................................................................................................223 Schematics ..................................................................................................................................................................................................................225 Introduction ............................................................................................................................................................................................................225 Legends..................................................................................................................................................................................................................226 Circuit numbering....................................................................................................................................................................................................226 Wire Coloring........................................................................................................................................................................................................228 Limit Switches.......................................................................................................................................................................................................232 Relay Layout.........................................................................................................................................................................................................234 Drive Chassis Controller Pin Legend..................................................................................................................................................................................235 Platform Controller Pin Legend.......................................................................................................................................................................................236 Turntable Controller Pin Legend......................................................................................................................................................................................237 Engine Relay and Fuse Panel Legend - Deutz TD2011 and Perkins 1104D Models...........................................................................................................................................238 Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models..............................................................................................................................................................239 Engine Relay and Fuse Panel Legend - Perkins 854F Models.............................................................................................................................................................240 Telematics Connector Pin Legend......................................................................................................................................................................................241 Electrical Symbols Legend............................................................................................................................................................................................242 Hydraulic Symbols Legend.............................................................................................................................................................................................243 Electrical Schematics....................................................................................................................................................................................................245 Safety Circuit Schematic.............................................................................................................................................................................................245 Engine Options - Perkins (S-100 from 1001 to 1381, S-105 from 983 to 1355 S-120 from 1012 to 1398, S-125 from 984 to 1333)...........................................................................................248 Engine Options - Perkins (S-100 from 1382 to 1673, S-105 from 1356 to 1714, S-120 from 1399 to 1705, S-125 from 1334 to 1715)........................................................................................249 Engine Options - Perkins (S-100 from 1674, S-105 from 1715, S-120 from 1706, S-125 from 1716)........................................................................................................................252 Relay Layout - Perkins (S-100 from 1001, S-105 from 983, S-120 from 1012, S-125 from 984)...........................................................................................................................254 Engine Options - Cummins (S-100 from 1001 to 1381, S-105 from 983 to 1355, S-120 from 1012 to 1398, S-125 from 984 to 1333)..........................................................................................255 Engine Options - Cummins (S-100 from 1382 to 1673, S-105 from 1356 to 1714, S-120 from 1399 to 1705, S-125 from 1334 to 1715) .......................................................................................258 Engine Option - Cummins (S-100 from 1674, S-105 from 1715, S-120 from 1706, S-125 from 1716).........................................................................................................................260 Electrical Schematic - Generator Options.............................................................................................................................................................................262 Electrical Schematic - 12 kW Generator (welder option)..............................................................................................................................................................263 Perkins 1104D-44T Engine Electrical Schematic........................................................................................................................................................................265 Perkins 854F-34T Engine Electrical Schematic.........................................................................................................................................................................268 Perkins 854F-34T Engine Electrical Harness...........................................................................................................................................................................269 Deutz TD2011L04i Engine Electrical Schematic.........................................................................................................................................................................272 Deutz TD2.9 Engine Electrical Schematic..............................................................................................................................................................................274 Deutz TD2.9 Engine Electrical Harness................................................................................................................................................................................275 Hydraulic Schematics.....................................................................................................................................................................................................275 Hydraulic Schematic - 12 kW Generator (welder option)...............................................................................................................................................................277 Hydraulic Schematic, S-100 • S-105 Models (serial number 136).......................................................................................................................................................280 Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290).............................................................................................................................281 Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738).............................................................................................................................284 Hydraulic Schematic, S-100 • S-105 Models (from serial number 739)..................................................................................................................................................285 Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430).............................................................................................................................288 Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194)............................................................................................................................289 Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634)...........................................................................................................................292 Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to serial number 3145)...........................................................................................................................293 Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921)..................................................................................................................................296 Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922)..........................................................................................................................................297 Large Electrical Schematics.............................................................................................................................................................................................. 0 Electrical Schematic with Deutz Engine Option (S-100 from S10015D-1001 to S10016D-1381, S-105 from S10515D-983 to S10516D-1355, S-120 from S12015D-1012 to S12016D-1398, S125 from S12515D-984 to S12516D-1333)......299 Electrical Schematic with Deutz Engine Option (S-100 from S10016D-1382 to S10016D-1673, S-105 from S10516D-1356 to S10516D-1714, S-120 from S12016D-1399 to S12016D-1705, S125 from S12516D-1334 to S12516D-1715)....300 Electrical Schematic with Deutz Engine Option (S-100 from S10016D-1674, S-105 from 10516D-1715, S-120 from S12016D-1706, S125 from S12516D-1716).....................................................................301 Back Cover ..................................................................................................................................................................................................................302
S.S 05/24
