Genie S-100, Service And Repair Manual

Page 1: ...S 12015D 1012 to S 12016D 1549 from S 12515D 984 to S 12516D 1549 Service and Repair Manual This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures Refer to the appropriate Maintenance Manual for your machine from S 100D 1550 from S 105D 1550 from S 120D 1550 from S 125D 1550 ...

Page 2: ...by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Copyright 2015 by Terex Corporation 1268494 Rev A4 March 2017 First Edition Fifth Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries Introduction Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible ...

Page 3: ...016 Add Deutz TD201104i Engine Electrical schematics A2 9 2016 Introduction Serial Number Legend A3 2 2017 Specifications Performance Specifications A4 3 2017 Repair Procedures Update illustration for cable adjustment Reference Examples Section Repair Procedure Section Fault Codes Section Schematics Legends and schematics Introduction Introduction ...

Page 4: ...l year Electrical schematic number Manufacture date Machine unladen weight Rated work load including occupants Maximum number of platform occupants Maximum allowable side force Maximum allowable inclination of the chassis S12016D 12345 1 2 16 2016 S120 16 D 12345 1 2 3 4 5 6 To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label located under cover 6 Serial number ...

Page 5: ...dentified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate t...

Page 6: ...d These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of t...

Page 7: ...ions 2 8 Deutz Engine F4L 913 Specifications 2 11 Deutz Engine BF4L 2011 Specifications 2 12 Deutz Engine TD2011L04i Specifications 2 13 Deutz Engine TD 2 9 Specifications 2 14 Perkins Engine 1104D 44T Specifications 2 15 Perkins Engine 854F 34T Specifications 2 16 Perkins Engine 1004 42 Specifications 2 18 Perkins Engine 1104C 44 Specifications 2 19 Perkins Engine 804D 33T Specifications 2 20 Cum...

Page 8: ...inder 3 16 2 3 Platform Rotator 3 18 2 4 Platform Level Sensor 3 21 2 5 Platform Overload System 3 22 2 6 Platform Overload Recovery Message Software V3 14 and later 3 25 Jib Boom Components S 105 and S 125 Models 3 1 Jib Boom S 105 and S 125 Models 3 26 3 2 Jib Boom Lift Cylinder S 105 and S 125 Models 3 28 Boom Components 4 1 Cable Track 3 30 4 2 Boom 3 33 4 3 Boom Lift Cylinder 3 44 4 4 Extensi...

Page 9: ... 3 59 7 2 Membrane Decal 3 60 7 3 Control Relays 3 61 Limit Switches 8 1 Limit Switches 3 64 8 2 Limit Switch and Level Sensor Locations 3 67 8 3 Limit Switch Functions 3 68 Hydraulic Pumps 9 1 Function Pumps 3 71 9 2 Drive Pump 3 72 9 3 Auxiliary Pump 3 75 Manifolds 10 1 Function Manifold Components S 100 and S 105 Models serial number 136 3 77 10 2 Function Manifold Components S 100 and S 105 Mo...

Page 10: ...20 Models 3 101 10 11Platform Manifold Components S 105 and S 125 Models 3 103 10 12Proportional Valves Platform Manifolds 3 105 10 13Platform Rotate Counterbalance Valve Manifold Components 3 105 10 14Turntable Rotation Manifold Components 3 106 10 15Steer and Axle Extend Retract Manifold Components View 1 3 107 10 16Steer and Axle Extend Retract Manifold Components View 2 3 109 10 17Valve Adjust...

Page 11: ... Turntable Rotation Hydraulic Motor and Drive Hub 3 129 Axle Components 13 1 Steer Sensors 3 133 13 2 Yoke and Hub 3 135 13 3 Drive Motor 3 137 13 4 Drive Hub 3 138 13 5 Steering Cylinders 3 139 13 6 Extendable Axles 3 140 Section 4 Diagnostic Codes Introduction 4 1 Diagnostic Code Chart 4 3 Control System Fault Codes 4 9 Deutz TD 2 9 L4 Engine Fault Codes 4 13 Perkins 854F 34T Engine Fault Code 4...

Page 12: ...Fuse Panel Legend Deutz TD2011 and Perkins 1104D Models 5 14 Engine Relay and Fuse Panel Legend Deutz TD2 9 Models 5 15 Engine Relay and Fuse Panel Legend Perkins 854F Models 5 16 Telematics Connector Pin Legend 5 17 Electrical Symbols Legend 5 18 Hydraulic Symbols Legend 5 19 Safety Circuit Schematic 5 21 Engine Options Perkins and Cummins S 100 105 before serial number 219 S 120 125 before seria...

Page 13: ...rial number 985 5 33 Electrical Schematic Generator Options 5 35 Electrical Schematic 12 kW Generator welder option 5 37 Electrical Schematic ES105C ES125G S 100 105 before serial number 231 S 120 125 before serial number 921 located at end of manual Electrical Schematic ES0427 S 100 105 from serial number 231 to 809 S 120 125 from serial number 921 to 2709 located at end of manual Electrical Sche...

Page 14: ...105 from serial number 291 to serial number 738 5 55 Hydraulic Schematic S 100 S 105 from serial number 739 5 57 Hydraulic Schematic S 120 S 125 from serial number 404 to serial number 430 5 59 Hydraulic Schematic S 120 S 125 from serial number 431 to serial number 1194 5 61 Hydraulic Schematic S 120 S 125 from serial number 1195 to serial number 2634 5 63 Hydraulic Schematic S 120 S 125 from seri...

Page 15: ...g 66 in 66 in axles retracted 168 cm 168 cm Turntable tailswing 48 in 48 in axles extended 122 cm 122 cm Wheelbase 12 ft 12 ft 366 cm 366 cm Turning radius outside 22 ft 2 in 22 ft 2 in axles retracted 6 75 m 6 75 m Turning radius inside 13 ft 2 in 13 ft 2 in axles retracted 4 01 m 4 01 m Turning radius outside 18 ft 10 in 18 ft 10 in axles extended 5 74 m 5 74 m Turning radius inside 8 ft 6 in 8 ...

Page 16: ...1 2 to 1 8 m Gradeability boom stowed See Operators Manual Boom function speeds maximum from platform controls Jib boom up S 125 models 28 to 32 seconds Jib boom down S 125 models 28 to 32 seconds Boom up Boom fully retracted 80 to 88 seconds Boom extended to 4 ft 1 2 m 100 to 110 seconds time between fully lowered and a fully raised position Boom extended to 80 ft 24 4 m 50 to 55 seconds time bet...

Page 17: ...rive enable to drive enable Platform rotate 160 18 to 22 seconds Machine Specifications S 100 and S 105 Models Stowed dimensions S 100 S 105 Length transport position 39 ft 11 in 39 ft 11 in 12 17 m 12 17 m Length stowed 42 ft 8 in 46 ft 13 m 14 m Width axles retracted 8 ft 2 in 8 ft 2 in 249 cm 249 cm Width axles extended 11 ft 11 ft 335 cm 335 cm Height stowed maximum 10 ft 1 in 10 ft 1 in 308 c...

Page 18: ...N385 65D22 5 FF Tire ply rating 18 Tire weight new foam filled minimum 622 lbs 282 kg Overall tire diameter 43 1 in 109 5 cm Wheel diameter 22 5 in 57 cm Wheel width 11 75 in 30 cm Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 570 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Fluid capacities Hydraulic tank 55 gallons 208 liters Hydraulic system 80 gallons including tank 303 liters Fuel tank...

Page 19: ...racted 80 to 88 seconds Boom extended to 4 ft 1 2 m 100 to 110 seconds time between fully raised and a fully lowered position Boom extended to 80 ft 24 4 m 50 to 55 seconds time between fully raised and the 50 envelope limit Boom extend boom fully raised 0 to 100 ft 0 to 30 5 m 120 to 140 seconds Boom retract boom fully raised 100 ft to 0 30 5 m to 0 120 to 140 seconds Turntable rotate 360 boom ho...

Page 20: ...pment and special installation instructions for the approved optional fluids Consult the Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range if the hydraulic fluid temperature consistently exceeds 200 F 90...

Page 21: ...y below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C 5 5 cSt 104 F 40 C 15 0 cSt 40 F 40 C 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A ...

Page 22: ...21 7 bar Function pump Type variable displacement piston pump Front Section Displacement 0 to 1 71 cu in 0 to 28 cc Flow rate 2350 rpm maximum 17 4 gpm 65 9 L min Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature SPE...

Page 23: ...re 3000 psi measured at test port 2 207 bar Jib and platform manifolds Platform rotate and platform level 0 3 gpm flow regulator 1 14 L min Jib manifold flow regulator 2 gpm 7 6 L min Steer Axle manifold Axle extend relief pressure 1800 psi 124 bar Drive manifold Hot oil relief pressure S 100 105 before serial number 291 250 psi S 120 125 before serial number 1195 17 2 bar Hot oil relief pressure ...

Page 24: ...draulic filters High pressure filter Beta 3 200 High pressure filter 102 psi bypass pressure 7 bar Medium pressure filter Beta 3 200 Medium pressure filter 25 psi bypass pressure 1 7 bar Hydraulic tank 10 micron with return filter 25 psi 1 7 bar bypass Drive motor case drain Beta 10 2 return filter ...

Page 25: ...te 300 minutes Deutz Engine F4L 913 Displacement 249 3 cu in 4 086 liters Number of cylinders 4 Bore and stroke 4 02 x 4 92 inches 102 x 125 mm Horsepower 77 2200 rpm Firing order 1 3 4 2 Compression ratio 18 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle rpm 1300 rpm Frequency 385 7 Hz High idle rpm 2350 rpm Frequency 570 4 H...

Page 26: ...Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Torque 8 18 ft lbs 11 24 Nm Oil temperature switch point 275 F 135 C Oil pressure switch Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 7 psi 0 48 bar Fuel injection system Injection pump make Bo...

Page 27: ...W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil pressure switch Installation torque 8 18 ft lbs 11 ...

Page 28: ...ove 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 22 psi 1 5 bar Fuel in...

Page 29: ...30 C 5W 20 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 8 psi 0 55 bar Oil Sensor Settings 0 psi 10 ohms 50 psi 120 ohms...

Page 30: ...net intermittent 2500 rpm 74 hp 55 2 KW Induction system turbocharged Firing order 1 3 4 2 Standby speed 1000 rpm Low idle 1500 rpm High idle 2500 rpm Compression ratio 17 0 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Governor Electronic Lubrication system Oil pressure hot 2000 rpm 40 to 60psi 2 8 to 4 1bar Minimum oil pressure 12ps...

Page 31: ...load 10 sec 40A Starter motor Current draw normal load 68 A Cranking speed 130 200 rpm Battery Auxiliary power units Type 6V DC Quantity 2 Battery capacity maximum 285AH Reserve capacity 25A rate 745 Minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Battery capacity maximum 1000A Reserve capacity 25A rate 200 Minutes Perkins 854F 34T cont Engine coolant Capacity 16...

Page 32: ... Engine capacity 9 5 quarts 9 liters System capacity 20 quarts 18 9 liters Perkins Engine 1004 42 Displacement 258 cu in 4 23 liters Number of cylinders 4 Bore stroke 4 06 x 5 inches 103 1 x 127 mm Horsepower 81 2200 rpm Firing order 1 3 4 2 Compression ratio 18 5 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle rpm 1300 rpm Fre...

Page 33: ...least 75 of the highest cylinder Governor centrifugal mechanical Valve clearance cold Intake 0 008 in 0 2 mm Exhaust 0 018 in 0 45 mm Lubrication system Oil pressure hot 40 to 60psi at 2000 rpm 2 8 to 4 1bar Oil capacity 7 3 quarts including filter 6 9 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requi...

Page 34: ... clearance cold Intake 0 0098 in 0 25 mm Exhaust 0 0098 in 0 25 mm Lubrication system Oil pressure hot 40 to 60psi at 2000 rpm 2 8 to 4 1bar Oil capacity 10 6 quarts including filter 10 liters SPECIFICATIONS Battery Engine starting Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 175 minutes Battery Control system Type 12V DC Group 4D Quantity 1 Cold cranking amper...

Page 35: ... make Bosch Injector opening pressure 2200 psi 152 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Battery Auxiliary power units Type 6V DC Quantity 2 AH rating 285AH Reserve capacity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Starte...

Page 36: ... Below 68 F 20 C 5W 30 10 to 68 F 23 to 20 C 10W 30 Above 14 F 10 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Fuel injection system Injection pump make Zexel Injection pressure 12 000 psi 827 bar Fuel requirement For fuel requirements refer to the engine Oper...

Page 37: ...8 quarts 8 3 liters System capacity 20 quarts 18 9 liters Cummins B3 9L Engine Displacement 238 cu in 3 9 liters Number of cylinders 4 Bore and stroke 4 02 x 4 72 inches 102 x 120 mm Horsepower 75 2200 rpm Firing order 1 3 4 2 Compression ratio 16 5 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle rpm 1300 rpm Frequency 368 3 Hz...

Page 38: ... operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Fuel injection system Injection pump make Delphi Injection pump pressure 3480 to 3680 psi 240 to 254 bar Injector opening pressure 3480 psi 240 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Battery Engine...

Page 39: ...bricated 280 ft lbs use blue thread locking compound 380 Nm Rotate drive motor mounting bolts dry 110 ft lbs 149 Nm Rotate drive motor mounting bolts lubricated 80 ft lbs 108 Nm Drive motor and hubs Drive hub mounting bolts dry 269 ft lbs 365 Nm Drive hub mounting bolts lubricated 202 ft lbs 274 Nm Drive motor mounting bolts dry 110 ft lbs 149 Nm Drive motor mounting bolts lubricated 80 ft lbs 108...

Page 40: ...e 4 ORFS 37 Adj 15 ft lbs 20 3 Nm ORFS Non Adj 26 ft lbs 35 3 Nm 37 Non Adj 22 ft lbs 30 Nm 6 ORFS Adj Non adj 35 ft lbs 47 5 Nm 37 Adj Non adj 29 ft lbs 39 3 Nm 8 ORFS Adj Non adj 60 ft lbs 81 3 Nm 37 Adj Non adj 52 ft lbs 70 5 Nm 10 ORFS 37 Adj 100 ft lbs 135 6 Nm 37 Non Adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All t...

Page 41: ...seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks JIC 37 fittings 1 Align the tube flare hex nut a...

Page 42: ...correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 a body hex fitting b reference mark c second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body h...

Page 43: ...670 3620 3560 4826 3000 4067 LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Black Oxide Bolts Grade 8 1 1 8 1 1 4 LUBED 1 4 LUBED DRY LUBED DRY 5 16 3 8 7 16 1 2 1 1 2 9 16 5 8 3 4 7 8 1 Size mm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm 5 16 1 8 21 2 ...

Page 44: ...2 30 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 2 Specifications SPECIFICATIONS This page intentionally left blank ...

Page 45: ... which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning...

Page 46: ...en press the enter button once to accept change Note If Programming mode is not exited properly all machine programming may be lost Screen or Menu Procedure Description Range or Selection Hour meter on power up Engine speed Engine oil pressure PSI English Engine oil pressure kPa metric Engine temperature F English Engine temperature C metric Primary boom angle sensor Turntable level sensor X Turnt...

Page 47: ...00 default 125 max and 25 min 100 default 100 max and 0 min 50 default With key switch off press and hold the button and turn the key switch to the on position Release the button and press 120 max and 10 min 100 default 120 max and 10 min 100 default 80 max and 10 min 80 default 80 max and 10 min 80 default 35 max and 10 min 29 default 35 max and 10 min 29 default 25 max and 10 min 20 default 25 m...

Page 48: ...d 0 min 250 0 25 sec default With key switch off press and hold the button and turn the key switch to the on position Release the button and press Reset drive valve defaults Reset boom up down valve defaults Reset boom extend retract valve defaults Reset turntable rotate valve defaults Allow boom up down speed calibration Allow turntable rotate speed calibration Reset drive joystick defaults Reset...

Page 49: ... and press Limit boom height to 100 ft 80 ft AC generator Alarm Lift drive cutouts Auxiliary drive Proximity kill switch Platform overload sensing Work lights Flashing beacon Drive lights Disable steer mode change while driving Rocker joystick steering Generator off delay 0 10 sec 100 ft 80 ft none belt hyd no motion travel descent travel and descent 0 1 2 3 4 5 no drive cutout while not stowed li...

Page 50: ...le controls The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment The operating parameters of the joysticks are stored in memory at the turntable controls If a joystick controller error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 3 How to Calibrate a Joystick Contro...

Page 51: ...n at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 1 1 Circuit Boards Note When an ECM circuit board is replaced the joystick controllers will need to be calibrated See 1 3 How to Calibrate a Joystick Controller How to Remove the ECM Circuit Board 1 Push in the Emergency Stop button to the off position at both the ground an...

Page 52: ...ane Decal How to Replace the Membrane Decal The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside The membrane contains touch sensitive areas that when pushed activates the machine functions The membrane buttons activate machine functions similar to toggle switches but do not have any moving parts 1 Push in the Emergency Stop button to the off p...

Page 53: ...e ribbon cables from the membrane decal to the membrane circuit board 1 3 Joysticks How to Calibrate a Joystick The joystick controllers on this machine utilize digital Hall Effect technology for proportional control If a joystick controller is disconnected or replaced it must be calibrated before that particular machine function will operate Note The joystick must be calibrated before the thresho...

Page 54: ... the ground controls should sound for a successful calibration Result If the alarm does not sound repeat the calibration procedure beginning with step 1 Drive functions Note If the calibration fault is already displayed at the ground box begin with step 6 1 Turn the key switch to the off position Confirm the red Emergency Stop button at the platform and ground controls is in the on position 2 Pres...

Page 55: ...ground controls should sound for a successful calibration Result If the alarm does not sound repeat the calibration procedure beginning with step 1 PLATFORM CONTROLS REV B Primary boom up down functions Note If the calibration fault is already displayed at the ground box begin with step 6 1 Turn the key switch to the off position Confirm the red Emergency Stop button at the platform and ground con...

Page 56: ...d for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat the calibration procedure beginning with step 1 How to Reset a Proportional Valve Coil Default Note Use this procedure for any software version other than 2 00 For software version 2 00 refer to the following proce...

Page 57: ...et the joystick controller threshold 6 Slowly move the joystick off center in the opposite direction just until the machine function starts to move then move the joystick very slowly towards the neutral or center position just before the machine function stops Do not let go of the joystick PLATFORM CONTROLS REV B How to Reset a Proportional Valve Coil Default software version 2 00 Note Software ve...

Page 58: ...tings in memory Note The red Emergency Stop button at the platform controls must be pushed in to the off position following calibration of the joystick controllers to save the settings in memory 16 At the ground controls turn the key switch to the off position wait a moment and then turn the key switch to platform controls 17 Check the display at the ground controls to be sure there are no calibra...

Page 59: ...Continue to perform this procedure until the machine function speed meets specification Refer to Specifications for function speeds How to Adjust the Function Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for h...

Page 60: ...y supported 2 2 Platform Leveling Cylinder The platform leveling cylinder keeps the platform level through the entire range of boom motion The platform is maintained level to the turntable The ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable level sensor The ECM at the ground controls sends a signal to the platform controls to open ...

Page 61: ...e the external snap ring from the barrel end pivot pin Do not remove the pin 7 Support the platform leveling cylinder with a suitable lifting device Protect the cylinder rod from damage 8 Use a soft metal drift to remove the rod end pivot pin Crushing hazard The platform S 100 and S 120 models or jib boom S 105 and S 125 models will fall when the platform leveling cylinder rod end pivot pin is rem...

Page 62: ...he Platform Rotator Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the wa...

Page 63: ...cally charged circuits could result in death or serious injury Remove all rings watches and other jewelry PLATFORM COMPONENTS 8 Support the platform mounting weldment but do not apply any lifting pressure 9 Remove the eight mounting bolts from the platform mounting weldment 10 Remove the center bolt and slide the platform mounting weldment off of the platform rotator Crushing hazard The platform m...

Page 64: ...f the damage is not visible How to Bleed the Platform Rotator Note Do not start the engine Use auxiliary power for all machine functions in this procedure S 105 Before serial number 251 and S 125 models Before serial number 999 1 At the ground controls simultaneously hold the auxiliary power button and the platform rotate right button until the platform is fully rotated to the right PLATFORM COMPO...

Page 65: ...ft until air is completely out of the rotator Bleeding the valve is not necessary PLATFORM COMPONENTS 2 4 Platform Level Sensor The platform level sensor is mounted to the side of the platform rotator The platform level sensor is monitored by the control system to maintain a level platform throughout boom range of motion If a platform level sensor is replaced it must be calibrated prior to machine...

Page 66: ...normal safe operation of the machine How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this proc...

Page 67: ...the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to s...

Page 68: ...so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Proceed to step 8 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding ...

Page 69: ...latform 2 Press and hold the enter button on the ground sontrol panel while turning the key switch to ground controls Hold the enter button for approximately 5 seconds Plus Minus Previous Enter 3 Press the buttons on the ground controls in the following sequence plus minus minus plus 4 Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed 5 Press the plus ...

Page 70: ...Support the jib boom with a suitable lifting device 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Support the barrel end of the cylinder with a ...

Page 71: ...bellcrank 17 Support the rod end of the platform leveling cylinder with a suitable lifting device Protect the cylinder rod from damage 18 Remove the pin retaining fastener from the platform leveling cylinder rod end pivot pin 19 Use a soft metal drift to remove the platform leveling cylinder rod end pivot pin Crushing hazard The platform leveling cylinder may fall if it is not properly supported w...

Page 72: ... penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the hose and cable cover retaining fasteners from the jib boom leveling arm Remove the hose and cable cover from the machine 4 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 5 Use ...

Page 73: ...3 29 March 2017 Section 3 Repair Procedures Boom Components a Number 0 b Number 1 c Number 2 d Number 3 a Number 1 b Number 2 c Number 3 a b c d Platform end Pivot end a b c Platform end Pivot end S 120 and S 125 Models S 100 and S 105 Models ...

Page 74: ...equipped with an airline to platform option and or weld cable option the airline and or cable must be disconnected from the platform before the cable track is removed 4 Tag and disconnect the black electrical connector from the bottom of the control box 5 Remove the platform end boom cable tube mounting fasteners at the engine side of the machine 6 Remove the cable track mounting fasteners from th...

Page 75: ...d next to the hose fittings that were removed in step 16 If not removing the boom from the machine proceed to step 19 18 Tag disconnect and plug the primary extension cylinder hydraulic hoses on the side of the number 2 boom tube at the ground controls side of the machine Cap the fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slow...

Page 76: ...Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Component damage hazard Cable tracks can be damaged if they are twisted 28 Attach a lifting strap from an overhead crane to each end of the cable track assembly Carefully lift the assembly from the boom and set it on a structure capable of supporting it Crushing hazard If the cable track assemblies are not proper...

Page 77: ...ot pins are installed from the inside out so the external snap rings are on the outside of the cable track 8 Install the cable track snap on spacers 4 2 Boom How to Shim the Boom 1 Measure each upper side and lower wear pad Boom wear pad specifications 1 2 inch Minimum thickness 12 7 mm Note If a wear pad is not less than specification perform the following procedure 2 Remove the retaining fastene...

Page 78: ...ing strap from an overhead crane to the rod end of the boom lift cylinder 7 Attach an overhead 10 ton 10 000 kg crane to the platform end of the boom for support Do not lift the boom 8 Remove the boom storage area cover retaining fasteners Remove the cover from the machine 9 Place support blocks under the boom lift cylinder 10 Remove the pin retaining fastener from the boom lift cylinder rod end p...

Page 79: ...e turntable riser when removing the boom assembly The boom envelope switch s can be damaged even if the damage is not visible 21 Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it Crushing hazard The boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead cranes BOOM COMPONENTS How...

Page 80: ...that the side of the pulley with the taller flange is facing the center of the boom tube 11 Locate the number 3 boom tube extension cable clevis pins on both sides of the number 2 boom tube at the pivot end of the boom 12 Remove the cotter pin and clevis pin from both cables Note When installing a clevis pin always replace the cotter pin with a new one 13 Remove the lower external snap ring and wa...

Page 81: ...rting it Crushing hazard The primary boom extension cylinder may become unbalanced and fall when it is removed from the boom if it is not properly supported and attached to the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched Note During removal the overhead crane strap will need to be adjusted for proper balancing 25 Remove the retaining fasteners from th...

Page 82: ... 2 boom tube at the platform end of the boom Do not remove the bottom wear pads Note Pay careful attention to the location and amount of shims used with each wear pad BOOM COMPONENTS 34 Attach a lifting strap from an overhead crane to the number 3 boom tube at the platform end of the boom 35 Support and slide the number 3 boom tube out of the number 2 boom tube When the number 3 boom tube is appro...

Page 83: ... Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 42 Support the secondary boom extension cylinder with an overhead crane or other suitable lifting device 43 Remove the pin retaining fasteners from both the rod end and...

Page 84: ...ed and fall when it is removed from the number 0 boom tube if it is not properly supported and attached to the overhead crane Note During removal the overhead crane strap will need to be adjusted for proper balancing BOOM COMPONENTS How to Disassemble the Boom S 100 and S 105 Models Note Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The primar...

Page 85: ...clevis pin from both cables Note When installing a clevis pin always replace the cotter pin with a new one 11 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin 12 Remove the cable break actuator mounting plate retaining fasteners Remove the lower plate from the machine 13 Remove the upper plate and actuator pivot pin Do not remove the cable break l...

Page 86: ...s from the top of the number 2 boom tube at the platform end of the boom Tip over hazard Failure to install the correct proximity and or limit switches in the correct location will result in the machine tipping over resulting in death or serious injury 25 Tag and disconnect the wiring connectors from the proximity and limit switches at the top of the number 2 boom tube at the platform end of the b...

Page 87: ...pported and attached to the overhead crane Note During removal the overhead crane strap will need to be adjusted for proper balancing 34 Remove and label the top and side wear pads from the number 2 boom tube at the pivot end of the boom Do not remove the bottom wear pads Note Pay careful attention to the location and amount of shims used with each wear pad 35 Remove and label the top and side wea...

Page 88: ...boom storage area cover retaining fasteners Remove the cover from the machine 5 Place support blocks under the boom lift cylinder 6 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Protect the cylinder rod from damage Crushing hazard The boom lift cylinder may fall when the rod end pivot pin is removed if the boom lift cylinde...

Page 89: ...engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 12 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 13 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving Crushing hazard Failure to install the...

Page 90: ...d Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position 2 Remove the retaining fasteners from the boom end cover at the pivot end of the boom Remove the cover from the machine BOOM...

Page 91: ...pivot end of the boom 13 Remove the cotter pin and clevis pin from both cables Note When installing a clevis pin always replace the cotter pin with a new one 14 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin 15 Remove the cable break actuator mounting plate retaining fasteners Remove the lower plate 16 Remove the upper plate and actuator pivot p...

Page 92: ...extend cylinder covers are properly installed Operating the machine with the covers removed could result in death or serious injury BOOM COMPONENTS 19 Remove the two cable adjustment bolts 20 Remove the cable end block mounting plate fasteners Remove the cable end block mounting plate 21 Remove the trunnion pin retaining fasteners 22 Use a slide hammer to remove the trunnion pins from the primary ...

Page 93: ...e lifing device 5 Remove the pin retaining fasteners from both the rod end and barrel end pivot pins Do not remove the pins 6 Protect the boom lift cylinder rod from damage 7 Use a soft metal drift to remove both pivot pins 8 Remove the secondary boom extension cylinder from the machine while guiding the barrel end of the cylinder out of the boom Crushing hazard The secondary boom extension cylind...

Page 94: ...g bracket and remove the bracket from the machine 7 Locate the retract cable equalizer bolt under the number 1 boom tube at the platform end of the boom assembly illustration 3 8 Loosen the nylock g and jam nut h on the cable tension equalizer bracket Do not remove the nuts a limit switch b extend cable adjustment bolts c red cable adjustment locking bracket d boom tube distance Illustration 1 9 A...

Page 95: ...e number 3 boom tube and the end of the number 2 boom tube Result The measurement between the end of the number 3 boom tube and the end of the number 2 boom tube should be 63 4 to 67 8 inches 17 to 17 5 cm d e boom tube 1 f boom tube 2 g nylock nut h hex jam nut Illustration 3 14 Install the red locking bracket over the cable adjustment bolts A flat edge of each bolt head b must be on top for the ...

Page 96: ...ure before installing the extend cables through the boom adjustment coupling that the tall end of the cable anchors are facing down 7 Install the new boom extend cable pulley pivot pin and snap rings Note Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cylinder 8 Install the boom extend cables to the lower extend cable bracket tha...

Page 97: ...ct cables at the pivot end of the boom 11 At the platform end of the boom pull on the boom retract cable that has the rope attached to it 12 Pull the old cable completely out of the boom tube Discard the old boom retract cable 13 Remove the rope from the old cable and securely attach the rope to the same end of the new boom retract cable 14 At the pivot end of the boom carefully pull the rope with...

Page 98: ...t pivot sockets off of the ball studs and remove the strut Protect the strut cylinder rod from damage Crushing hazard The turntable cover will fall when the gas struts are removed if it is not properly supported Turntable Covers 4 Mark the location of the hinges on the bulkhead to ensure proper cover alignment during installation 5 Remove the cover hinge to bulkhead retaining fasteners 6 Carefully...

Page 99: ...ounting fasteners 4 Carefully remove the cover from the machine Crushing hazard The turntable cover may become unbalanced and fall when it is removed from the machine if it is not properly supported Bodily injury hazard Safety decals are essential to safe machine operation Failure to replace all safety and instructional decals could result in death or serious injury If a turntable cover must be re...

Page 100: ...rive pump 2 Remove the hose clamp from the air cleaner hose at the air cleaner Carefully disconnect the hose from the air cleaner 3 Remove the air cleaner mounting fasteners Remove the air cleaner from the machine 4 Remove the fuel filter water separator retaining fasteners from the pump mounting plate Do not disconnect the fuel hoses 5 Remove the fuel filter water separator and lay it to the side...

Page 101: ...ins engines before serial number 1029 and Deutz 913 engines Torque the set screw to 20 ft lbs 27 Nm Perkins and Cummins engines after serial number 1028 and Deutz 2011 engines Torque the set screw to 61 ft lbs 83 Nm 5 Install the bell housing mounting plate assembly Apply Loctite removable thread sealant to the mounting fasteners Then torque the pump retaining fasteners to Cummins Perkins and Deut...

Page 102: ...ure screen Component damage hazard Do not crank the engine with a low oil pressure fault shown on the display at the ground controls 6 3 Oil Pressure and Coolant Temperature Sending Units Cummins and Perkins Models The coolant temperature sending unit is an electrical device If the coolant temperature reaches 210 F 99 C the ECM will shut the engine off to prevent damage and will not start until th...

Page 103: ...The ECM circuit board is the main circuit board for the machine There are relays on the ECM circuit board that can be replaced All operating parameters and configuration of options for the machine are stored in the ECM memory Note The ECM circuit board inside the ground control box TCON cannot be replaced by itself If the ECM circuit board is faulty and needs to be replaced contact the Genie Indus...

Page 104: ...e on the backside The membrane contains touch sensitive areas that when pushed activates the machine functions The membrane buttons activate machine functions similar to toggle switches but do not have any moving parts How to Replace the Membrane Decal 1 Turn the key switch at the ground controls to the off position 2 Push in the Emergency Stop button to the off position at both the ground and pla...

Page 105: ...9 Close the control box lid and install the retaining fasteners 7 3 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic...

Page 106: ...oil and should not be tested in any other combination Test Desired result terminal 85 to 86 85 to 95 Ω terminal 87 to 87a 30 no continuity infinite Ω terminal 87a to 30 continuity zero Ω 4 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87 to 87a no continuity infinite Ω terminal 87a to 30 no continuity infin...

Page 107: ...4ES 75 5 ft 23 m LSB4EO 100 ft 30 5 m LSB2RS 101 ft 30 8 m LSB3EO 75 ft 22 9 m LSB2RO 102 ft 31 1 m LSB3RS 3 5 ft 1 1 m LSB3RO 3 ft 0 9 m LSB4ES 75 5 ft 23 m LSB3EO 75 ft 22 9 m LSB13AO 53 LSB1DO 10 LSB7DS 11 LSB8AS 50 0 ft 0 m 10 ft 3 m 20 ft 6 1 m 30 ft 9 1 m 40 ft 12 2 m 50 ft 15 2 m 60 ft 18 3 m 70 ft 21 3 m 80 ft 24 4 m 90 ft 27 4 m 100 ft 30 5 m 110 ft 33 5 m 120 ft 36 6 m S 100 and S 105 Mo...

Page 108: ...rminal 3 to 4 no continuity infinite Ω terminal 1 to 3 and 4 no continuity infinite Ω terminal 2 to 3 and 4 no continuity infinite Ω 3 Activate the limit switch Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity terminal 1 to 2 no continuity infinite Ω terminal 3 to 4 continuity zero Ω terminal 1 to 3 ...

Page 109: ...ximity switch Proximity switch a target area a 3 Place a piece of ferrous metal steel iron etc in front of the target area so it is no more than 1 2 inch 12 7 mm away from the target area of the proximity switch 4 Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity terminal 3 to 4 continuity zero Ω 5 Mo...

Page 110: ...he switch contacts open Repeat the process until the switch contacts open between 65 and 65 5 degrees 12 Tighten the 65 degree safety switch mounting fasteners 13 Lower the boom to 52 5 degrees All models 14 S 100 and S 105 models Raise the boom to 52 5 degrees 15 Loosen the mounting fasteners from the 53 degree proximity switch LSB13AO 16 Disconnect the deutsch connector from the 53 degree proxim...

Page 111: ...edures 8 2 Limit Switch and Level Sensor Locations LIMIT SWITCHES LSB2RO LSB2RS LSB6S LSAX1ES LSAX1EO LST1O LSAX2EO LSAX2RO LSAX2ES PLATFORM LEVEL SENSOR LSB19LO TURNTABLE LEVEL SENSOR LSAX1RO LSB3RO LSB4ES LSB4EO LSB3RS LSB3EO LSB1DO LSB13AO LSB8AS LSB9AS LSB7DS LSB14AO LSB19LO ...

Page 112: ... to recover LSAX1ES Safety Limit Switch Front Axle Ex tend If this switch is tripped then the axle is not fully extended In this condition if unit is out of stowed power is cut to boom up boom extend and axle retract LSAX2ES Safety Limit Switch Rear Axle Ex tend If this switch is tripped then the axle is not fully extended In this condition if unit is out of stowed power is cut to boom up boom ext...

Page 113: ...an 65O the BO lockout valve will activate allowing hydraulic flow to the external cylinder to continue to extend to 120 feet LIMIT SWITCHES LSB6S Safety Limit Switch Cable Tension Cuts power to the extend directional valve if extend cables are out of adjustment or one breaks LSB1DO Operational Limit Switch 10O Angle This switch activates anytime the boom is raised above 10O If axles are not extend...

Page 114: ... out of the inner cylinder LSB19LO Operational Limit Switch Down Overload This switch disables all functions except boom retract and boom up and activates a medi um frequency alarm and the boom down overload diagnostic code LST1O Operational Limit Switch Drive Enable This switch is activated when the turntable is rotat ed in the standard drive zone Turntable Level Sensor Measures the X axis and Y ...

Page 115: ...nk shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Tag disconnect and plug the hydraulic hoses from the function pumps Cap the fittings on the pumps Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very ...

Page 116: ...cification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the function pumps See How to Remove the Function Pumps 2 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump 3 Close the two hydraulic tank valves located at the hydraulic tank Component damage hazard The engine must not be start...

Page 117: ...ydraulic tank shutoff valves in the closed position or component damage will occur 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to one of the test ports located under the drive pump Cummins and Perkins models 2 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine to access the fuel injection pump a engine pivot plate anchor hole b engine pi...

Page 118: ... shutoff solenoid 6 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 250 psi 17 2 bar Bodily injury hazard Keep hands loose clothing and hair clear of all moving engine parts while the engine is cranking 7 Deutz models Connect the engine wiring harness to the fuel shutoff solenoid...

Page 119: ...gauge to the high pressure port on pump number 1 3 Turn the key switch to ground control and pull out the Emergency Stop button to the on position 4 Activate any function using auxiliary power Result If the pressure gauge reads 2500 psi 172 bar immediately stop The pump is good Result If pressure fails to reach 2500 psi 172 bar the internal relief valve setting is incorrect or the pump is bad and ...

Page 120: ...ction 3 Repair Procedures How to Remove the Auxiliary Pump 1 Open the ground controls side turntable cover 2 Tag disconnect and plug the hydraulic hoses from the pumps 3 Remove the pump mounting fasteners and remove the pump from the pump motor HYDRAULIC PUMPS ...

Page 121: ...ate left right 25 27 ft lbs 34 36 7 Nm 4 DO3 valve 3 position 4 way FD Boom up down 30 35 in lbs 3 4 Nm 5 Priority flow regulator valve 0 1 gpm 0 38 L min FE Bleeds off differential sensing valves to tank 18 20 ft lbs 24 27 Nm 6 Proportional solenoid valve FF Boom up down proportional speed control 33 37 ft lbs 44 9 50 3 Nm 7 Proportional solenoid valve FG Turntable rotate proportional speed contr...

Page 122: ...3 78 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS FQ FR FA FD FE FB FC FF FG FH FI FJ FK FL FM TP FP 14 2 3 1 15 16 17 9 10 11 12 13 5 7 8 6 4 ...

Page 123: ... Torque 11 Orifice plug 0 040 inch 1 02 mm FK Differential sensing dampening 12 Check valve FL Load sensing circuit turntable rotate 12 14 ft lbs 16 19 Nm 13 Diagnostic Nipple Testing 14 Check valve FM Load sensing circuit boom extend retract 12 14 ft lbs 16 19 Nm 15 Differential sensing valve FP Directs flow to functions 25 27ft lbs 34 37Nm 16 Solenoid valve 2 position 3 way FQ Boom retract contr...

Page 124: ...3 80 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS FQ FR FA FD FE FB FC FF FG FH FI FJ FK FL FM TP FP 14 2 3 1 15 16 17 9 10 11 12 13 5 7 8 6 4 ...

Page 125: ...n 3 way AA Auxiliary drive steer selector 25 27ft lbs 34 37Nm 5 Relief Valve 3000 psi 206 8 bar AC Platform manifold pressure limit 18 20ft lbs 24 27Nm 6 Flow Regulator Valve 3 gpm 11 36 L min AD Priority flow to platform 25 27ft lbs 34 37Nm 7 Check Valve 5 psi 0 34 bar AE Blocks flow from pump 2 to auxiliary pump 12 14 ft lbs 16 3 19 Nm 8 Proportional Solenoid Valve N C FF Primary lift proportion...

Page 126: ...105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures FQ FR FA AC FD FE AD FB FC FF FG AA AB AE FH FI FJ TP FK FL AF FM FP AG 1 22 21 17 18 19 23 16 24 11 12 13 14 15 3 4 2 8 7 9 10 5 6 20 MANIFOLDS ...

Page 127: ...Boom extend retract solenoid valve proportional speed control 33 37 ft lbs 45 50 Nm 17 Check Valve 5 psi 0 34 bar FM Extension cylinder load sense check 12 14 ft lbs 16 3 19 Nm 18 Check Valve 5 psi 0 34 bar FJ Primary lift load sense check 12 14 ft lbs 16 3 19 Nm 19 Differential Sensing Valve 110 psi 7 58 bar FP Directs flow to functions 25 27ft lbs 34 37Nm 20 Check Valve 5 psi 0 34 bar FL Extensi...

Page 128: ...105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures FQ FR FA AC FD FE AD FB FC FF FG AA AB AE FH FI FJ TP FK FL AF FM FP AG 1 22 21 17 18 19 23 16 24 11 12 13 14 15 3 4 2 8 7 9 10 5 6 20 MANIFOLDS ...

Page 129: ...essure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 to confirm the relief valve pressure How to Adjust the Boom Extend Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the test port on the function manifold 2 Start the engine from the...

Page 130: ...es 10 4 Proportional Valves Function Manifold Note When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity the proportional valve cartridge or coil will need to be calibrated See Repair Procedure How to Calibrate a Joystick MANIFOLDS ...

Page 131: ...7 Nm 4 DO3 valve 3 position 4 way BD Boom up down 30 35 in lbs 3 4 Nm 5 Priority flow regulator valve 0 1 gpm 0 38 L min BE Bleeds off differential sensing valves to tank 18 20 ft lbs 24 27 Nm 6 Proportional solenoid valve BF Boom up down proportional speed control 33 37 ft lbs 45 50 Nm 7 Proportional solenoid valve BG Turntable rotate proportional speed control 18 20 ft lbs 24 27 Nm 8 Counterbala...

Page 132: ...3 88 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 15 4 3 2 1 17 19 18 16 9 10 11 13 5 7 8 6 14 12 BQ BR BA BD BE BB BC BF BG BH BI BJ TP BK BL BM BN BO BP ...

Page 133: ...alve BL Load sensing circuit turntable rotate 12 14 ft lbs 16 19 Nm 14 Check valve BM Load sensing circuit boom extend retract 12 14 ft lbs 16 19 Nm 15 Solenoid valve N C Poppet BN Boom retract sequence control 33 37ft lbs 45 50Nm 16 Solenoid valve N C Poppet BO Boom extend sequence control 33 37ft lbs 45 50Nm 17 Differential sensing valve BP Directs flow to functions 25 27ft lbs 34 37Nm 18 Soleno...

Page 134: ...3 90 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 15 4 3 2 1 17 19 18 16 9 10 11 13 5 7 8 6 14 12 BQ BR BA BD BE BB BC BF BG BH BI BJ TP BK BL BM BN BO BP ...

Page 135: ...bs 34 37 Nm 5 Relief Valve 3000 psi 206 8 bar AC Platform manifold pressure limit 18 20 ft lbs 25 27 Nm 6 Flow Regulator Valve 3 gpm 11 36 L min AD Priority flow to platform 25 27 ft lbs 34 37 Nm 7 Check Valve 5 psi 0 34 bar AE Blocks flow from pump 2 to auxiliary pump 12 14 ft lbs 16 2 18 9 Nm 8 Proportional Solenoid Valve N C BF Primary lift proportional speed control 33 37 ft lbs 45 50 Nm 9 Che...

Page 136: ...120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 16 1 23 24 22 18 19 20 17 25 26 11 12 13 14 15 3 2 8 7 9 10 5 4 6 21 BQ BR BA AC BD BE AD BB BC BG AA AB AE BH BI BJ TP BK BL AF BM BN BO BP AG BF ...

Page 137: ...ence control 33 37 ft lbs 45 50 Nm 18 Check Valve 5 psi 0 34 bar BM Extension cylinder load sense check 12 14 ft lbs 16 3 19 Nm 19 Check Valve 5 psi 0 34 bar BJ Primary lift load sense check 12 14 ft lbs 16 3 19 Nm 20 Differential Sensing Valve 110 psi 7 58 bar BP Directs flow to functions 25 27 ft lbs 34 37 Nm 21 Check Valve 5 psi 0 34 bar BL Turntable rotate load sense check 12 14 ft lbs 16 3 19...

Page 138: ...120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 16 1 23 24 22 18 19 20 17 25 26 11 12 13 14 15 3 2 8 7 9 10 5 4 6 21 BQ BR BA AC BD BE AD BB BC BG AA AB AE BH BI BJ TP BK BL AF BM BN BO BP AG BF ...

Page 139: ...3 9 Nm 5 Check Valve 10 psi 0 69 bar AB Blocks flow from pump 1 and 2 to auxiliary pump 18 20 ft lbs 25 27 Nm 6 Solenoid Valve 3 position 4 way BC Turntable rotate control left right 25 27 ft lbs 34 37 Nm 7 Proportional Solenoid Valve BG Turntable rotate proportional speed control 18 20 ft lbs 25 27 Nm 8 Differential Sensing Valve 230 psi 15 9 bar BP Directs flow to functions 33 37 ft lbs 45 50 Nm...

Page 140: ... S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS BB 1 2 3 4 5 22 26 25 27 21 18 24 23 13 14 15 16 12 7 6 8 9 10 11 17 20 19 BR BD AD BC BF BG AA AB AE BH BI BJ TP BK BE BL BM BN BS BO BP BA AC AF AG BQ ...

Page 141: ... Regulator Valve 0 1 gpm 0 38 L min BE Leads off differential sensing valve to tank 18 20 ft lbs 25 27 Nm 19 Check Valve 5 psi 0 34 bar BM Extension cylinder load sense check 12 14 ft lbs 16 3 19 Nm 20 Check Valve 5 psi 0 34 bar BJ Primary lift load sense check 12 14 ft lbs 16 3 19 Nm 21 Orifice Plug 0 040 inch 1 016 mm BK Differential sensing damping 22 Check Valve 30 psi 2 06 bar BS Back pressur...

Page 142: ... S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS BB 1 2 3 4 5 22 26 25 27 21 18 24 23 13 14 15 16 12 7 6 8 9 10 11 17 20 19 BR BD AD BC BF BG AA AB AE BH BI BJ TP BK BE BL BM BN BS BO BP BA AC AF AG BQ ...

Page 143: ...ressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 to confirm the relief valve pressure How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the test port on the function manifold 2 Start the engine from the gro...

Page 144: ...res 10 9 Proportional Valves Function Manifold Note When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity the proportional valve cartridge or coil will need to be calibrated See 1 3 How to Calibrate a Joystick Controller MANIFOLDS ...

Page 145: ...mpening 23ft lbs 31Nm 5 Differential sensing valve N O GI Platform level differential sensing circuit 23 25 ft lbs 31 34 Nm 6 Differential sensing valve N O GE Platform rotate differential sensing circuit 23 25 ft lbs 31 34 Nm 7 Orifice plug 0 030 inch 0 762 mm GB Platform rotate left circuit 8 Orifice plug 0 030 inch 0 762 mm GC Platform rotate right circuit 9 Shuttle valve GG Platform level load...

Page 146: ...3 102 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 10 9 8 4 1 11 12 5 6 3 7 2 GQ GI GE GB GG GA GO GD GH GC GF GJ ...

Page 147: ...Jib boom differential sensing circuit 23 25 ft lbs 31 34 Nm 8 Differential sensing valve N O CI Platform level differential sensing circuit 23 25 ft lbs 31 34 Nm 9 Flow control valve 0 1 gpm 0 38 L min CP Bleeds off differential sensing valve to tank 10 Differential sensing valve N O CE Platform rotate differential sensing circuit 23 25 ft lbs 31 34 Nm 11 Shuttle valve CK Jib boom load sense circu...

Page 148: ...3 104 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 12 11 14 15 6 4 1 16 17 7 8 9 10 5 3 2 13 CD CO CH CL CF CJ CN CQ CM CP CI CE CB CC CK CG CA ...

Page 149: ...ed to a different valve cartridge or cavity the proportional valve cartridge or coil will need to be calibrated See 1 3 How to Calibrate a Joystick 10 13 Platform Rotate Counterbalance Valve Manifold Components Index Schematic No Description Item Function Torque 1 Counterbalance valve A Platform rotate left 37 44ft lbs 50 60Nm 2 Counterbalance valve B Platform rotate right 37 44ft lbs 50 60Nm 2 1 ...

Page 150: ...manifold is mounted to the turntable rotation motor Index Schematic No Description Item Function Torque 1 Counterbalance valve A Turntable rotate left 37 44ft lbs 50 60Nm 2 Counterbalance valve B Turntable rotate right 37 44ft lbs 50 60Nm 3 Shuttle valve 2 position 3 way C Turntable rotation brake release 10 12ft lbs 14 16Nm 2 1 3 MANIFOLDS A B C B A C ...

Page 151: ...ve 3 position 4 way ED Steering cylinder control round end left side 18 20 ft lbs 24 27 Nm 5 Flow Regulator Valve 1 4 gpm 5 3 L min ET Steering cylinder speed round end right side retract 18 20 ft lbs 24 27 Nm 6 Flow Regulator Valve 2 gpm 7 6 L min EU Steering cylinder speed round end left side extend 18 20 ft lbs 24 27 Nm 7 Flow Regulator Valve 2 gpm 7 6 L min EV Steering cylinder speed square en...

Page 152: ...3 108 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures ES 5 7 6 2 1 3 11 10 9 8 4 EO EB EC ED ET EU EP EV EW EA MANIFOLDS ...

Page 153: ...e 5 psi 0 34 bar EX Axle extend load sense both ends 12 14 ft lbs 16 3 19 Nm 6 Relief Valve 1800 psi 124 bar EQQ Axle extend 18 20ft lbs 25 27Nm 7 Relief Valve 3000 psi 207 bar EZ Steering pressure limit 18 20ft lbs 25 27Nm Removed from S 120 125 at serial number 522 S 100 105 at serial number 148 8 Check Valve 5 psi 0 34 bar EY Axle retract load sense both ends 12 14 ft lbs 16 3 19 Nm 9 Check Val...

Page 154: ...00 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures 20 19 16 14 12 13 11 10 15 17 18 4 5 3 2 1 21 8 9 6 7 EH EK ELL EMM EOO EPP TP EQ ER EX EE EJ EQQ EKK EY EII EG EM EJJ ENN EZ MANIFOLDS ...

Page 155: ...inder lock circle end right side extend retract 18 20 ft lbs 25 27 Nm 16 Check Valve 5 psi 0 34 bar ELL Steering load sense circle end right side retract 12 14 ft lbs 16 3 19 Nm 17 Check Valve EG Steering cylinder lock circle end left side extend retract 12 14 ft lbs 16 3 19 Nm 18 Check Valve 5 psi 0 34 bar EMM Steering load sense circle end right side extend 12 14 ft lbs 16 3 19 Nm 19 Check Valve...

Page 156: ...00 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures 20 19 16 14 12 13 11 10 15 17 18 4 5 3 2 1 21 8 9 6 7 EH EK ELL EMM EOO EPP TP EQ ER EX EE EJ EQQ EKK EY EII EG EM EJJ ENN EZ MANIFOLDS ...

Page 157: ...rn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat steps 2 through 6 to confirm relief valve pressure How to Adjust the Axle Extend Relief Valve Note Perform this procedure with the axles retracted the boom in the stowed position and the machine on a paved s...

Page 158: ...3 114 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS This page intentionally left blank ...

Page 159: ...ve motors in forward and reverse 130 140 ft lbs 176 190 Nm 4 Flow regulator valve 2 gpm 7 57 L min DD Drive slip limit front 35 40ft lbs 47 54Nm 5 Flow divider combiner valve DE Controls flow to front drive motors in forward and reverse 130 140 ft lbs 176 190 Nm 6 Flow divider combiner valve DF Controls flow to front and rear flow divider combiner valves items DC and DE 130 140 ft lbs 176 190 Nm 7...

Page 160: ...3 116 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 9 11 10 1 2 3 17 16 15 12 14 13 5 6 7 8 4 DA DO DB DC DD DE DF DG DH DI DJ DK DL TP DM DP DN ...

Page 161: ...em Function Torque 12 Diagnostic fitting TP Testing 13 Shuttle valve 3 position 3 way DL Charge pressure circuit that gets hot oil out of low presure side of the drive pump 35 40 ft lbs 47 54 Nm 14 Check valve 50 psi 3 45 bar DP 2 speed brake charge pressure circuit 25 30 ft lbs 38 41 Nm 15 Relief valve 250 psi 17 2 bar DM Charge pressure circuit 35 40ft lbs 47 54Nm 16 Orifice plug 0 030 inch 0 76...

Page 162: ...3 118 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS 9 11 10 1 2 3 17 16 15 12 14 13 5 6 7 8 4 DA DO DB DC DD DE DF DG DH DI DJ DK DL TP DM DP DN ...

Page 163: ... lbs 27 1 33 9 Nm 5 Shuttle Valve 3 position 3 way HE Charge pressure circuit that directs hot oil out of low pressure side of drive pump 50 55 ft lbs 67 8 74 6 Nm 6 Relief Valve 250 psi 17 23 bar HF Charge pressure circuit 20 25 ft lbs 27 1 33 9 Nm 7 Orifice Plug 0 030 inch 0 762 mm HG Brake and two speed circuit 20 25 ft lbs 27 1 33 9 Nm 8 Check Valve HH Anti cavitation 20 25 ft lbs 27 1 33 9 Nm...

Page 164: ...3 120 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS HJ 11 12 1 2 3 4 5 16 18 17 14 13 15 9 10 6 7 8 HB HA HC HD HE HF HH HG HI HK HL HQ HP HM HN HO HR ...

Page 165: ...izes pressure on both sides of divider combiner valve FQ 30 35 ft lbs 40 7 47 5 Nm 14 Bi directional Flow Control Valve 2 gpm 7 6 L min HN Equalizes pressure on both sides of divider combiner valve FQ 30 35 ft lbs 40 7 47 5 Nm 15 Check Valve HO Anti cavitation 20 25 ft lbs 27 1 33 9 Nm 16 Flow Divider Combiner Valve HP Controls flow to circle end drive motors in forward and reverse 90 100 ft lbs 1...

Page 166: ...3 122 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures MANIFOLDS HJ 11 12 1 2 3 4 5 16 18 17 14 13 15 9 10 6 7 8 HB HA HC HD HE HF HH HG HI HK HL HQ HP HM HN HO HR ...

Page 167: ...olenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valv...

Page 168: ...ms ES FC BC before serial number 292 Solenoid valve 3 position 4 way 12V 7 1 Ω schematic items ES after serial number 291 Solenoid valve 2 position 3 way 12V 7 2 Ω schematic items AA How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case Properly functioning coil diodes protect the elec...

Page 169: ...t either end of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the curr...

Page 170: ... 3 Remove the fuel filler cap from the tank 4 Using an approved hand operated pump drain the fuel tank into a suitable container See capacity specifications Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with diesel fuel 5 Remove the fuel tank hold down strap retainin...

Page 171: ... end must be replaced and then torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the ground controls side turntable cover See 5 1 How to Remove a Hinged Turntable Cover 2 Close the two hydraulic shutoff valves located at the hydraulic tank Component damage hazard Be sure that the hydraulic tank shutoff valves are in the o...

Page 172: ...er unit Cap the fitting on the hydraulic tank 9 Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing 10 Remove the hydraulic tank retaining fasteners 11 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 12 Remove t...

Page 173: ...a motor b motor brake mounting bolts c brake d drive hub mounting bolts e drive hub 12 1 Turntable Rotation Hydraulic Motor and Drive Hub How to Remove the Turntable Rotation Hydraulic Motor Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting...

Page 174: ...ne could tip over when the drive hub is removed from the machine which could result in death or serious injury Crushing hazard The drive hub may become unbalanced and fall if it is not properly supported by the overhead crane or lifting device 6 Remove the plug from the side of the drive hub Drain the oil from the hub Installing the Drive Hub 7 Install the drive hub Use blue thread locking seal on...

Page 175: ...ote It may be necessary to raise the boom slightly to access all the turntable rotate drive hub mounting bolts a adjustment bolt with lock nut b pivot plate mounting bolts 4 Loosen the lock nut on the turntable drive hub adjustment bolt 5 Tighten the turntable drive hub adjustment bolt until the turntable drive hub gear is fully engaged and tight into the turntable rotate gear 6 Turn the adjustmen...

Page 176: ...3 132 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 3 Repair Procedures TURNTABLE ROTATION COMPONENTS This page intentionally left blank ...

Page 177: ...nsor measures steer angle and communicates that information to the ground controls ECM The steer sensor on the ground controls side of the machine at the square end acts as the lead sensor The other three sensors follow the position or steer angle of the lead sensor There is a steer sensor mounted to the top of each upper yoke pivot pin Note If the square end steering function becomes inoperative ...

Page 178: ...t a Steer Sensor 8 Repeat step 4 for the other square end tire How to Adjust a Steer Sensor Square end steer sensors 1 At the platform controls press the circle end steer mode button 2 Locate the steer sensor on top of the yoke pivot pin 3 Loosen the steer sensor cover retaining fasteners Do not remove them 4 Rotate the steer sensor cover either clockwise or counterclockwise Measure the distance b...

Page 179: ...Yoke and Hub The yoke installation utilizes bushings and a thrust washer that may require periodic replacement There is a steer sensor mounted to the upper yoke pivot pin Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specificatio...

Page 180: ...e pivot pin 7 Remove the steer sensor activator pin retaining fasteners Remove the steer sensor activator pin from the machine Note It is very important that the steer sensor activator pin is installed in the exact position it was in prior to removal If the steer sensor activator pin is not installed correctly the steer function may operate improperly If any steer functions operate improperly afte...

Page 181: ...cifications 13 3 Drive Motor How to Remove a Drive Motor Component damage hazard Repairs to the motor should only be performed by an authorized dealer Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a ...

Page 182: ...e to dissipate gradually Do not allow oil to squirt or spray 3 Loosen the wheel lug nuts Do not remove them 4 Center a lifting jack of ample capacity under the axle of the drive hub to be removed Do not raise the machine 5 Block the wheels at the opposite end of the machine 6 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 7 Remove the wheel lug nuts R...

Page 183: ...hose bracket retaining fasteners from the steering cylinder 4 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Remove the pin retaining fasteners...

Page 184: ...xle through an entire cycle Check for tight spots that could cause binding or scraping of the axle tubes Note Always maintain squareness between the inner and outer axle tubes Top and bottom wear pads 3 Center a lifting jack of ample capacity under the axle that needs to be shimmed Do not raise the machine 4 Block the wheels at the opposite end of the machine 5 Raise the machine just until the wei...

Page 185: ...h wear pad 8 Remove the pin retaining fasteners from the axle stop pin Use a slide hammer to remove the pin 9 Remove the access cover fasteners from the end of the inner axle to access the axle extension cylinder clevis pin Remove the cover 10 Place support blocks under the end of the axle extension cylinder for support 11 Remove the cotter pin from the axle extension cylinder clevis pin Note Alwa...

Page 186: ...for the switches can be accessed through the access holes on either side of the chassis end plate 6 Place blocks under the axle extension cylinder for support 7 Attach a lifting strap from an overhead crane to the end of the axle extension cylinder Note Attach the lifting strap to the end of the cylinder that has the inner axle removed 8 Remove the cotter pin from the axle extension cylinder clevi...

Page 187: ...g hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note Perform all troubleshooting on a firm level surface Note Two persons will be required to safely perform some troubleshooting procedures Diagnostic Codes Observe and Obey Troubleshooting and repair procedures shall be complete...

Page 188: ...Releasing the switch will clear the error and allow all machine functions The joystick operates similarly All other fault testing is done continuously 1 When a fault is diagnosed the PCON fault indicator will flash and a fault message will be displayed on the TCON LCD The message will contain the fault source and type 2 Additional information including the occurrence counter and a time stamp is av...

Page 189: ...ond beep of audible warning device Limited Speed and Direction frozen at zero and neutral Alarm sounds Normal function except threshold for one or the other direction is zero Dis play message on LCD Initiate one second beep of audible warning device Limited Speed and Direction frozen at zero and neutral Alarm sounds Calibrate Thresholds Self clearing transient Not calibrated Just calibrated Value ...

Page 190: ... Value at 0 V Power up controller with problem corrected Limited Speed and Direction frozen at zero and neutral Alarm sounds Stop all boom functions allow only boom retract once fully retracted allow boom down Display message on LCD Power up controller with problem corrected Power up controller with problem corrected Power up controller with problem corrected Power up controller with problem corre...

Page 191: ...Y SWITCH P18 SAFETY SWITCH P22 SAFETY SWITCH P22R Display message on LCD P3 SAFETY SWITCH FAULT Display message on LCD P6R1 SAFETY SWITCH FAULT Display message on LCD P6R2 SAFETY SWITCH FAULT Display message on LCD P7 SAFETY SWITCH FAULT Display message on LCD P7R SAFETY SWITCH FAULT Display message on LCD P9A SAFETY SWITCH FAULT Display message on LCD P9B SAFETY SWITCH FAULT Display message on LC...

Page 192: ...reshold for one or the other directions is zero dis play message on LCD Power up controller with problem corrected Power up controller with problem corrected Correct problem Fault Check Display message on LCD and sound audible alarm Initiate one second beep of audible warning device Calibrate Thresholds Self clearing transient Value at 5 0 V Value Too High Value Too Low Value at 0 V Not calibrated...

Page 193: ...on is zero Dis play message on LCD Initiate one second beep of audible warning device Shut down engine Limited Speed and Direction frozen at zero and neutral Alarm sounds Calibrate Thresholds Self clearing transient Not calibrated Just calibrated Value at 5 0 V Value Too High Value Too Low Value at 0 V Power up controller with problem corrected Limited Speed and Direction frozen at zero and neutra...

Page 194: ...ral Alarm sounds Display message on LCD Power up controller with problem corrected Power up controller with problem corrected Power up controller with problem corrected LR Steer Valves RR Steer Valves Limited Speed and Direction frozen at zero and neutral Alarm sounds Power up controller with problem corrected Value at 5 0 V Value Too High Value Too Low Value at 0 V Value at 5 0 V Value Too High V...

Page 195: ...OFF OFF OFF Primary 2 Cylinder crosscheck OFF OFF OFF Boom Envelope Safety Interlock OFF OFF OFF Axle Safety Not Stowed OFF OFF Axles crosscheck Angle sensor vs safety switch es OFF OFF OFF OFF Axle not fully extended and TT Rotate stowed and in drive disable zone OFF OFF Turntable Tilt Angle crosscheck SCON internal sensor 3 in a delta configuration OFF OFF OFF OFF OFF Loss of CAN OFF OFF OFF OFF...

Page 196: ...cription 3 SCON Controller Area Network 4 Primary Boom Angle Zone 5 Primary Boom Length Switches Cross Check 8 PCON Controller Area Network 9 Engine 18 DCON Controller Area Network 20 Boom Extend Retract Joystick 21 Boom Up Down Joystick 26 Boom Extend Retract Buttons 27 Boom Up Down Buttons 28 Boom Angle Sensors Cross Check SCON 29 LSB2RS LSB4ES Cross Check SCON 30 Propel Joystick 35 Propel Valve...

Page 197: ... Rotate Buttons 113 Jib Rotate Buttons 117 Propel Power P38 118 Turntable Rotate Power P39 121 Valve Power P6R1 122 Engine Power P6R2 123 Enable Input Power P7 Fault Source ID Description 124 Enable Output Power P7R 125 Primary Down Power P9A 126 IGN Fuel Power P9B 127 Primary Extend Power P10 128 Primary Up Power P11 129 Axle Retract Power P12 132 Platform Level Power P22 133 Primary Up Down Valv...

Page 198: ...ch 174 Platform Rotate Toggle Switch 175 Platform Level Flow Valve 176 Platform Rotate Valve 180 Boom Length Sensor 195 Safety Platform Overload SCON 220 RSB1AO Active Cross Check 221 LTB1LO Active Cross Check 222 Axle Extend Retract Toggle Switch 235 RSB1AO LSB1DO Cross Check 236 LTB1LO LSB3RO Cross Check 237 LTB1LO LSB4EO Cross Check 238 Pressure Comp Enable 1 Valve 239 Pressure Comp Enable 2 Ge...

Page 199: ...check low 51 5 1223 Actuator EGR Valve open load 51 6 1014 Actuator error EGR Valve signal range check high DEUTZ TD 2 9 L4 ENGINE FAULT CODES SPN FMI KWP Description 51 6 1022 Actuator error EGR Valve signal range check high 51 6 1224 Actuator EGR Valve over current 51 6 1230 Actuator error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible 51 11 1231 Actu...

Page 200: ...error charged air temperature signal range check high 105 4 995 Sensor error charged air temperature signal range check low SPN FMI KWP Description 108 3 412 Sensor error ambient air press signal range check high 108 4 413 Sensor error ambient air press signal range check low 110 0 98 High coolant temperature warning threshold exceeded 110 0 99 High coolant temperature shut off threshold exceeded ...

Page 201: ...ure 172 2 9 Sensor ambient air temperature plausibility error 172 2 983 Intake air sensor plausibility error 172 3 981 Sensor error intake air signal range check high 172 4 982 Sensor error intake air signal range check low SPN FMI KWP Description 174 0 481 High low fuel temperature warning threshold exceeded 174 0 482 High low fuel temperature shut off threshold exceeded 175 0 740 Physical range ...

Page 202: ...t EGR signal range check high 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Rec...

Page 203: ...the injector 4 in firing order 654 5 571 Injector 4 in firing order interruption of electric connection 676 11 543 Cold start aid relay error 676 11 544 Cold start aid relay open load SPN FMI KWP Description 677 3 956 Starter relay high side short circuit to battery 677 3 960 Starter relay low side short circuit to battery 677 4 957 Starter relay high side short circuit to ground 677 4 961 Starter...

Page 204: ...62 Exhaust gas temperature upstream turbine warning threshold exceeded 1180 1 1194 Physical range check low for exhaust gas temperature upstream turbine 1180 1 1461 Turbocharger Wastegate CAN feedback shut off threshold exceeded SPN FMI KWP Description 1180 1 1463 Exhaust gas temperature upstream turbine shut off threshold exceeded 1180 3 1067 Sensor error exhaust gas temperature upstream turbine ...

Page 205: ...ulation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 SPN FMI KWP Description 2798 4 1338 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 2798 4 1339 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 0 2798 4 1340 Injector diagnostics short circuit to...

Page 206: ...stream DOC signal range check low 523006 3 34 Controller mode switch short circuit to battery 523006 4 35 Controller mode switch short circuit to ground 523008 1 648 Manipulation control was triggered SPN FMI KWP Description 523008 2 649 Timeout error in Manipulation control 523009 9 825 Pressure Relief Valve PRV reached maximum allowed opening count 523009 10 833 Pressure Relief Valve PRV reached...

Page 207: ...AR Retarder 523612 12 387 Internal software error ECU injection cut off 523612 12 612 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 613 Internal ECU monitoring detection reported error 523612 12 614 Internal ECU monitoring detection reported error 523612 12 615 Internal ECU monitoring detection reported error 523612 12 616 Internal ECU monitoring detection repo...

Page 208: ... Setpoint of metering unit in overrun mode not plausible 523613 3 594 Metering unit Fuel System short circuit to battery high side SPN FMI KWP Description 523615 3 596 Metering unit Fuel System short circuit to battery low side 523615 4 595 Metering unit Fuel System short circuit to ground high side 523615 4 597 Metering unit Fuel System short circuit to ground low side 523615 5 592 Metering unit ...

Page 209: ...tor adjustment value programming IMA injector 1 in firing order 523896 13 560 Check of missing injector adjustment value programming IMA injector 2 in firing order SPN FMI KWP Description 523897 13 561 Check of missing injector adjustment value programming IMA injector 3 in firing order 523898 13 562 Check of missing injector adjustment value programming IMA injector 4 in firing order 523910 6 126...

Page 210: ...tor 4 in firing order maximum value exceeded 523932 1 118 Fuel Balance Control integrator injector 4 in firing order minimum value exceeded 523935 12 168 Timeout Error of CAN Transmit Frame EEC3VOL1 Engine send messages SPN FMI KWP Description 523936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zerofuel calibration injector 1 in firing order maximum value ...

Page 211: ...er bank 2 slave short circuit 523999 12 1328 Injector powerstage output Slave defect 524014 1 1254 Air pressure glow plug flush line below limit SPN FMI KWP Description 524016 2 1259 Amount of air is not plausible to pumb speed 524016 2 1260 Calculated amount of air is not plausible to HFM reading 524016 11 1258 HFM sensor electrical fault 524021 11 1263 Burner fuel line pipe leak behind Shut Off ...

Page 212: ...76 Timeout Error of CAN Receive Frame ComRxDPFCtl 524105 9 1668 Timeout Error of CAN Transmit Frame ComEGRMsFlw 524106 9 1677 Timeout Error of CAN Receive Frame ComRxEGRMsFlw1 524107 9 1678 Timeout Error of CAN Receive Frame ComRxEGRMsFlw2 SPN FMI KWP Description 524108 9 1669 Timeout Error of CAN Transmit Frame ComEGRTVActr 524109 9 1679 Timeout Error of CAN Receive Frame ComRxEGRTVActr 524110 9 ...

Page 213: ...82 Timeout Error of CAN Receive Frame ComRxSCRHtDiag 524121 9 1683 Timeout Error of CAN Receive Frame ComRxTrbChActr 524122 9 1684 Timeout Error of CAN Receive Frame ComRxUQSens 524123 9 1685 Timeout Error of CAN Receive Frame ComSCRHtCtl 524124 9 1686 Timeout Error of CAN Receive Frame ComTxAT1IMG 524125 9 1687 Timeout Error of CAN Receive Frame ComTxTrbChActr DEUTZ TD 2 9 L4 ENGINE FAULT CODES ...

Page 214: ...t Test 97 4 Water In Fuel Indicator High least severe Fuel Contains Water 100 2 Engine Oil Pressure Erratic Intermittent or Incorrect Switch Circuits Test 100 17 Engine Oil Pressure Low least severe 1 Oil Pressure Is Low 102 3 Engine Intake Manifold 1 Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 102 4 Engine Intake Manifold 1 Pressure Voltage Below Normal Engine ...

Page 215: ...re Problem 3 157 2 Engine Injector Metering Rail 1 Pressure Erratic Intermittent Fuel Rail Pressure Problem or Incorrect 157 3 Engine Injector Metering Rail 1 Pressure Voltage Above Engine Temperature Sensor Open or Normal Short Circuit Test 157 4 Engine Injector Metering Rail 1 Pressure Voltage Below Engine Temperature Sensor Open or Normal Short Circuit Test 157 10 Engine Injector Metering Rail ...

Page 216: ...ircuits Test Intermittent or Incorrect 593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle shutdown is about to occur This code does not represent a fault If equipped the warning lamp will come on 594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut down has occurred This code does not represent a fault If equipped the warni...

Page 217: ...r 04 Current Below Normal Injector Solenoid Circuit Test 654 6 Engine Injector Cylinder 04 Current Above Normal Injector Solenoid Circuit Test 654 20 Engine Injector Cylinder 04 Data Drifted High Injector Data Incorrect Test 654 21 Engine Injector Cylinder 04 Data Drifted Low Injector Data Incorrect Test 676 5 Engine Glow Plug Relay Current Below Normal Glow Plug Starting Aid Test 676 6 Engine Glo...

Page 218: ...5 Engine Turbocharger Wastegate Actuator 1 Solenoid Value Test Position Current Below Normal 1188 6 Engine Turbocharger Wastegate Actuator 1 Solenoid Value Test Position Current Above Normal 1209 3 Engine Exhaust Gas Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 1209 4 Engine Exhaust Gas Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit Te...

Page 219: ...840 14 ECU Instance Special Instruction Electrical Power Supply Test 2880 2 Engine Operator Primary Intermediate Speed Select Throttle Switch Circuit Test Erratic Intermittent or Incorrect 2880 3 Engine Operator Primary Intermediate Speed Select Throttle Switch Circuit Test Voltage Above Normal 2880 4 Engine Operator Primary Intermediate Speed Select Throttle Switch Circuit Test Voltage Below Norm...

Page 220: ...ential Pressure Voltage Above Engine Pressure Sensor Open or Normal Short Circuit Test 3251 4 Particulate Trap Differential Pressure Voltage Below Engine Pressure Sensor Open or Normal Short Circuit Test 3251 7 Particulate Trap Differential Pressure Not Responding Diesel Particulate Filter Has Properly Differential Pressure Problem 3251 10 Particulate Trap Differential Pressure Abnormal Rate of Di...

Page 221: ...Glow Plug Starting Aid Test 5325 7 Engine Glow Plug 2 Not Responding Properly Glow Plug Starting Aid Test 5326 7 Engine Glow Plug 3 Not Responding Properly Glow Plug Starting Aid Test 5327 7 Engine Glow Plug 4 Not Responding Properly Glow Plug Starting Aid Test 5419 5 Engine Throttle Actuator 1 Current Below Normal Motorized Valve Test 5419 6 Engine Throttle Actuator 1 Current Above Normal Motoriz...

Page 222: ...ing the WEB GPI software to the TCON with an RS 232 cable 2 Select the Safety folder then the Fault Status screen 3 Change any safety switch drop down menus displaying fault to ok Press send 4 Exit Web GPI Using the TCON LCD Note Take care when using this method to avoid resetting threshold defaults 1 With the key switch off press and hold the button and turn the key switch to the on position Rele...

Page 223: ...rator s Manual and the Genie S 120 Genie S 125 Operator s Manual Be sure that all necessary tools and parts are available and ready for use About This Section This section explains various parts of the machine software operating system and how to access some of the adjustable parameters of the control system Web GPI The software system used on the machine is called Web GPI It is a software applica...

Page 224: ...4 38 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 4 Diagnostic Codes This page intentionally left blank ...

Page 225: ...ctions printed in the Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remo...

Page 226: ... circuit number for work lamps and LP stands for Lamp R 48 LP R stands for relay In this case it is the wire that feeds the relay coil for the work lamp All other numbers remain the same Circuit prefix C Control D Data E Engine G Gauges N Neutral P Power R Relay Output S Safety V Valve Circuit suffix Definition Suffix AC Generator GEN Alternator Field AF Angle ANG Auxiliary Boom Valve ABV Auxiliar...

Page 227: ...tform Tilt Alarm PTA Platform Tilt Sensor PTS Definition Suffix Pressure Comp Enable PCE Pressure Sender PSR Pressure Switches PS Primary Boom Angle Sensor PBS Primary Boom Down PBD Primary Boom Ext Ret Lockout Valve PBL Primary Boom Extend PBE Primary Boom Extend Retract Flow Control PER Primary Boom Retract PBR Primary Boom Angle Sensor PBS Primary Boom Down PBD Primary Boom Ext Ret Lockout Valv...

Page 228: ...ight CW TRR Turntable Rotate Signal TRS Turntable Tilt Alarm TTA Turntable Tilt Sensor TTS Test Switch TSW Wire Coloring 1 All cylinder extension colors are solid and all retract functions are striped black When using black wire the stripe shall be white 2 All rotations that are LEFT or CW are solid RIGHT or CCW are striped and black When the wire is black the stripe is white 3 All proportional va...

Page 229: ...atform ESTOP WH 23 Power to platform RD 24 Power to warning senders WH BK 25 Power to oil pressure sender WH RD 26 Power to temp sender RD 27 Auxiliary power RD BK 28 Platform level alarm RD WH 29 Drive motor shift speed WH 30 Forward EDC A Color Circuit and Primary function WH BK 31 Reverse EDC B WH RD 32 Brake BK 33 Start BK WH 34 Start aid glow plug or choke BK RD 35 High engine speed select BL...

Page 230: ...erlock WH BK 92 Motor speed LO HI WH RD 93 Motor bypass WH 94 Load sensor OR 95 Tether ESTOP return RD 96 Tether power BK 97 Tether ESTOP power WH 98 J1708 high Color Circuit and Primary function BK 99 J1708 low WH RD 100 Outrigger lowered WH BK 101 Outrigger raised OR 102 Pothole protector up OR RD 103 Pothole protector down BK WH 104 Proprietary data buss i e ITT or AP BK RD 105 Proprietary data...

Page 231: ...signal WH BK 161 Sec boom joystick signal OR 162 Joystick 5 VDC power Color Circuit and Primary function BL WH 163 Pri extend retract signal RD WH 164 Pri up down signal WH RD 165 TT Rotate signal OR 166 Boom length signal safety OR BK 167 Boom length signal operational BL RD 168 Primary boom hydraulic valve lockout GN 169 Envelope active LED WH RD 170 Load sense relay source WH BK 171 Load sense ...

Page 232: ...used to sense very specific positions of a part of the machine in relation to the remainder of the machine Proximity switches must be correctly aligned for the machine functions to operate Proximity switches are found at the front and rear axle the turntable and several locations on the boom Limit Switch Numbering LSAX1RO Front axle retract proximity LSAX2RO Rear axle retract proximity LSAX1EO Fro...

Page 233: ...B9AS 65 LSB4ES 75 5 ft 23 m LSB4EO 100 ft 30 5 m LSB2RS 101 ft 30 8 m LSB3EO 75 ft 22 9 m LSB2RO 102 ft 31 1 m LSB3RS 3 5 ft 1 1 m LSB3RO 3 ft 0 9 m LSB4ES 75 5 ft 23 m LSB3EO 75 ft 22 9 m LSB13AO 53 LSB1DO 10 LSB7DS 11 LSB8AS 50 0 ft 0 m 10 ft 3 m 20 ft 6 1 m 30 ft 9 1 m 40 ft 12 2 m 50 ft 15 2 m 60 ft 18 3 m 70 ft 21 3 m 80 ft 24 4 m 90 ft 27 4 m 100 ft 30 5 m 110 ft 33 5 m 120 ft 36 6 m LSAX2ES...

Page 234: ...y K4 powers primary valves 1 and 2 ignition glow plug starter relay generator and the boom retract multifunction and platform rotate valve coils j CR14 relay K2 powers P7R or S56PRV circuit including the auxiliary valve boom extend retract and turntable rotate valve coils k CR10 relay K6 powers C21IGN and C107AF circuits Fuel on off solenoid and alternator field l CR15 relay K1 powers P22R or C03P...

Page 235: ...BR 15 V32BRK WH RD 16 V36LRS BL 17 V37LRS BL BK 18 V36RFS BL 19 P110RT BK 20 P109ANG GN WH 21 V37RFS BL BK 22 V36LFS BL 23 V37LFS BL BK DCON DRIVE CHASSIS CONTROLLER J1 1 GND DCON BR 2 P21DCON WH 3 P53LS GR 4 UNUSED 5 S56PRV RD 6 C61AXRT GR 7 UNUSED 8 P61LS GR 9 C61LS GR 10 UNUSED 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 C61LS A GR 16 UNUSED 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 UNUSED 21 UNUSE...

Page 236: ...4PLU OR 8 C15PLD OR BK 9 UNUSED 10 R90PXS RD BK 11 C90PXS RD BK 12 RET94LDS GR 13 C94LDS WH 14 R94LDS BK 15 C88PTS RD BK 16 R56PTS RD 17 C56PTS RD 18 UNUSED 19 PLATRET BR 20 C84TAY GR BK 21 P85PTS GR 22 PTSRET BR 23 P87PTS RD PCON PLATFORM CONTROLLER J1 1 GNDPCON BR 2 P52PCON BL RD 3 UNUSED 4 S56PRV RD WH 5 UNUSED 6 UNUSED 7 P56PRV RD 8 UNUSED 9 UNUSED 10 UNUSED 11 UNUSED 12 UNUSED 13 UNUSED 14 UN...

Page 237: ...RD 24 V75PRLO RD WH 25 SNSR GND BR 26 UNUSED 27 G119SR BL 28 UNUSED 29 C77AS WH 30 UNUSED 31 UNUSED 32 UNUSED 33 UNUSED 34 UNUSED 35 VLVRET1 BR TCON TURNTABLE CONTROLLER J3 1 UNUSED 2 R35RPM BK RD 3 C21IGN WH 4 C34SA BK WH 5 V30FWD WH 6 V31REV WH BK 7 C46HRN WH 8 UNUSED 9 C33STR BK 10 C30EDC WH 11 C31EDC WH BK 12 C25PSR WH BK 13 C26TSR WH RD 14 RET85TTSR BR 15 P85TTSR GN 16 VLVRET2 BR 17 UNUSED 18...

Page 238: ... 20A Hydraulic Oil Cooler Horn 11 B BAT 3 Fused Power from B1 12 B1BAT Power from Battery 13 R21PIGN Ignition PCE 2 Flashing Beacon Relay 1 CR77A CR28 CR17 CR77B 4 CR28 CR41 5 CR5 6 F20 7 8 F23 9 10 F22 F7 13 14 11 12 CR1 15 CR15 16 CR77A C 28 R C 17 R C 77B R C 41 R C 5 R F20 F23 F22 14 02PGND Ground 15 C 1 R Start Relay 16 C 15 R Glow Plug Relay Engine Relay and Fuse Panel Legend Deutz TD2011 an...

Page 239: ...Glow Plug 12 F7 Fuse 20A Hydraulic Oil Cooler Horn 13 B3BAT Fused Power from B1 Hydraulic Oil Cooler Fan Relay Fuel Pump CR77A CR2 CR17 CR77B 6 CR41 7 CR5 8 F27 9 10 F23 11 12 F22 F7 15 16 13 14 CR15 17 C 39 R C 77A R C 2 R C 17 R C 28 R C 77B R C 41 R C 5 R F27 14 B1BAT Power from Battery 15 R21PIGN Ignition 16 02PGND Ground 2 CR77A CR77B 1 CR39 5 1 CR28 3 4 30 86 85 87 17 Glow Plug Relay C 17 R ...

Page 240: ...Fuse 60A Glow Plug 12 F7 Fuse 20A Hydraulic Oil Cooler Horn 13 B3BAT Fused Power from B1 PCE 2 Fuse 30A ECU Power CR2 CR17 CR41 7 CR5 8 F27 9 10 F23 11 12 F22 F7 15 16 13 14 CR81 18 C 77A R C 2 R C 17 R C 77B R F 1 X F 2 X C 41 R C 5 R F27 14 B1BAT Power from Battery 15 R21PIGN Ignition 16 02PGND Ground 1 CR77A 4 1 CR77B 2 3 30 86 85 87 17 Engine Starter C 1 R 86 87 30 85 FX1 FX2 5 7 2 4 1 3 18 EC...

Page 241: ...engine run 0V engine off 4 Digital Output 2 12VDC Key Switch Activation Monitor mechine utilization 12V key switch run 0V key switch off 5 Digital Output 3 12VDC Foot Switch Monitor mechine utilization 12V active 0V inactive 6 Digital Input 1 12VDC Remote Disable Engine Start Remotely Prevent Engine Start 7 Databus H CAN HIGH Genie Databus J1939 Engine Messages Receive Proprietary Genie Telematics...

Page 242: ... Aux Auxiliary pump FAN Hydraulic oil cooling fan G1 Gauge Tilt sensor LED L3 Limit switch N C H O N O H C LS3 Fuse with amperage 25A F1 Starting aid glow plug or flame ignitor Control relay contact normally open CR4 N O Battery separator MAIN AUX Coil Fuel or RPM solenoid PULL IN HOLD C A B Main key switch A A B A A B B B 2 2 4 4 1 1 3 3 OFF KS1 MAIN KEYSWITCH PCON TCON Service bypass recovery ke...

Page 243: ...relief setting 25 psi 1 7 bar Motor 2 speed bi directional Pump bi directional variable displacement E Pump prime mover engine or motor Directional valve mechanically activated o Relief valve with pressure setting 200 psi 13 8 bar Orifice with size 035 0 89 mm Solenoid operated 3 position 4 way directional valve Directional valve pilot operated 2 position 2 way Flow divider combiner valve with pre...

Page 244: ...March 2017 Section 5 Schematics 5 20 S 100 S 105 S 120 S 125 Part No 1268494 This page intentionally left blank ...

Page 245: ...BOOM EXTEND VAVLE 85 87a 87 30 86 85 87a 87 30 86 85 TCON J4 7 TO BOOM UP VALVE TCON J3 3 TO FUEL SOLENOID TO ROTATE CCW VALVE TO ROTATE CCW VALVE TO ROTATE CW VALVE GND OUT 1 OUT 2 PWR STAT IN 1 IN 2 GND OUT 1 OUT 2 PWR STAT IN 1 IN 2 PWR STAT IN 1 IN 2 PWR STAT IN 1 IN 2 TCON J4 25 TCON J4 26 GND OUT 1 OUT 2 NFET TCON J4 10 TCON J3 9 TO STARTER RELAY GND OUT 1 OUT 2 NFET PWR STAT IN 1 IN 2 GND O...

Page 246: ...March 2017 Section 6 Schematics 6 22 Safety Circuit Schematic 6 21 ...

Page 247: ...Section 6 Schematics March 2017 6 23 Engine Options Perkins and Cummins S 100 105 to serial number 218 S 120 125 to serial number 932 6 24 ...

Page 248: ...ET2 BR VLVRET2 BR WH PULL IN BATGND A BK RD HOLD PULL IN HOLD 2 1 3 V31REV WH BK VLVRET2 BR V30FWD WH FWD VLV A SOLENOID SOLENOID REV VLV B C34SA BK WH P46HRN WH 1 P114BAT RD BAT GND BR C45GEN GR WH 1 3 2 J32 ENG HARN P1 04 AUX START_BAT_PWR AUX START_BAT_GND J5 BLACK 4 PIN POWER HARN P1 01 P1 03 P1 02 SYS_BAT_PWR SYS_BAT_GND P1 12 P1 01 VALVE RTN1 J3 WHITE 23 PIN ENGINE HARN THROTTLE P1 04 P1 02 ...

Page 249: ...4SA BK WH P46HRN WH P114BAT RD BAT GND BR C45GEN GN WH 1 3 2 J32 ENG HARN P1 04 AUX START_BAT_PWR AUX START_BAT_GND J5 BLACK 4 PIN POWER HARN P1 01 P1 03 P1 02 SYS_BAT_PWR SYS_BAT_GND P1 12 P1 01 J3 WHITE 23 PIN ENGINE HARN THROTTLE P1 04 P1 02 P1 03 P1 06 P1 05 P1 08 P1 09 P1 07 P1 11 P1 10 CHOKE GLOW PLUG IGNITION FUEL FWD REV OIL_PRESSURE SERVICE_HORN ALTENATOR_RPM TT_TILT_SNSR_PWR TT_TILT_SNSR...

Page 250: ...March 2017 Section 6 Schematics 6 26 Engine Options Perkins S 100 105 from serial number 219 to 247 S 120 125 from serial number 933 to 984 6 25 ...

Page 251: ...Section 6 Schematics March 2017 6 27 Engine Options Perkins S 100 105 from serial number 248 S 120 125 from serial number 985 6 28 ...

Page 252: ... P1 04 AUX START_BAT_PWR AUX START_BAT_GND J5 BLACK 4 PIN POWER HARN P1 01 P1 03 P1 02 SYS_BAT_PWR SYS_BAT_GND P1 12 P1 01 J3 WHITE 23 PIN ENGINE HARN THROTTLE P1 04 P1 02 P1 03 P1 06 P1 05 P1 08 P1 09 P1 07 P1 11 P1 10 CHOKE GLOW PLUG IGNITION FUEL FWD REV OIL_PRESSURE SERVICE_HORN ALTENATOR_RPM TT_TILT_SNSR_PWR TT_TILT_SNSR_GND VALVE_RTN2 TT_TILT_Y_AXIS AC_GENERATOR TT_TILT_X_AXIS ALT_FIELD_WIRE...

Page 253: ...Section 6 Schematics March 2017 6 29 Engine Options Perkins S 100 105 120 125 from serial number 874 6 30 ...

Page 254: ...mber 874 Number Component Description 1 2 Engine Fule Relay 3 Oil Cooler 4 5 Horn Relay 6 Speed Solenoid 7 Fuse 30A Eng Start Fuel 8 Fuse 60A Glow Plug 9 Fuse 20A Hydraulic Oil Cooler Horn 10 B3PBAT Fused Power from B1 11 B1PBAT Power from Battery 12 R21PIGN Ignition Fuse 20A RPM Solenoid 13 02PGND Ground Start Relay Glow Plug Relay ...

Page 255: ...BAT_GND AUX START_BAT_PWR P1 04 J32 ENG HARN 2 3 1 C45GEN GN WH BAT GND BR P114BAT RD P46HRN WH C34SA BK WH REV VLV B SOLENOID SOLENOID FWD VLV A VLVRET2 BR 3 1 2 HOLD PULL IN RD HOLD BK COM WH PULL IN VLVRET2 BR VLVRET2 BR R46HRN WH HORN RELAY GRID HEATER RELAY P34SA RD 2 86 1 30 5 85 87 ALTERNATOR REGULATOR BAT IND STA BAT EXCT PR1 C27AUX RD VLVRET6 BR BAT GND BR C107AF RD C41RPM OR BK 85 87a 4 ...

Page 256: ...March 2017 Section 6 Schematics 6 32 Engine Options Cummins S 100 105 from serial number 219 to 247 S 120 125 from serial number 933 to 984 6 31 ...

Page 257: ...Section 6 Schematics March 2017 6 33 Engine Options Cummins S 100 105 from serial number 248 S 120 125 from serial number 985 6 34 ...

Page 258: ... C34SA BK WH REV VLV B SOLENOID SOLENOID FWD VLV A VLVRET2 BR 3 1 2 HOLD PULL IN RD HOLD BK COM WH PULL IN VLVRET2 BR VLVRET2 BR R46HRN WH HORN RELAY GRID HEATER RELAY P34SA RD 2 86 1 30 5 85 87 ALTERNATOR REGULATOR BAT IND STA BAT EXCT PR1 C27AUX RD VLVRET6 BR BAT GND BR C107AF RD C41RPM OR BK 85 87a 4 87 5 86 30 1 2 MAIN AUX P114BAT RD 87a STARTER RELAY STARTER START BAT BAT MAIN SYS 4 SERVICE H...

Page 259: ...Section 6 Schematics March 2017 6 35 6 36 Electrical Schematic Generator Options ...

Page 260: ...85 3 C45GEN GN WH BAT GND BR P114BAT RD 240VAC 50Hz 1 PH ENGINE HARNESS GENERATOR JUMPER HARNESS AC GENERATOR T2 T1 YELLOW RED WHITE GREEN T3 T4 8 5 BLACK BLACK BLACK WHITE BLACK WHITE WHITE BLACK GREEN L2 L1 C45GEN GR WH BATGND BR P114 BAT RD PLUG PLUG PLUG 1 2 4 3 3 4 2 1 RD BK BL PLUG PURGE BL DTP04 4P BLACK RED GREEN WHITE BLACK BLUE YELLOW WHITE BLACK GND ENGINE HARNESS GENERATOR JUMPER HARNE...

Page 261: ... 1 GENERATOR ON F3 DI G I N 2 RS232TxD CR4 HIGH IDLE RELAY C45GEN GR WH V151HG GR V150HG GR BK 1K 124 ohms 124 ohms A B C 2 1 3 MOTOR STROKE VALVE SX CONTROLLER CR50 OMRON RELAY J3 2 J32 4 J3 22 12 5 BK 8 10 11 9 7 6 WH COLOR 3 4 2 WH BK PI N 1 CKT BR BK GR WH GR BK BR PLUG WH BK WH BK GND P23PWR V150HG C45GEN C31EDC A C30EDC A GND1 C31EDC C30EDC P23PWR A TCON DCON J21 18 J21 17 J1 17 J1 18 J31 17...

Page 262: ...March 2017 Section 6 Schematics 6 38 6 37 Electrical Schematic 12 kW Generator welder option ...

Page 263: ...Part No 1268494 S 100 S 105 S 120 S 125 6 39 March 2017 Section 6 Schematics Perkins 1104D 44T Engine Electrical Schematic ...

Page 264: ...March 2017 Section 6 Schematics 6 40 Perkins 1104D 44T Engine Electrical Schematic 6 39 ...

Page 265: ...Section 6 Schematics March 2017 6 41 Perkins 854F 34T Engine Electrical Schematic 6 42 ...

Page 266: ...6 42 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 6 Schematics Perkins 854F 34T Engine Electrical Schematic ...

Page 267: ...Part No 1268494 S 100 S 105 S 120 S 125 6 43 March 2017 Section 6 Schematics Perkins 854F 34T Engine Electrical Harness ...

Page 268: ...March 2017 Section 6 Schematics 6 44 Perkins 854F 34T Engine Harness 6 45 ...

Page 269: ...Section 6 Schematics March 2017 6 45 Deutz TD2011L04i Engine Electrical Schematic 6 46 ...

Page 270: ...6 46 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 6 Schematics Deutz TD2011L04i Engine Electrical Schematic ...

Page 271: ...Section 6 Schematics March 2017 6 47 Deutz TD2 9 Engine Electrical Schematic 6 48 ...

Page 272: ...6 48 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 6 Schematics Deutz TD2 9 Engine Electrical Schematic ...

Page 273: ...Part No 1268494 S 100 S 105 S 120 S 125 6 49 March 2017 Section 6 Schematics Deutz TD2 9 Engine Electrical Harness ...

Page 274: ...March 2017 Section 6 Schematics 6 50 Deutz TD2 9 Engine Electrical Harness 6 51 ...

Page 275: ...welder option OIL COOLER 0 030 inch 0 76 mm WELDER MANIFOLD DRIVE PUMP B A 3 5 GPM 13 25L min PMP B CLR PMP A 270 PSI 18 6 BAR 3 5 GPM 13 25 L min MTR B MTR A 21 GPM 79 5 L min G1 G2 21 GPM 79 5 L min G2 G1 21CC TANK 3 4 GENERATOR 12 5 KW HYDRAULIC ROTARY COUPLER PRESSURE SWITCH 200 PSI 13 8 BAR N O CY CX CW CV CU ...

Page 276: ...March 2017 Section 6 Schematics 6 52 6 53 Hydraulic Schematic 12 kW Generator welder option ...

Page 277: ...Section 6 Schematics March 2017 6 53 Hydraulic Schematic S 100 S 105 Models serial number 136 6 54 ...

Page 278: ... PSI 900 PSI 600 PSI 2 1 4 5 1 1 5 1 3 1 3 1 3 1 3000 PSI 4 5 1 3200 PSI 3 1 3 1 2200 PSI ES EA EB EO EP EZ EQ EV ENN EJJ EK ER EW EKK EM EII EX EY P LS P1 EG EH ET EOO EPP EE ED EC EJ EU ELL EMM FLR T1 T FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR BRAKE 2 SPD TANK BRAKE 2 SPD TEST LA LB RA RB FRB FRA FLB FLA A B B A DO DA DE DD DF DL DC DB DG DH DI DK DJ DM DN JD JA JB JC JF JE B A LS P1 TP EQQ D...

Page 279: ...EOO EPP EE ED EC EJ EU ELL EMM FLR T1 T FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR BRAKE 2 SPD TANK BRAKE 2 SPD TEST LA LB RA RB FRB FRA FLB FLA A B B A DO DA DE DD DF DL DC DB DG DH DI DK DJ DM DN JD JA JB JC JF JE B A LS P1 TP EQQ DP I D I D LEFT REAR RIGHT REAR 4 WHEEL DRIVE MANIFOLD LEFT RIGHT FRONT FRONT FOUR WHEEL STEER MANIFOLD FRONT AXLE EXTENSION REAR AXLE EXTENSION FRONT LEFT STEERING F...

Page 280: ...March 2017 Section 6 Schematics 6 56 Hydraulic Schematic S 100 S 105 Models from serial number 137 to serial number 290 6 57 ...

Page 281: ...Section 6 Schematics March 2017 6 57 Hydraulic Schematic S 100 S 105 Models from serial number 291 to serial number 738 6 58 ...

Page 282: ...FT STEERING 1 40 0 1GPM GPM 2 00 GPM 2 00 GPM 1 40 GPM GPM 1 40 GPM 2 00 GPM 1 40 2 00 GPM 1800 psi 4WD TRACTION MANIFOLD X M1 LEFT REAR M3 M5 2 0 50 GPM 50 RIGHT REAR M7 2 0 GPM T M2 FRONT LEFT M4 A B TEST 50 280 PSI 50 2 0 50 GPM 50 RIGHT M6 FRONT M8 0 030 LBRAKE L2SPEED CDL CDR RBRAKE R2SPEED LBRAKE L2SPEED R2SPEED RBRAKE FL FJ FE FF FH FR FP FN FD FK FQ FM FA FI FG FD FB FC CHECK VALVE REMOVED...

Page 283: ...D D C J PLATFORM MANIFOLD S 100 PLATFORM LEVEL PLATFORM ROTATE 0 47 GPM 0 3 GPM 500 psi 0 030 0 030 4 6 in cu TO FUNCTION MANIFOLD P3 TO FUNCTION MANIFOLD T2 A B C D E F G I J K COUNTERBALANCE VALVE RATIO PRESS 5000 PSI 5000 PSI 3500 PSI 3000 PSI 900 PSI 600 PSI 5 1 4 5 1 1 5 1 3 1 3 1 3 1 3000 PSI 4 5 1 3 1 2200 PSI 1 5 1 2000 PSI 600 PSI 1 1 A B C ES EA EB EO EP EQ EV ENN EJJ EK ER EW EKK EM EII...

Page 284: ...March 2017 Section 6 Schematics 6 60 Hydraulic Schematic S 100 S 105 Models from serial number 739 6 61 ...

Page 285: ...Section 6 Schematics March 2017 6 61 Hydraulic Schematic S 120 S 125 Models from serial number 404 to serial number 430 6 62 ...

Page 286: ... GPM JIB TEST P1 T1 LS PLU 3 gpm P GE GI PRL PRR PLD T 3 gpm GD GB GC GA GO GF GJ GG GH GQ D D C J PLATFORM LEVEL PLATFORM ROTATE 0 47 GPM 0 3 GPM 500 psi 0 030 0 030 4 6 in cu PLATFORM MANIFOLD S 120 A B C D E F G H I COUNTERBALANCE VALVE RATIO PRESS 5000 PSI 5000 PSI 3000 PSI 3000 PSI 900 PSI 600 PSI 5 1 4 5 1 1 5 1 3 1 3 1 3 1 3000 PSI 4 5 1 3200 PSI 3 1 3 1 2200 PSI ES EA EB EO EP EZ EQ EV ENN...

Page 287: ...old relief valve EZ was removed at Serial No 522 BRAKE TANK BRAKE TEST LA LB RA RB FRB FRA FLB FLA A B B A DO DA DE DD DF DL DC DB DG DH DI DK DJ DM DN JD JA JB JC JF JE B A LS P1 DP LEFT REAR RIGHT REAR 4 WHEEL DRIVE MANIFOLD LEFT RIGHT FRONT FRONT OPTION AUXILIARY 50 50 50 50 50 0 030 250 PSI 50 0 1GPM DRIVE 2 0 GPM 2 0 GPM 2 7 GPM 5 2A 1 4 3 A B C D E F G H I J K COUNTERBALANCE VALVE RATIO PRES...

Page 288: ...March 2017 Section 6 Schematics 6 64 Hydraulic Schematic S 120 S 125 Models from serial number 431 to serial number 1194 6 65 ...

Page 289: ...Section 6 Schematics March 2017 6 65 Hydraulic Schematic S 120 S 125 Models from serial number 1195 to serial number 2634 6 66 ...

Page 290: ... EOO EPP EE ED EC EJ EU ELL EMM FLR T1 T FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR TP EQQ FOUR WHEEL STEER MANIFOLD 4WD TRACTION MANIFOLD 1 40 0 1GPM GPM 2 00 GPM 2 00 GPM 1 40 GPM GPM 1 40 GPM 2 00 GPM 1 40 2 00 GPM 1800 psi M1 LEFT REAR M3 M5 2 0 50 GPM 50 2 0 GPM M2 FRONT LEFT M4 50 280 PSI 50 2 0 50 GPM 50 0 030 LBRAKE L2SPEED CDL RBRAKE R2SPEED LBRAKE L2SPEED R2SPEED RBRAKE FL FJ FP FN FD F...

Page 291: ...I PRL PRR PLD T 3 gpm GD GB GC GA GO GF GJ GG GH GQ D D C J PLATFORM MANIFOLD S 120 PLATFORM LEVEL PLATFORM ROTATE 0 47 GPM 0 3 GPM 500 psi 0 030 0 030 4 6 in cu TO FUNCTION MANIFOLD P3 TO FUNCTION MANIFOLD T2 C ES EA EB EO EP EQ EV ENN EJJ EK ER EW EKK EM EII EX EY P LS P1 EG EH ET EOO EPP EE ED EC EJ EU ELL EMM FLR T1 T FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR TP EQQ 4 4 3 3 2B 2 5 5 2A 1 1 I...

Page 292: ...March 2017 Section 6 Schematics 6 68 Hydraulic Schematic S 120 S 125 Models from serial number 2635 to serial number 3145 6 69 ...

Page 293: ...Section 6 Schematics March 2017 6 69 Hydraulic Schematic S 120 S 125 Models from serial number 3146 to S12514D 921 6 70 ...

Page 294: ...6 70 S 100 S 105 S 120 S 125 Part No 1268494 March 2017 Section 6 Schematics Hydraulic Schematic S 120 S 125 Models from serial number 3146 to S12514D 921 ...

Page 295: ...Part No 1268494 S 100 S 105 S 120 S 125 6 71 March 2017 Section 6 Schematics Hydraulic Schematic S 120 S 125 Models from serial number S12514D 922 ...

Page 296: ...March 2017 Section 6 Schematics 6 72 Hydraulic Schematic S 120 S 125 Models from serial number S12514D 922 6 73 ...

Page 297: ...56PRV RD S56PRV RD WH C47OUT WH BK D82CAN YL D81CAN GN GN J8 J7 2 4 3 6 5 2 BL YL BR OR RD 1 BK WH 1 2 6 5 4 3 2 1 P7 LIMIT SW HARN 1 P8 LIMIT SW HARN P6R1 DCON PWR DCON GND P18 P11 P12 P9A P7R WH BK 2 2 1 P18 1 GN YL BL 6 6 5 4 4 5 P17 OR BR RD 2 2 3 3 1 1 C C CAN SHIELD B B A P16 A YEL GRN CAN HIGH CAN LOW C C B A B A YEL GRN P6 BOOM HARN J6 SLIP RING SLIP RING D81CAN GN D82CAN YL P57PBD RD WH P...

Page 298: ...1 MEMBRANE LED INTERFACE CARD J1 10PIN P1 P1 P1 P1 P1 P1 START ASSIST AC GENERATOR AUXILIARY HORN START J2 10PIN P1 P1 P1 P2 P2 P2 P2 P2 P2 ENGINE SPEED AXLE RETRACT DRIVE ENABLE 1 SPARE 1 CRAB STEER FRONT STEER DRIVE SPEED REAR STEER AXLE EXTEND 4 2 3 5 6 PCON MEMBRANE PANEL P2 P2 P2 P2 FUEL TYPE COORD STEER 7 8 10 9 SPARE 2 P1 01 P1 02 P1 03 P1 04 P1 05 P1 06 P1 07 P1 08 P1 09 P1 11 P1 10 P1 12 ...

Page 299: ...3 1 P 3 4 1 3 SJ3 WH C68PBD BL S62BSTO ORN P53LS WH BK C60AXEX GN WH S56PRV RD C64LS OR BK C77AS WH 3 1 24 P53LS WH BK P54ENG BK WH P58LS RD BK P57PBD RD WH J20 12 WAY P20 12 WAY 8 9 10 11 12 S56PRV RD SJ3 WH C71PBE BL BK C64LS OR BK P57PBD RD WH 1 3 4 2 1 3 2 4 S56PRV RD C64LS OR BK S62BSTO OR C61AXRT GN P57PBD RD WH P57PBD RD WH P53LS WH BK P54ENG BK WH P58LS RD BK C70PBE BL WH P63LS OR RD SJ3 W...

Page 300: ... SJ3 WH C68PBD BL S62BSTO ORN P53LS WH BK C60AXEX GN WH S56PRV RD C64LS OR BK C77AS WH 3 1 24 P53LS WH BK P54ENG BK WH P58LS RD BK P57PBD RD WH J20 12 WAY P20 12 WAY 8 9 10 11 12 S56PRV RD SJ3 WH C71PBE BL BK C64LS OR BK P57PBD RD WH 1 3 4 2 1 3 2 4 S56PRV RD C64LS OR BK S62BSTO OR C61AXRT GN P57PBD RD WH P57PBD RD WH P53LS WH BK P54ENG BK WH P58LS RD BK C70PBE BL WH P63LS OR RD SJ3 WH 3 4 5 6 7 8...

Page 301: ... 9 10 11 12 S56PRV RD SJ3 WH C71PBE BL BK C64LS OR BK P57PBD RD WH 1 3 4 2 1 3 2 4 S56PRV RD C64LS OR BK S62BSTO OR C61AXRT GN P57PBD RD WH P57PBD RD WH P53LS WH BK P54ENG BK WH P58LS RD BK C70PBE BL WH P63LS OR RD SJ3 WH 3 4 5 6 7 8 1 2 C61AXRT GN S62BSTO OR P63LS OR RD C70PBE BL WH P54ENG BK WH P53LS WH BK 3 4 5 6 1 2 J21 8 WAY P21 8 WAY P58LS RD BK 7 P56PRV RD 2 4 3 1 C64LS OR BK C71PBE BL BK 4...

Page 302: ...BK WH P58LS RD BK C70PBE BL WH P63LS OR RD SJ3 WH 3 4 5 6 7 8 1 2 C61AXRT GN S62BSTO OR P63LS OR RD C70PBE BL WH P54ENG BK WH P53LS WH BK 3 4 5 6 1 2 J21 8 WAY P21 8 WAY P58LS RD BK 7 P56PRV RD 2 4 3 1 C64LS OR BK C71PBE BL BK 4 3 1 2 PRESSURE SENSOR OPTIONAL HYDRAULIC C77AS WH SNSR GND BR G119SR BL P57PBD RD WH P54ENG BK WH P58LS RD BK S59CNBK GR WH C60AXEX GR WH C61AXRT GR C68PBD RD C65LOFL BL W...

Page 303: ... exhaust do not idle the engine except as necessary service your equipment and vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your equipment or vehicle and after operation For more information go to www P65Warnings ca gov passenger vehicle Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and bi...