Terex Genie S-100HD Service And Repair Manual Download

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S-100HD • S-120HD

Part No. 1268495

September 2016

Section 3 • Repair Procedures

Primary boom extend/retract 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 Press and hold the enter button

on the

ground control panel while turning the key

switch to platform controls. Hold the enter

button for approximately 5 seconds.

3 Press the minus button

twice, then press the

enter button

twice.

4 Use the scroll button to scroll through the

menu until

reset

primary

boom

extend

retract

joystick

defaults

is displayed. Press the

button to select

yes

, then press the

button.

5 Exit programming mode.

Note: To exit programming mode, use the scroll

button to scroll through the menu until the

screen displays exit, then press the plus button

once, change the NO to YES, and press the enter
button

6 Do not start the engine.

7 Locate the primary boom/turntable rotate

joystick.

8 Move the primary boom extend/retract joystick

full stroke in the extend direction and hold for

5 seconds, then return to the center or neutral

position.

9 Move the primary boom extend/retract joystick

full stroke in the retract direction and hold 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.

PLATFORM CONTROLS

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 controls is in the on position.

2 Press and hold the enter button

on the

ground control panel while turning the key

switch to platform controls. Hold the enter

button for approximately 5 seconds.

3 Press the minus button

twice, then press the

enter button

twice.

4 Use the scroll button to scroll through the

menu until

reset

primary

boom

down

joystick

defaults

is displayed. Press the

button to

select

yes

, then press the

button.

5 Exit programming mode.

Note: To exit programming mode, use the scroll

button to scroll through the menu until the

screen displays exit, then press the plus button

once, change the NO to YES, and press the enter
button

6 Do not start the engine.

7 Locate the primary boom/turntable rotate

joystick.

8 Move the boom/turntable rotate joystick

full stroke in the up direction and hold for 5

seconds, then return to the center or neutral

position.

9 Move the boom/turntable rotate joystick full

stroke in the down direction and hold 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.

Summary of Contents for Genie S-100HD

Page 1: ...4D 200 to S 100HD16D 229 from S120HD14D 201 to S 120HD16D 229 S 100HD S 120HD 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 100HDD 230 from S 120HDD 230 ...

Page 2: ...esign Life Unrestricted with proper operation inspection and scheduled maintenance Copyright 2015 by Terex Corporation 1268495 Rev A1 September 2016 First Edition Third Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries S is a trademark of Terex South Dakota Inc Printed on recycled paper Printed in U S A Introduction Technical Publications Geni...

Page 3: ...Procedure Page Description A 9 2015 Release A1 9 2016 Introduction Serial Number Legend Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...Serial number Model 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 S120HD16D 12345 1 2 16 2016 S120HD 1 D 12345 6 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...

Page 5: ... 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 tools lifting...

Page 6: ...e not reused 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 ope...

Page 7: ... 100HD and S 120HD Models 2 1 Performance Specifications S 120HD Models 2 2 Performance Specifications S 100HD Models 2 3 Hydraulic Specifications 2 5 Hydraulic Component Specifications 2 6 Deutz Engine TD2011L04i Specifications 2 7 Cummins Engine B3 3T C80 Specifications 2 9 Machine Torque Specifications 2 10 Manifold Plug Torque Specifications 2 10 Hydraulic Hose and Fitting Torque Specification...

Page 8: ...10 Platform Components 2 1 Platform 3 17 2 2 Platform Leveling Cylinder 3 17 2 3 Platform Rotator 3 19 2 4 Platform Level Sensor 3 20 2 5 Platform Overload System 3 21 2 6 Platform Overload Recovery Message Software V3 14 and later 3 24 Boom Components 4 1 Cable Track 3 26 4 2 Boom 3 29 4 3 Boom Lift Cylinder 3 40 4 4 Extension Cylinders 3 42 4 5 Boom Extend Retract Cables 3 46 viii TABLE OF CONTE...

Page 9: ...and Perkins Models 3 52 6 4 Oil Pressure and Temperature Sending Units Deutz Models 3 52 Ground Controls 7 1 Circuit Boards 3 53 7 2 Membrane Decal 3 54 7 3 Control Relays 3 55 Limit Switches 8 1 Limit Switches 3 58 8 2 Limit Switch and Level Sensor Locations 3 61 8 3 Limit Switch Functions 3 62 Hydraulic Pumps 9 1 Function Pumps 3 65 9 2 Drive Pump 3 66 9 3 Auxiliary Pump 3 69 ix TABLE OF CONTENT...

Page 10: ...0 6 Proportional Valves Function Manifold 3 82 10 7 Platform Manifold Components S 100 and S 120 Models 3 83 10 8 Proportional Valves Platform Manifolds 3 85 10 9 Platform Rotate Counterbalance Valve Manifold Components 3 85 10 10Turntable Rotation Manifold Components 3 86 10 11Steer and Axle Extend Retract Manifold Components 3 87 10 12Valve Adjustments Steer and Axle Extend Retract Manifold 3 89...

Page 11: ...mponents 12 1 Turntable Rotation Hydraulic Motor and Drive Hub 3 102 Axle Components 13 1 Steer Sensors 3 105 13 2 Yoke and Hub 3 106 13 3 Drive Motor 3 108 13 4 Drive Hub 3 109 13 5 Steering Cylinders 3 109 13 6 Hub and Bearings 2WD Models 3 110 13 7 Extendable Axles 3 112 Section 4 Diagnostic Codes Introduction 4 1 Diagnostic Code Chart 4 3 Software 4 10 xi TABLE OF CONTENTS ...

Page 12: ...ols Legend 5 14 Hydraulic Symbols Legend 5 15 Electrical Schematic S 100HD Models View 1 5 18 Electrical Schematic S 100HD Models View 2 5 19 Electrical Schematic S 100HD Models View 3 5 22 Electrical Schematic S 100HD Models View 4 5 23 Electrical Schematic S 100HD Deutz Engine Models View 5 5 26 Electrical Schematic S 100HD Cummins Engine Models View 6 5 27 Electrical Schematic S 100HD Models Vi...

Page 13: ...cal Schematic S 120HD Models View 3 5 38 Electrical Schematic S 120HD Models View 4 5 39 Electrical Schematic S 120HD Deutz Engine Models View 5 5 42 Electrical Schematic S 120HD Cummins Engine Models View 6 5 43 Electrical Schematic S 120HD Models View 7 5 46 Electrical Schematic Safety Circuit Schematic S 120HD Models 5 47 Hydraulic Schematic S 100HD Models 5 50 Hydraulic Schematic S 120HD Model...

Page 14: ...September 2016 S 100HD S 120HD Part No 1268495 xiv This page intentionally left blank ...

Page 15: ...8 m 36 58 m Working height maximum 106 ft 126 ft 32 48 m 38 58 m Horizontal reach maximum 73 ft 73 ft 22 25 m 22 25 m Maximum load capacity 750 lb 750 lb 340 kg 340 kg Turntable tailswing 5 ft 6 in 5 ft 6 in axles retracted 1 68 m 1 68 m Turntable tailswing 4 ft 4 ft axles extended 1 22 m 1 22 m Wheelbase 12 ft 12 ft 3 66 m 3 66 m Turning radius outside 46 ft 5 in 62 ft 3 in axles retracted 2WD 14...

Page 16: ... extended to 100 ft 30 5 m 24 to 28 seconds time between 68 envelope limit and a fully raised position Boom down Boom fully retracted 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 extended to 100 ft 30 5 m 24 to 28 seconds ...

Page 17: ...d stowed 8 0 8 4 sec 36 ft 11 m Low drive speed stowed 14 4 16 4 sec 18 ft 5 5 m High drive speed non stowed 80 ft 18 20 sec 18 ft 5 5 m High drive speed non stowed 80 ft 32 6 36 6 sec 18 ft 5 5 m Braking distance maximum High range on paved surface 4 to 6 ft 1 2 to 1 8 m Gradeability boom stowed See Operator s Manual Boom up Boom fully retracted 80 to 88 seconds Boom extended to 4 ft 1 2 m 100 to...

Page 18: ... ft to 0 30 5 m to 0 120 to 140 seconds Turntable rotate 360 boom horizontal and fully retracted 170 to 190 seconds Turntable rotate 360 boom horizontal and 63 to 70 seconds extended 0 ft 0 m drive enable to drive enable Turntable rotate 360 boom fully raised and 109 to 120 seconds extended 80 ft 24 4 m drive enable to drive enable Platform rotate 160 18 to 22 seconds SPECIFICATIONS ...

Page 19: ... 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 C an optional oi...

Page 20: ...ront Section Displacement 0 to 1 77 cu in 0 to 29 cc Flow rate 2350 rpm maximum 17 4 gpm 65 9 L min Rear Section Displacement 0 to 1 16 cu in 0 to 19 cc Flow rate 2350 rpm maximum 11 2 gpm 42 4 L min Pressure maximum continuous 3350 psi 231 bar Standby pressure 250 psi 17 bar Auxiliary pumps Type fixed displacement gear pump Displacement 0 15 cu in 2 47 cc Section 1 Flow rate 1600 rpm 1 7 gpm 6 4 ...

Page 21: ...s Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 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 Steer Axle manifold Axle extend relief pressure 1800 psi 124 bar Drive manifold Hot oil relief pre...

Page 22: ... cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm SPECIFICATIONS Deutz TD 2 9 Engine Displacement 177 cu in 2 9 liters Number of cylinders 4 Bore and stroke 3 6 x 4 3 inches 92 x 110 mm Horsepower net intermittent 74 2hp 2600 rpm 55KW Induction system turbocharged Firing order 1 3 4 2 Low idle 1000 rpm High idle...

Page 23: ...put 95A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Perkins 854F 34T Displacement 207 cu in 3 4 liters Number of cylinders 4 Bore and stroke 3 89 x 4 33 inches 99 x 110 mm Horsepower 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 p...

Page 24: ...ec 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 5 quarts...

Page 25: ...m Engine capacity 4 75 quarts 4 5 liters System capacity 9 1 quarts 8 6 liters Cummins B3 3T C80 Engine Displacement 199 cu in 3 3 liters Number of cylinders 4 Bore and stroke 3 74 x 4 528 inches 95 x 115 mm Horsepower 80 hp 2200 rpm 60 kW 2200 rpm Firing order 1 3 4 2 Compression ratio 17 3 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylind...

Page 26: ...icated 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 N...

Page 27: ... ORFS 37 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 Adj Non adj 100 ft lbs 135 6 Nm 37 Adj 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...

Page 28: ...d 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 SPECIFICATIONS Torque Procedure JIC 37 fittings 1 Align the tube f...

Page 29: ...ect 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 fittting 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 th esecond mark on the body hex ...

Page 30: ...2 16 S 100HD S 120HD Part No 1268495 September 2016 Section 2 Specifications 10 9 12 9 8 8 4 6 SPECIFICATIONS ...

Page 31: ...ituation 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 malfun...

Page 32: ...n press the plus button once and change no to yes then press the enter button once to accept change Note If Programming mode is not exited properly all machine programming may be lost Boom Function Speeds 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 m...

Page 33: ...Metric English measurements Language selection With key switch off press and hold the button and turn the key switch to the on position Release the button and press Drive output max forward Drive output max reverse Elevated drive 75 ft 24 m Elevated drive 75 ft 24 m Stowed drive Drive acceleration Drive deceleration Speed limit on steer angle Drive Functions 100 max and 10 min 100 default 100 max ...

Page 34: ...min 500 0 50 sec default 1600 max and 100 min 500 0 50 sec default 5000 max and 100 min 2000 2 0 sec default 3000 max and 100 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 ...

Page 35: ... to the on position Release the button and press yes no yes no yes no yes no yes no Level Sensor Calibration With key switch off press and hold the button and turn the key switch to the on position Release the button and press Set unit level to gravity Turntable Y axis millivolts per degree Turntable X axis millivolts per degree Platform level to gravity Platform millivolts per degree yes no yes n...

Page 36: ... pltfs yes no yes no yes no yes no yes no o to 10 seconds 2 is the default shown only when hyd gen is selected 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 Options With key s...

Page 37: ... 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 Refer to Repair Procedure How to Calibrate a Joystick...

Page 38: ...nting fasteners 9 Carefully remove the ECM circuit board from the platform control box 1 1 Circuit Boards Note When an ECM circuit board is replaced the joystick controllers will need to be calibrated Refer to Repair Procedure 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 and platform controls 2...

Page 39: ...rd retaining fasteners 6 Carefully remove the membrane circuit board from the platform control box lid 1 2 Membrane 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 functi...

Page 40: ...box lid and carefuly connect the 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 b...

Page 41: ...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 Press and...

Page 42: ... 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 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 controls...

Page 43: ...eady 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 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the ent...

Page 44: ...controls to set the joystick controller threshold PLATFORM CONTROLS 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 7 While holding the joystick in position press the engine start button at the ...

Page 45: ...ns on Then move the joystick full stroke to the right ccw When the alarm sounds move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to center 15 Once all the joystick controllers have been calibrated push in the red Emergency Stop button at the platform controls to save the settings in memory Note The red Emergency Stop button at the platform co...

Page 46: ...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 hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on ...

Page 47: ...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 or...

Page 48: ...t 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 removed if it is not properly supported Crushing hazard The platform leveling cylinder will fall if it is not properly supported when the rod end pivot pin is removed Component damage hazard The platform leveling...

Page 49: ...onnect the electrical connector from the platform angle sensor 3 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on platform rotator manifold Cap the fittings on the manifold 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 4 Remo...

Page 50: ...ll machine functions in this procedure 1 Rotate the platform full right then full left 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 ...

Page 51: ...ormal 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 proce...

Page 52: ... increments until 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...

Page 53: ...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 54: ...ess 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 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 button or minus button to select YES T...

Page 55: ...Part No 1268495 S 100HD S 120HD 3 25 September 2016 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 S 100HD Models S 120HD Models ...

Page 56: ... the cable track covers from the number 0 boom tube 4 Tag disconnect and plug the two hydraulic hoses from the boom pull tube to the platform manifold Secure them to the cable track assembly 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 Tag and d...

Page 57: ...hoses boom cable tube and cable track can be damaged if they are kinked or pinched Component damage hazard The boom cable tube and cable tracks can be damaged if they are twisted How to Repair the Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Product Support for each of the cable tracks Use...

Page 58: ...ion of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the pivot pins and external snap rings or orange twist fasteners Note Be sure that the pivot pins are installed from the inside out so the external snap rings or poly buttons are on the outside of the ca...

Page 59: ... 000 kg crane to the platform end of the boom for support Do not lift the boom 7 Remove the boom storage area cover retaining fasteners Remove the cover from the machine 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 ...

Page 60: ...ylinder at the pivot end of the boom 15 Tag and disconnect the wiring connector from the cable break limit switch 16 Tag disconnect and plug the hydraulic hoses from the primary boom extension 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 ...

Page 61: ...ss covers 3 Secure the number 2 and number 3 boom tubes together with a strap or chain to prevent them from moving 4 Remove the cable clamp from the cable break limit switch wiring a cable break limit switch b cable pulley 5 Disconnect the wiring connector from the cable break limit switch 6 Tag disconnect and plug the hydraulic hoses from the primary boom extension cylinder Cap the fittings on th...

Page 62: ...ne 15 Remove the upper plate and actuator pivot pin Do not remove the cable break limit switch from the mounting plate 16 Push the cable break actuator and cables towards the platform end of the boom approximately 18 inches 46 cm 17 Remove the red cable adjustment locking bracket retaining fasteners Remove the red locking bracket from the machine Bodily injury hazard Failure to install the red cab...

Page 63: ... the number 2 boom tube at the platform end of the boom Do not remove the proximity or limit switches 28 Remove the retaining fasteners from the limit switch cover on the side of the number 0 boom tube at the platform end of the boom 29 Carefully remove the cover with proximity and limit switches from the number 0 boom tube at the platform end of the boom Tip over hazard Failure to install the cor...

Page 64: ...reful attention to the location and amount of shims used with each wear pad 38 Attach a lifting strap from an overhead crane to the number 2 boom tube at the platform end of the boom 39 Support and slide the number 2 boom tube out of the number 1 boom tube When the number 2 boom tube is approximately halfway removed remove the bottom wear pads from the number 1 boom tube at the platform end of the...

Page 65: ...m the number 0 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 47 Attach a lifting strap from an overhead crane to the number 1 boom tube at the platform end of the boom 48 Support and slide the number 1 boom tube out of the number 0 boom tube When the number 1 boom tube is approxima...

Page 66: ... connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the pivot end of the boom 8 Remove the pulley pivot pins cable guards and pulleys Note When installing the pulleys be sure that the side of the pulley with the taller flange is facing the center of the boom tu...

Page 67: ...e Bodily injury hazard Failure to install the red cable adjustment locking bracket will allow the cable mounting bolts to loosen and fall out which could result in death or serious injury 16 Remove the two cable adjustment bolts 17 Remove the cable end block mounting plate fasteners Remove the cable end block mounting plate from the machine 18 Remove the trunnion pin retaining fasteners 19 Use a s...

Page 68: ...om Do not remove the proximity or limit switches 26 Remove the retaining fasteners from the limit switch cover on the side of the number 1 boom tube at the platform end of the boom 27 Carefully remove the cover with proximity and limit switches from the number 1 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 l...

Page 69: ...careful attention to the location and amount of shims used with each wear pad 35 Remove and label the top and side wear pads from the number 1 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 36 Attach a lifting strap from an overhead crane to the number 2 boom tube at the platform en...

Page 70: ...om 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 cylinder ...

Page 71: ... Remove the pin retaining fastener from the barrel end pivot pin Do not remove the pin 15 Support the boom lift cylinder with an overhead crane 16 Use a slide hammer to remove the boom lift cylinder barrel end pivot pin through the access hole in the engine side turntable riser 17 With the boom lift cylinder being supported by the overhead crane pull the boom lift cylinder toward the platform unti...

Page 72: ... 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 3 Remove t...

Page 73: ...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 pin Do not remove the cabl...

Page 74: ...they are kinked pinched or snagged during removal Note During removal the overhead crane strap will need to be adjusted for proper balancing How to Remove the Secondary Boom Extension Cylinder S 120HD Models Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or ...

Page 75: ... other suitable 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 ex...

Page 76: ...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 At ...

Page 77: ... 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 locking br...

Page 78: ...te Be sure 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 brac...

Page 79: ...oom retract 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 ...

Page 80: ...ve 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 6...

Page 81: ...propriate gap between coupler and pump end plate for your engine 4 Apply Loctite removable thread sealant to the pump coupler set screw 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 engines 28 ft lbs 38 Nm Deutz engines 47 ft lbs 63 Nm Co...

Page 82: ...ressure 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 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 the coolan...

Page 83: ...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 Product S...

Page 84: ...tronic 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 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 ...

Page 85: ...d 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 discharge ESD can damage prin...

Page 86: ...l 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 infinit...

Page 87: ...Part No 1268495 S 100HD S 120HD 3 57 September 2016 Section 3 Repair Procedures S 100HD Models S 120HD Models Limit Switches ...

Page 88: ...on listed below and check for continuity terminal 1 to 2 continuity zero Ω terminal 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 ...

Page 89: ... 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 Move the piece of ferrous metal steel iron etc so it is more than 1 2 inch 12 7 mm away...

Page 90: ...witch 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 14 S 100HD 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 proximity switch LSB13AO and connect an ohmmeter or continuity tester to termin...

Page 91: ...Part No 1268495 S 100HD S 120HD 3 61 September 2016 Section 3 Repair Procedures 8 2 Limit Switch and Level Sensor Locations LIMIT SWITCHES ...

Page 92: ... are disabled Axle can be extended while driving 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 i...

Page 93: ... 65O the BO lockout valve will activate allowing hydraulic flow to the external cylinder to continue to extend to 120 feet 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 extended boom up is dis...

Page 94: ...tracted while this switch is activated the BN lockout valve is activated allowing hydraulic flow out of the inner cylinder 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 axis of the turntable The alarm sounds at 4 5O Platform Level Sensor Measures the angle of the platfo...

Page 95: ...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 slowly to a...

Page 96: ...fication during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the function pumps Refer to Repair Procedure 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 engi...

Page 97: ...k 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 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 pivot plate retaining fast...

Page 98: ...hutoff solenoi 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 at...

Page 99: ...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 will need to be serviced or replaced 5 Turn the key switch to the off position 6 Remove the pressure gauge and reconnect the hyd...

Page 100: ...3 70 S 100HD S 120HD Part No 1268495 September 2016 Section 3 Repair Procedures This page intentionally left blank ...

Page 101: ...y drive steer selector 25 27ft lbs 34 37Nm 9 Relief Valve 3000 psi 206 8 bar AC Platform manifold pressure limit 18 20ft lbs 24 27Nm 10 Flow Regulator Valve 3 gpm 11 36 L min AD Priority flow to platform 25 27ft lbs 34 37Nm 11 Check Valve 5 psi 0 34 bar AE Blocks flow from pump 2 to auxiliary pump 12 14 ft lbs 16 3 19 Nm 12 Proportional Solenoid Valve N C FF Primary lift proportional valve speed c...

Page 102: ...D Part No 1268495 September 2016 Section 3 Repair Procedures MANIFOLDS FQ FR FA AC FD FE AD FB FC FF FG AA AB AE FH FI FJ TP FK FL AF FM FP AG 2 1 3 4 5 27 26 22 23 24 28 21 29 15 16 17 18 19 20 7 8 6 12 11 13 14 9 10 25 ...

Page 103: ...ract solenoid valve proportional speed control 33 37 ft lbs 45 50 Nm 22 Check Valve 5 psi 0 34 bar FM Extension cylinder load sense check 12 14 ft lbs 16 3 19 Nm 23 Check Valve 5 psi 0 34 bar FJ Primary lift load sense check 12 14 ft lbs 16 3 19 Nm 24 Differential Sensing Valve 110 psi 7 58 bar FP Directs flow to functions 25 27ft lbs 34 37Nm 25 Check Valve 5 psi 0 34 bar FL Extension cylinder loa...

Page 104: ...D Part No 1268495 September 2016 Section 3 Repair Procedures MANIFOLDS FQ FR FA AC FD FE AD FB FC FF FG AA AB AE FH FI FJ TP FK FL AF FM FP AG 2 1 3 4 5 27 26 22 23 24 28 21 29 15 16 17 18 19 20 7 8 6 12 11 13 14 9 10 25 ...

Page 105: ...he 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 ground controls...

Page 106: ...NIFOLDS 10 3 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 Refer to Repair Procedure How to Calibrate a Joystick ...

Page 107: ...ve 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 9 Check Valve BL ...

Page 108: ... Part No 1268495 September 2016 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 109: ...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 pressure check boom exte...

Page 110: ... Part No 1268495 September 2016 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 111: ...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 ground controls 3 F...

Page 112: ...DS 10 6 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 Refer to Repair Procedure How to Calibrate a Joystick Controller ...

Page 113: ...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 sense circuit 7 4 9 ft ...

Page 114: ...3 84 S 100HD S 120HD Part No 1268495 September 2016 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 115: ...08 Proportional Valves Platform Manifolds 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 Refer to Repair Procedure How to Calibrate a Joystick MANIFOLDS ...

Page 116: ...dures MANIFOLDS 10 09 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 B A A B ...

Page 117: ...otation 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 A B C B A C ...

Page 118: ...ylinder 24 26 ft lbs 32 5 35 3 Nm 5 Flow Regulator Valve 2 0 gpm 7 6 L min EF Controls flow to left front steer cylinder 19 21 ft lbs 25 8 28 6 Nm 6 Flow Regulator Valve 1 4 gpm 5 3 L min EH Controls flow to left front steer cylinder retract 19 21 ft lbs 25 8 28 6 Nm 7 Flow Regulator Valve 1 4 gpm 5 3 L min EG Controls flow to right front steer cylinder retract 19 21 ft lbs 25 8 28 6 Nm 8 Flow Reg...

Page 119: ...Part No 1268495 S 100HD S 120HD 3 89 September 2016 Section 3 Repair Procedures MANIFOLDS HJ EA ES EB EF EH EG EO EP EE EI ...

Page 120: ...ise 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 surface 1 Con...

Page 121: ...kes released in case of temporary loss of charge pressure 20 25 ft lbs 27 34 Nm 5 Solenoid valve 2 position 3 way DA Brake release 26 30 ft lbs 35 41 Nm 6 Solenoid valve 2 position 3 way DC 2 speed drive motor shift 26 30 ft lbs 35 41 Nm 7 Relief valve 250 psi 17 2 bar DM Charge pressure circuit 20 25 ft lbs 27 34 Nm 8 Shuttle valve 3 position 3 way DL Charge pressure circuit that directs hot oil ...

Page 122: ...3 92 S 100HD S 120HD Part No 1268495 September 2016 Section 3 Repair Procedures MANIFOLDS DH DG DN DP DA DC DM DL DB DC ...

Page 123: ...20 25 ft lbs 27 1 33 9 Nm 5 Shuttle Valve 3 position 3 way DL 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 DM Charge pressure circuit 20 25 ft lbs 27 1 33 9 Nm 7 Orifice Plug 0 030 inch 0 762 mm DN Brake and two speed circuit 20 25 ft lbs 27 1 33 9 Nm 8 Check Valve DG Anti cavitation 20 25 ft lbs 27 1...

Page 124: ...3 94 S 100HD S 120HD Part No 1268495 September 2016 Section 3 Repair Procedures MANIFOLDS ...

Page 125: ...er combiner valve FQ 30 35 ft lbs 40 7 47 5 Nm 14 Bi directional Flow Control Valve 2 gpm 7 6 L min DE Equalizes pressure on both sides of divider combiner valve FQ 30 35 ft lbs 40 7 47 5 Nm 15 Check Valve DJ Anti cavitation 20 25 ft lbs 27 1 33 9 Nm 16 Flow Divider Combiner Valve DC Controls flow to circle end drive motors in forward and reverse 90 100 ft lbs 122 135 6 Nm 17 Flow Divider Combiner...

Page 126: ...3 96 S 100HD S 120HD Part No 1268495 September 2016 Section 3 Repair Procedures MANIFOLDS ...

Page 127: ...d 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 valves may...

Page 128: ...tic items AA Solenoid valve 2 position 3 way 10V DC schematic items FB FC FD 5 Ω 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 electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit ...

Page 129: ...ither 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 current...

Page 130: ...d plug the fuel supply and return hoses Cap the fittings on the fuel tank 3 Remove the fuel filler cap from the tank 4 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to specifications Machine 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 ope...

Page 131: ... and then torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the ground controls side turntable cover Refer to Repair Procedure 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 open...

Page 132: ...y power 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 Rem...

Page 133: ...otor 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 Torque Spe...

Page 134: ...e 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 135: ...ove them Note 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...

Page 136: ...me the lead sensor Note This procedure will require a minimum of two people Note Perform this procedure with the axles extended How to Measure the Tire Alignment 1 Start the engine from the platform controls 2 Press down the foot switch and push the engine idle select button until the engine switches to high rpm Measure the steer end tires 3 Measure the distance between the inside of one square en...

Page 137: ...stallation 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 Specifications 1 Remove the hose han...

Page 138: ...tor pin mounted to the top of the yoke 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 st...

Page 139: ... to Specifications Machine Torque Specifications 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...

Page 140: ...ressure 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 ...

Page 141: ...se 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 f...

Page 142: ...stall a new cotter pin Bend the cotter pin to secure the castle nut Note Always use a new cotter pin when installing a castle nut 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Specifications Machine Specifications AXLE COMPONENTS 13 6 Hub and Bearings 2WD Models How to Remove the Hub and Bearings 2WD Models 1 Loosen the wheel lug nuts ...

Page 143: ...retract the axle 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 6 Center a lifting jack of ample capacity under the axle that needs to be shimmed Do not raise the machine 7 Block the wheels at the opposite end of the machine 8 Raise the machine just ...

Page 144: ... 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 Alway...

Page 145: ... The wiring connectors 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 e...

Page 146: ... 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 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a...

Page 147: ...ns 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 fualt 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...

Page 148: ...nitiate one second 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 ca...

Page 149: ...h Value Too Low 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 wit...

Page 150: ...WITCH P14 SAFETY 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 Displa...

Page 151: ...ction except threshold 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...

Page 152: ... 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 neutral ...

Page 153: ...l 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 Val...

Page 154: ...ength crosscheck OFF OFF 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 Lo...

Page 155: ...iption 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 4...

Page 156: ...otate 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 Valve ...

Page 157: ... 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 Gene...

Page 158: ...tor error EGR Valve signal range check low 51 5 1223 Actuator EGR Valve open load 51 6 1014 Actuator error EGR Valve signal range check high 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 Actuat...

Page 159: ...eshold exceeded 105 3 994 Sensor 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 tempera...

Page 160: ...e 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 ch...

Page 161: ...81 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low DEUTZ TD 2 9 L4 ENGINE FAULT CODES 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 Recei...

Page 162: ...e 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 r...

Page 163: ... 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 si...

Page 164: ...ation 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 g...

Page 165: ...rror exhaust gas temperature downstream 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 ...

Page 166: ...t Error of CAN Receive Frame TSC1AR 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 Inter...

Page 167: ...e exceeded RailMeUn3 523613 2 864 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...

Page 168: ...895 13 559 Check of missing injector 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 inject...

Page 169: ... Balance Control integrator injector 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...

Page 170: ...emp 523998 4 1327 Injector cylinder 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 fue...

Page 171: ...ame ComRxDPFBrnAirPmp 524104 9 1676 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 Recei...

Page 172: ...N FMI KWP Description 524120 9 1682 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 ...

Page 173: ...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 Pr...

Page 174: ... 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 1 ...

Page 175: ... Erratic Idle Validation Switch Circuits 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 repres...

Page 176: ...est 654 5 Engine Injector Cylinder 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 S...

Page 177: ... Pressure Is Low severity 2 1188 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 Pressur...

Page 178: ...0 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 Normal...

Page 179: ...ot 3251 3 Particulate Trap Differential 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 Differen...

Page 180: ...w Plug 1 Not Responding Properly 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 Actuat...

Page 181: ... 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 W 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 Relea...

Page 182: ...perator s Manual and the Genie S 120HD 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 application tha...

Page 183: ...rules and operating instructions 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 Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and othe...

Page 184: ...ircuit 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 Auxiliary ...

Page 185: ...orm 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 Valve ...

Page 186: ...ht 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 valv...

Page 187: ...form 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 3...

Page 188: ...lock 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 b...

Page 189: ...gnal 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 GR 169 Envelope active LED WH RD 170 Load sense relay source WH BK 171 Load sense re...

Page 190: ...ted past the rear axles indicated by the square end of the drive chassis In some cases the engine will be stopped if safety parameters are exceeded Magnetic proximity switches are 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...

Page 191: ...September 2016 Section 5 Schematics Part No 1268495 S 100HD S 120HD 5 9 LIMIT SWITCHES S 100HD Models S 120HD Models ...

Page 192: ...R12 relay 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...

Page 193: ...SED 12 C111RFS OR 13 C111LFS OR 14 VLVRET2 BR 15 V32BRK WH RD 16 UNUSED 17 UNUSED 18 V36RFS BL 19 P110RT BK 20 P109ANG GR 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 C61LS GR 9 P61LS GR 10 UNUSED 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 C61LS A GR 16 UNUSED 17 D81CAN GR 18 D82C...

Page 194: ...0PXS RD BK 12 LDSGND GR YL 13 LDSSIG OR 14 LDSPWR BK 15 C88PTS RD BK 16 R56FTS RD 17 C56FTS 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 WH 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 UNUSED 15 C47OUT WH BK 16 C46HN WH 17 D81CAN GR 18 D82CAN...

Page 195: ...BD RD WH 7 P58LS RD BK 8 S59CNBK GR WH 9 C60AXEX GR WH 10 C61AXRT GR 11 S62BSTO OR 12 P63LS OR RD 13 C64LS OR BK 14 C65LOFL BL WH 15 C66DREN BL 16 UNUSED 17 C68PBD RD 18 C69PBE BK 19 C70PBE BL WH 20 C71PBE BL BK 21 UNUSED 22 UNUSED 23 UNUSED 24 UNUSED 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 UNUSED TCON TURNTABLE CONTROLLER J3...

Page 196: ...9 Fuse 20A RPM Solenoid 10 F23 Fuse 30A Eng Start Fuel 11 F22 Fuse 60A 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...

Page 197: ...y 8 Horn Relay 9 Fuse 20A RPM Solenoid 10 F23 Fuse 30A Eng Start Fuel 11 F22 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 ...

Page 198: ...gine 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 M...

Page 199: ...September 2016 Section 5 Schematics Part No 1268495 S 100HD S 120HD 5 17 Electrical Symbols Legend ...

Page 200: ...September 2016 Section 5 Schematics 5 18 S 100HD S 120HD Part No 1268495 Hydraulic Symbols Legend ...

Page 201: ...Section 5 Schematics September 2016 5 19 Electrical Schematic View 1 S 100HD Models 5 20 ...

Page 202: ... RD WH C111RFS OR C111LFS OR P110RT BK V36RFS BL V32BRK WH RD P109ANG GR WH V37RFS BL BK V36LFS BL V37LFS BL BK RF STEER RIGHT LF STEER RIGHT J2 WHITE 23 PIN DRIVE CHASSIS HARN DRIVE CHASSIS HARN DCON OUT PWR ENABLE PWR PCON ESTOP D82CAN YL D81CAN GR P63LS OR RD P53LS WH BK C60AXEX GN WH P57PBD RD WH P21DCON RD GNDDCON BR S56PRV RD C61AXRT GR 2 2 WAY DEUTSCH BOOM HARN LIMIT SW HARN 4 WAY DEUTSCH C...

Page 203: ...OUT LOAD SNSR GND PROX KILL CMD C90PXS RD BK PROX KILL GND R90PXS RD BK C15PLD OR BK C14PLU OR PROP VLV2_A ON OFF VLV3_B C18PRR GR BK ON OFF VLV3_A C17PRL GR VLV RTN VLVRET BR PROP VLV2_B PROP VLV1_A PROP VLV1_B PLAT ROT CCW PLAT LEVEL DN PLAT LEVEL UP PLAT ROT CW 3 1 4 2 PROX SWITCH OPTION 2 1 FOOTSWITCH U20 9 10 7 6 5 4 8 3 2 1 3 2 1 6 5 4 9 8 7 10 BOOM HARN PCON MANIFOLD GR YL OR BK PLATFORM TI...

Page 204: ...September 2016 Section 5 Schematics 5 22 Electrical Schematic View 2 S 100HD Models 5 21 ...

Page 205: ...Section 5 Schematics September 2016 5 23 Electrical Schematic View 3 S 100HD Models 5 24 ...

Page 206: ...WH P53LS WH BK P63LS OR RD GNDDCON BR S56PRV RD C61AXRT GR TO FLASHING BEACON TO WORK LIGHTS J27 BOOM HARN BOOM DWN RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL BOOM UP DWN FC RECOVERY SIGNAL BOOM EXT RET FC RECOVERY SIGNAL AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BM DWN O BM E R FC O BM RET O MLT FNC VLV O AUX HYD O BM DWN ST I BM 100 I BM 3 I PRI LO 1 O BM U D FC O LOCKOUT VA...

Page 207: ...S LST10 LSB1DO P2 16 P2 14 P2 15 P2 17 P2 18 P2 19 P2 20 P2 22 P2 21 P_14 P_11 P_12 P_18 P_9A P_7R P_6R2 P_9B P_10 P2 06 P2 05 P2 04 P2 07 P2 08 P2 11 P2 09 P2 10 P2 12 OPER SW PWR P2 13 P57PBD RD WH P54ENG BK WH P58LS RD BK S59CNBK GR WH C60AXEX GR WH C61AXRT GR C68PBD RD C65LOFL BL WH C66DREN BL C70PBE BL WH C69PBE BK C71PBE BL BK C64LS OR BK P63LS OR RD S62BSTO OR S56PRV RD DCON ECU GND DCON EC...

Page 208: ...September 2016 Section 5 Schematics 5 26 Electrical Schematic View4 S 100HD Models 5 25 ...

Page 209: ...Section 5 Schematics September 2016 5 27 Electrical Schematic View 5 S 100HD Models 5 28 ...

Page 210: ...86 30 1 2 MAIN AUX P114BAT RD 87a STARTER RELAY START BATTERY MAIN BATTERY 4 SERVICE HORN DEUTZ ENGINE OPTION ENGINE BLOCK HI RPM SOLENOID BAT GND BR BATVLV RD BATGND BR BATGND BR BATECU RD C21IGN WH C34SA BK WH R35RPM BK RD C46HRN WH C30EDC WH C31EDC WH BK C33STR BK C25PSR WH BK C26TSR WH RD RET85TTSR BR VLVRET2 BR P85TTSR GR C41RPM OR BK C107AF RD C84TAY GR BK C83TAX GR WH C45GEN GR WH 87a 5 85 ...

Page 211: ...UX P114BAT RD 87a STARTER RELAY START BATTERY MAIN BATTERY 4 SERVICE HORN CUMMINS ENGINE OPTION ENGINE BLOCK HI RPM SOLENOID BAT GND BR BATVLV RD BATGND BR BATGND BR BATECU RD C21IGN WH C34SA BK WH R35RPM BK RD C46HRN WH C30EDC WH C31EDC WH BK C33STR BK C25PSR WH BK C26TSR WH RD RET85TTSR BR VLVRET2 BR P85TTSR GR C41RPM OR BK C107AF RD C84TAY GR BK C83TAX GR WH C45GEN GR WH 87a 5 85 4 87 2 86 1 30...

Page 212: ...September 2016 Section 5 Schematics 5 30 Electrical Schematic View 6 S 100HD Models 5 29 ...

Page 213: ...Section 5 Schematics September 2016 5 31 Electrical Schematic View 7 S 100HD Models 5 32 ...

Page 214: ...BOOM_RETRACT_VLV LSB4ES MONITOR INPUT LSB8AS MONITOR INPUT J4 WHITE 35 PIN S7PLE1 BL BK S2PLD1 BL RD P4 03 P4 02 P4 01 P4 13 P4 08 P4 04 P4 05 P4 06 P4 07 P4 09 P4 10 P4 11 P4 12 P4 14 P4 15 P4 16 P4 17 P4 18 MANIFOLD HARN TO MICRO P4 19 VALVE RTN7 VALVE RTN6 C27AUX RD C113MFV OR RD C05TTL WH C06TTR WH BK TO PR1 TURNTABLE ROT CCW VLV TURNTABLE ROT CW VLV MULTI FUNC VLV C06TRF WH RD VLVRET4 BR C03P...

Page 215: ...AT IN 1 IN 2 TCON J4 8 GND OUT 1 OUT 2 TCON J4 9 TO 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...

Page 216: ...September 2016 Section 5 Schematics 5 34 5 33 Safety Circuit Schematic S 100HD Models ...

Page 217: ...Section 5 Schematics September 2016 5 35 5 36 Electrical Schematic View 1 S 120HD Models ...

Page 218: ... RD WH C111RFS OR C111LFS OR P110RT BK V36RFS BL V32BRK WH RD P109ANG GR WH V37RFS BL BK V36LFS BL V37LFS BL BK RF STEER RIGHT LF STEER RIGHT J2 WHITE 23 PIN DRIVE CHASSIS HARN DRIVE CHASSIS HARN DCON OUT PWR ENABLE PWR PCON ESTOP D82CAN YL D81CAN GR P63LS OR RD P53LS WH BK C60AXEX GN WH P57PBD RD WH P21DCON RD GNDDCON BR S56PRV RD C61AXRT GR 2 2 WAY DEUTSCH BOOM HARN LIMIT SW HARN 4 WAY DEUTSCH C...

Page 219: ... PRO X KILL CMD C90PXS RD BK PRO X KILL GND R90PXS RD BK C15PLD OR BK C14PLU O R PRO P VLV2_A ON OFF VLV3_B C18PRR GR B K ON OFF VLV3_A C17PRL GR VLV R TN VLVRET BR PRO P VLV2_B PRO P VLV1_A PRO P VLV1_B PLAT R OT CCW PLAT LEVEL DN PLAT LEVEL UP PLAT R OT CW 3 1 4 2 PROX SWITCH OPTION 2 1 FOOTSWITCH U20 9 10 7 6 5 4 8 3 2 1 3 2 1 6 5 4 9 8 7 10 BOOM HARN PCON MANIFOLD GR Y L OR BK PLATFORM TILT SE...

Page 220: ...September 2016 Section 5 Schematics 5 38 Electrical Schematic View 2 S 120HD Models 5 37 ...

Page 221: ...Section 5 Schematics September 2016 5 39 Electrical Schematic View 3 S 120HD Models 5 40 ...

Page 222: ...WH P53LS WH BK P63LS OR RD GNDDCON BR S56PRV RD C61AXRT GR TO FLASHING BEACON TO WORK LIGHTS J27 BOOM HARN BOOM DWN RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL BOOM UP DWN FC RECOVERY SIGNAL BOOM EXT RET FC RECOVERY SIGNAL AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BM DWN O BM E R FC O BM RET O MLT FNC VLV O AUX HYD O BM DWN ST I BM 100 I BM 3 I PRI LO 1 O BM U D FC O LOCKOUT VA...

Page 223: ...S LST10 LSB1DO P2 16 P2 14 P2 15 P2 17 P2 18 P2 19 P2 20 P2 22 P2 21 P_14 P_11 P_12 P_18 P_9A P_7R P_6R2 P_9B P_10 P2 06 P2 05 P2 04 P2 07 P2 08 P2 11 P2 09 P2 10 P2 12 OPER SW PWR P2 13 P57PBD RD WH P54ENG BK WH P58LS RD BK S59CNBK GR WH C60AXEX GR WH C61AXRT GR C68PBD RD C65LOFL BL WH C66DREN BL C70PBE BL WH C69PBE BK C71PBE BL BK C64LS OR BK P63LS OR RD S62BSTO OR S56PRV RD DCON ECU GND DCON EC...

Page 224: ...September 2016 Section 5 Schematics 5 42 Electrical Schematic View 4 S 120HD Models 5 41 ...

Page 225: ...Section 5 Schematics September 2016 5 43 Electrical Schematic View 5 S 120HD Models 5 44 ...

Page 226: ...86 30 1 2 MAIN AUX P114BAT RD 87a STARTER RELAY START BATTERY MAIN BATTERY 4 SERVICE HORN DEUTZ ENGINE OPTION ENGINE BLOCK HI RPM SOLENOID BAT GND BR BATVLV RD BATGND BR BATGND BR BATECU RD C21IGN WH C34SA BK WH R35RPM BK RD C46HRN WH C30EDC WH C31EDC WH BK C33STR BK C25PSR WH BK C26TSR WH RD RET85TTSR BR VLVRET2 BR P85TTSR GR C41RPM OR BK C107AF RD C84TAY GR BK C83TAX GR WH C45GEN GR WH 87a 5 85 ...

Page 227: ...UX P114BAT RD 87a STARTER RELAY START BATTERY MAIN BATTERY 4 SERVICE HORN CUMMINS ENGINE OPTION ENGINE BLOCK HI RPM SOLENOID BAT GND BR BATVLV RD BATGND BR BATGND BR BATECU RD C21IGN WH C34SA BK WH R35RPM BK RD C46HRN WH C30EDC WH C31EDC WH BK C33STR BK C25PSR WH BK C26TSR WH RD RET85TTSR BR VLVRET2 BR P85TTSR GR C41RPM OR BK C107AF RD C84TAY GR BK C83TAX GR WH C45GEN GR WH 87a 5 85 4 87 2 86 1 30...

Page 228: ...September 2016 Section 5 Schematics 5 46 Electrical Schematic View 6 S 120HD Models 5 45 ...

Page 229: ...Section 5 Schematics September 2016 5 47 5 48 Electrical Schematic View 7 S 120HD Models ...

Page 230: ...BOOM_RETRACT_VLV LSB4ES MONITOR INPUT LSB8AS MONITOR INPUT J4 WHITE 35 PIN S7PLE1 BL BK S2PLD1 BL RD P4 03 P4 02 P4 01 P4 13 P4 08 P4 04 P4 05 P4 06 P4 07 P4 09 P4 10 P4 11 P4 12 P4 14 P4 15 P4 16 P4 17 P4 18 MANIFOLD HARN TO MICRO P4 19 VALVE RTN7 VALVE RTN6 C27AUX RD C113MFV OR RD C05TTL WH C06TTR WH BK TO PR1 TURNTABLE ROT CCW VLV TURNTABLE ROT CW VLV MULTI FUNC VLV C06TRF WH RD VLVRET4 BR C03P...

Page 231: ...AT IN 1 IN 2 TCON J4 8 GND OUT 1 OUT 2 TCON J4 9 TO 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...

Page 232: ...September 2016 Section 5 Schematics 5 50 Safety Circuit Schematic S 120HD Models 5 49 ...

Page 233: ...Section 5 Schematics September 2016 5 51 Perkins 854F 34T Engine Electrical Schematic 5 52 ...

Page 234: ...September 2016 Section 5 Schematics 5 52 S 100HD S 120HD Part No 1268495 Perkins 854F 34T Engine Electrical Schematic ...

Page 235: ...Section 5 Schematics September 2016 Part No 1268495 S 100HD S 120HD 5 53 ...

Page 236: ...September 2016 Section 5 Schematics 5 54 Perkins 854F 34T Engine Electrical Harness 5 53 ...

Page 237: ...Section 5 Schematics September 2016 5 55 Deutz TD2 9 Engine Electrical Schematic 5 56 ...

Page 238: ...September 2016 Section 5 Schematics 5 56 S 100HD S 120HD Part No 1268495 Deutz TD2 9 Engine Electrical Schematic ...

Page 239: ...Section 5 Schematics September 2016 Part No 1268495 S 100HD S 120HD 5 57 Deutz TD2 9 Engine Electrical Harness ...

Page 240: ...September 2016 Section 5 Schematics 5 58 Deutz TD2 9 Engine Electrical Harness 5 57 ...

Page 241: ...Section 5 Schematics September 2016 5 59 Hydraulic Schematic S 100HD Models 5 60 ...

Page 242: ...September 2016 Section 5 Schematics 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N 5 60 S 100HD S 120HD Part No 1268495 Hydraulic Schematic S 100HD Models 2WD 2WS ...

Page 243: ...Section 5 Schematics September 2016 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 1268495 S 100HD S 120HD 5 61 Hydraulic Schematic S 100HD Models 4WD 2WS ...

Page 244: ...September 2016 Section 5 Schematics 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N 5 62 S 100HD S 120HD Part No 1268495 Hydraulic Schematic S 100HD Models 4WD 4WS ...

Page 245: ...Section 5 Schematics September 2016 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 1268495 S 100HD S 120HD 5 63 Hydraulic Schematic S 120HD Models 2WD 2WS ...

Page 246: ...September 2016 Section 5 Schematics 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N 5 64 S 100HD S 120HD Part No 1268495 Hydraulic Schematic S 120HD Models 4WD 2WS ...

Page 247: ...Section 5 Schematics September 2016 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 1268495 S 100HD S 120HD 5 65 Hydraulic Schematic S 120HD Models 4WD 4WS ...

Page 248: ...September 2016 Section 5 Schematics 5 66 Hydraulic Schematic S 120HD Models 5 60 ...

Page 249: ......

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