Genie S-100 Installations- und Betriebsanleitung

Part No. 1268494

Rev A4

March 2017

Serial Number Range

from S-10015D-1001

to S-10016D-1549

from S-10515D-983

to S-10516D-1549

from 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

March 2017

 S-100•S-105•S-120•S-125 PartNo.1268494

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the Genie S-100 and

Genie S-105 Operator's Manual or the Genie

S-120 and Genie S-125 Operator's Manual before

attempting any maintenance or repair procedure.

This manual provides troubleshooting and repair

procedures for qualied service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills,

tools, lifting equipment and a suitable workshop.

In these instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classication

Group B/Type 3 as dened by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

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. However, continuous

improvement of our products is a Genie policy.

Therefore, product specications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: [email protected]

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Operator's, Parts or Service

Manuals.

Hyper link is:http://www.genielift.com/en/service-

support/manuals/index.htm

March 2017

Part No. 1268494 S-100 • S-105 • S-120 • S-125 iii

Revision History

Revision Date Section Procedure / Description

A 9/2015 Initial Release

A1 1/2016

Add Deutz TD201104i Engine &

Electrical schematics

A2 9/2016 Introduction Serial Number Legend

A3 2/2017 Specications Performance Specications

A4 3/2017 Repair Procedures Update illustration for cable adjustment

Reference Examples:

Section - Repair Procedure

Section - Fault Codes

Section - Schematics,Legends and schematics

Introduction

March 2017

 S-100•S-105•S-120•S-125 PartNo.1268494

iii

Serial Number Legend

Model:

Serial number:

Electrical schematic number:

Year of manufacture:

Machine unladenweight:

Rated work load(including occupants):

Maximum numberofplatformoccupants:

Maximumallowable side force:

Maximumallowable inclination of thechassis:

S120D-12345

2016

S0D-1234512

1 2 3

Model:

Serial number:

Model year:

Electrical schematic number:

Manufacturedate:

Machine unladenweight:

Rated work load(including occupants):

Maximum numberofplatformoccupants:

Maximumallowable side force:

Maximumallowable inclination of thechassis:

S12016D-12345

1/2/16 2016

S120 16 D-12345

1 2 3 4

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (located under cover)

6 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

Introduction

March 2017

Part No. 1268494 S-100 • S-105 • S-120 • S-125

Danger

Failure to obey the instructions and safety rules in

this manual, and the Genie S-100 & Genie S-105

Operator's Manual or the Genie S-120 & Genie

S-125 Operator's Manual will result in death or

serious injury.

Many of the hazards identied 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 qualied 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

equipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules

March 2017

 S-100•S-105•S-120•S-125 PartNo.1268494

Section 1 - Safety Rules

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Workplace Safety

Be sure to keep sparks, ames and

lighted tobacco away from ammable

and combustible materials like battery

gases and engine fuels. Always have an approved

re extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free

of debris that could get into machine components

and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other uids. 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 the

machine should be your top priority.

Read each procedure thoroughly. This manual and

the decals on the machine, use signal words to

identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of

a potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used

to indicate the presence of a

potentially hazardous situation

which, if not avoided, may cause

minor or moderate injury.

Used to indicate the presence of

a potentially hazardous situation

which, if not avoided, may result in

property damage.

Safety Rules

March 2017

Part No. 1268494 S-100 • S-105 • S-120 • S-125

Table of Contents

Introduction

Important Information................................................................................................... ii

Serial Number Information ........................................................................................... ii

Serial Number Legend .................................................................................................iii

Section 1 Safety Rules

General Safety Rules................................................................................................... v

Section 2 Specications

Machine Specications, S120 and S-125 Models...................................................2 - 1

Performance Specications, S120 and S-125 Models............................................2 - 2

Machine Specications, S100 and S-105 Models...................................................2 - 3

Performance Specications, S100 and S-105 Models............................................2 - 5

Hydraulic Specications..........................................................................................2 - 6

Hydraulic Component Specications ......................................................................2 - 8

Deutz Engine F4L 913 Specications ...................................................................2 - 11

Deutz Engine BF4L 2011 Specications...............................................................2 - 12

Deutz Engine TD2011L04i Specications.............................................................2 - 13

Deutz Engine TD 2.9 Specications......................................................................2 - 14

Perkins Engine 1104D-44T Specications............................................................2 - 15

Perkins Engine 854F-34T Specications ..............................................................2 - 16

Perkins Engine 1004-42 Specications.................................................................2 - 18

Perkins Engine 1104C-44 Specications..............................................................2 - 19

Perkins Engine 804D-33T Specications..............................................................2 - 20

Cummins Engine B3.3T Specications.................................................................2 - 22

Cummins Engine B3.9L Specications .................................................................2 - 23

Cummins Engine B4.5L Specications .................................................................2 - 24

Machine Torque Specications.............................................................................2 - 25

Manifold Plug Torque Specications.....................................................................2 - 25

Hydraulic Hose and Fitting Torque Specications ................................................2 - 26

SAE and Metric Fasteners Torque Charts ............................................................2 - 26

vii

March 2017

 S-100•S-105•S-120•S-125 PartNo.1268494

TABLE OF CONTENTS

viii

Section 3 Repair Procedures

Introduction .............................................................................................................3 - 1

Display Module........................................................................................................3 - 2

Platform Controls

1-1 Circuit Boards................................................................................................3 - 7

1-2 Membrane Decal ...........................................................................................3 - 8

1-3 Joystick Controllers .......................................................................................3 - 9

Platform Components

2-1 Platform .......................................................................................................3 - 16

2-2 Platform Leveling Cylinder ..........................................................................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 Extension Cylinders.....................................................................................3 - 46

4-5 Boom Extend/Retract Cables ......................................................................3 - 50

Turntable Covers

5-1 Turntable Covers.........................................................................................3 - 54

March 2017

Part No. 1268494 S-100 • S-105 • S-120 • S-125 ix

TABLE OF CONTENTS

Section 3 Repair Procedures, continued

Engines

6-1 RPM Adjustment .........................................................................................3 - 56

6-2 Flex Plate ....................................................................................................3 - 56

6-3 Oil Pressure and Coolant Temperature Sending Units,

Cummins and Perkins Models.....................................................................3 - 58

6-4 Oil Pressure and Temperature Sending Units, Deutz Models.....................3 - 58

Ground Controls

7-1 Circuit Boards..............................................................................................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 Models

(after serial number 136) .............................................................................3 - 81

10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models .............3 - 85

10-4 Proportional Valves - Function Manifold......................................................3 - 86

March 2017

 S-100•S-105•S-120•S-125 PartNo.1268494

TABLE OF CONTENTS

Section 3 Repair Procedures, continued

10-5 Function Manifold Components, S-120 and S-125 Models

(before serial number 431) ..........................................................................3 - 87

10-6 Function Manifold Components, S-120 and S-125 Models

(from serial number 431 to 574) ..................................................................3 - 91

10-7 Function Manifold Components, S-120 and S-125 Models

(after serial number 574) .............................................................................3 - 95

10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models .............3 - 99

10-9 Proportional Valves - Function Manifold....................................................3 - 100

10-10 Platform Manifold Components, S-100 and S-120 Models .......................3 - 101

10-11 Platform Manifold Components, S-105 and S-125 Models .......................3 - 103

10-12 Proportional Valves - Platform Manifolds ..................................................3 - 105

10-13 Platform Rotate Counterbalance Valve Manifold Components .................3 - 105

10-14 Turntable Rotation Manifold Components.................................................3 - 106

10-15 Steer and Axle Extend/Retract Manifold Components - View 1 ................3 - 107

10-16 Steer and Axle Extend/Retract Manifold Components - View 2 ................3 - 109

10-17 Valve Adjustments - Steer and Axle Extend/Retract Manifold ..................3 - 113

10-18 Traction Manifold Components

(S-100/105 before serial number 291)

(S-120/125 before serial number 1195) ....................................................3 - 115

10-19 Traction Manifold Components

(S-100/105 after serial number 290)

(S-120/125 after serial number 1194) .......................................................3 - 119

10-20 Valve Adjustments - Traction Manifold......................................................3 - 123

10-21 Valve Coils ................................................................................................3 - 123

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