Transcript
Service Manual Serial Number Range
S-100 S-105
from S100/105-136 to S10012/S10512-941
S-120 S-125
from S120/125-404 to S12012/S12512-3399
from S10011D-114 to S10015D-1000 from S10511D-133 to S10515D-1011
from S12011D-113 to S12015D-1011 from S12511D-134 to S12515D-983
Part No. 102916 Rev F 2FWRber 2015
October 2015
Introduction
Introduction Important
Technical Publications
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.
Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.
This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals.
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.
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.
Contact Us: Internet: www.genielift.com E-mail:
[email protected]
Find a Manual for this Model Go to http://www.genielift.com
Compliance Machine Classification Group B/Type 3 as defined by ISO 16368
Use the links to locate Operator's, Parts or Service Manuals.
Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance.
Copyright © 2001 by Terex Corporation 102916 Rev F September 2015 Second Edition, Sixth Printing Genie is a registered trademark of Terex South Dakota, Inc.in the U.S.A and many other countries.
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INTRODUCTION
Serial Number Legend
Model: S-120 S12006-12345 Serial number: Model year: 2006 Manufacture date: 01/05/06 Electrical schematic number: Es0427 Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg Maximum number of platfrm occupants: 2 Maximum allowable side force : 150 lb / 670 N Maximum allowable inclination of the chassis: 0 deg Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 126 ft/ 38.6 m Maximum platform reach : 75 ft/ 22.9 m Gradeability: N/A
S120 06
D - 12345
Model
Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4
Sequence number
Model year Facility code (used only for model manufactured in multiple facilities)
Terex South Dakota 500 Oak Wood Road PO Box 1150 Watertown, SD 57201 USA
Serial number stamped on chassis
Part No. 102916
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Serial label (located under cover)
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Section 1 • Safety Rules
Safety Rules
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 identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.
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Section 1 - Safety Rules
SAFETY RULES
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.
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, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire 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 fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit.
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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
Specifications
Machine Specifications, S120 and S-125 Models....................................................2 - 1
Performance Specifications, S120 and S-125 Models.............................................2 - 2
Machine Specifications, S100 and S-105 Models....................................................2 - 3
Performance Specifications, S100 and S-105 Models.............................................2 - 5
Hydraulic Specifications...........................................................................................2 - 6
Hydraulic Component Specifications.......................................................................2 - 8
Deutz Engine F4L 913 Specifications....................................................................2 - 11
Deutz Engine BF4L 2011 Specifications................................................................2 - 12
Deutz Engine TD2011L04i Specifications..............................................................2 - 13
Deutz Engine TD 2.9 Specifications......................................................................2 - 14
Perkins Engine 1104D-44T Specifications.............................................................2 - 15
Perkins Engine 854F-34T Specifications...............................................................2 - 16
Perkins Engine 1004-42 Specifications.................................................................2 - 18
Perkins Engine 1104C-44 Specifications...............................................................2 - 19
Perkins Engine 804D-33T Specifications...............................................................2 - 20 Cummins Engine B3.3T Specifications..................................................................2 - 22
Cummins Engine B3.9L Specifications..................................................................2 - 23
Cummins Engine B4.5L Specifications..................................................................2 - 24
Machine Torque Specifications..............................................................................2 - 25
Manifold Plug Torque Specifications......................................................................2 - 25
Hydraulic Hose and Fitting Torque Specifications.................................................2 - 26
SAE and Metric Fasteners Torque Charts.............................................................2 - 26
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TABLE OF CONTENTS Section 3
Scheduled Maintenance Procedures
Introduction..............................................................................................................3 - 1
Pre-delivery Preparation..........................................................................................3 - 3
Maintenance Inspection Report...............................................................................3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals....................................................................3 - 7
A-2 Perform Pre-operation Inspection..................................................................3 - 8
A-3 Perform Function Tests..................................................................................3 - 8
A-4 Perform Engine Maintenance - Perkins Models.............................................3 - 9
A-5 Perform Engine Maintenance - Deutz Models................................................3 - 9
A-6 Perform Engine Maintenance - Cummins Models........................................3 - 10
A-7 Check the Hydraulic Filter Condition Indicators...........................................3 - 10
A-8 Perform 30 Day Service...............................................................................3 - 12
A-9 Perform Engine Maintenance - Perkins Models...........................................3 - 12
A-10 Perform Engine Maintenance - Deutz Models..............................................3 - 13
A-11 Grease the Turntable Rotation Bearing and Rotate Gear............................3 - 14
A-12 Grease the Extendable Axles.......................................................................3 - 15
A-13 Replace the Drive Hub Oil............................................................................3 - 15
Checklist B Procedures
B-1 Inspect the Batteries.....................................................................................3 - 18
B-2 Inspect the Electrical Wiring.........................................................................3 - 19
B-3 Check the Engine Oil Cooler and Cooling Fins - Deutz Models...................3 - 21
B-4 Inspect the Engine Air Filter.........................................................................3 - 22
B-5 Perform Hydaulic Oil Analysis......................................................................3 - 23
B-6 Perform Engine Maintenance - Deutz Models..............................................3 - 23
B-7 Perform Engine Maintenance - Cummins Models........................................3 - 24
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TABLE OF CONTENTS Section 3
Scheduled Maintenance Procedures, continued
Checklist B Procedures
B-8 Check the Exhaust System..........................................................................3 - 25
B-9 Inspect the Tires, Wheels and Lug Nut Torque............................................3 - 26
B-10 Check the Dirve Hub Oil Level and Fastener Torque...................................3 - 26
B-11 Confirm the Proper Brake Configuration......................................................3 - 28
B-12 Check and Adjust the Engine RPM..............................................................3 - 29
B-13 Test the Key Switches..................................................................................3 - 32
B-14 Test the Ground Control Override................................................................3 - 33
B-15 Test the Platform Self-leveling.....................................................................3 - 34
B-16 Test the Safety Envelope and Circuits.........................................................3 - 35
B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems........................3 - 41
B-18 Test the Engine Idle Select Operation..........................................................3 - 42
B-19 Test the Drive Brakes...................................................................................3 - 43
B-20 Test the Drive Speed - Stowed Position.......................................................3 - 43
B-21 Test the Drive Speed - Raised or Extended Position...................................3 - 44
B-22 Inspect the Boom Extend/Retract Cables....................................................3 - 45
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models..............................................3 - 46
C-2 Perform Engine Maintenance - Cummins Models........................................3 - 46
C-3 Perform Engine Maintenance - Perkins Models...........................................3 - 47
C-4 Perform Engine Maintenance - Perkins Models...........................................3 - 47
C-5 Replace the Engine Air Filter Element.........................................................3 - 48
C-6 Grease the Platform Overload Mechanism (if equipped).............................3 - 48
C-7 Test the Platform Overload System (if equipped)........................................3 - 49
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TABLE OF CONTENTS Section 3
Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1 Check the Boom Wear Pads........................................................................3 - 51
D-2 Check the Extendable Axle Wear Pads.......................................................3 - 52
D-3 Check the Free-wheel Configuration............................................................3 - 53
D-4 Check the Turntable Rotation Bearing Bolts................................................3 - 54
D-5 Check the Turntable Rotation Gear Backlash..............................................3 - 55
D-6 Replace the Drive Hub Oil............................................................................3 - 57
D-7 Inspect for Turntable Bearing Wear.............................................................3 - 59
D-8 Perform Engine Maintenance - Deutz Models..............................................3 - 60
D-9 Perform Engine Maintenance - Perkins Models...........................................3 - 60
D-10 Perform Engine Maintenance - Perkins Models...........................................3 - 61
D-11 Perform Engine Maintenance - Cummins Models........................................3 - 61
D-12 Replace the Hydraulic Filter Elements.........................................................3 - 62
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil.................................................................3 - 64
E-2 Perform Engine Maintenance - Cummins Models........................................3 - 66
E-3 Perform Engine Maintenance - Perkins Models...........................................3 - 66
E-4 Perform Engine Maintenance - Deutz Models..............................................3 - 67
E-5 Perform Engine Maintenance - Perkins Models...........................................3 - 67
E-6 Perform Engine Maintenance - Deutz Models..............................................3 - 68
E-7 Perform Engine Maintenance - Perkins Models...........................................3 - 68
E-8 Perform Engine Maintenance - Deutz Models..............................................3 - 69
E-9 Perform Engine Maintenance - Perkins Models...........................................3 - 69
E-10 Replace the Boom Extend/Retract Cables...................................................3 - 70
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TABLE OF CONTENTS Section 4
Repair Procedures
Introduction..............................................................................................................4 - 1
Display Module........................................................................................................4 - 2
Platform Controls
1-1 Circuit Boards.................................................................................................4 - 7
1-2 Membrane Decal............................................................................................4 - 8
1-3 Joystick Controllers........................................................................................4 - 9
Platform Components
2-1 Platform........................................................................................................4 - 16
2-2 Platform Leveling Cylinder...........................................................................4 - 16
2-3 Platform Rotator...........................................................................................4 - 18
2-4 Platform Level Sensor..................................................................................4 - 21
2-5 Platform Overload System...........................................................................4 - 22 2-6
Platform Overload Recovery Message (Software V3.14 and later)..............4 - 25
Jib Boom Components, S-105 and S-125 Models
3-1 Jib Boom, S-105 and S-125 Models.............................................................4 - 26
3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models.........................................4 - 28
Boom Components
4-1 Cable Track..................................................................................................4 - 30
4-2 Boom............................................................................................................4 - 33
4-3 Boom Lift Cylinder........................................................................................4 - 44
4-4 Extension Cylinders......................................................................................4 - 46
4-5 Boom Extend/Retract Cables.......................................................................4 - 50
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TABLE OF CONTENTS Section 4
Repair Procedures, continued
Turntable Covers
5-1 Turntable Covers..........................................................................................4 - 54
Engines
6-1 RPM Adjustment..........................................................................................4 - 56
6-2 Flex Plate.....................................................................................................4 - 56
6-3 Oil Pressure and Coolant Temperature Sending Units, Cummins and Perkins Models......................................................................4 - 58
6-4 Oil Pressure and Temperature Sending Units, Deutz Models......................4 - 58
Ground Controls
7-1 Circuit Boards...............................................................................................4 - 59
7-2 Membrane Decal..........................................................................................4 - 60
7-3 Control Relays..............................................................................................4 - 61
Limit Switches
8-1 Limit Switches..............................................................................................4 - 64
8-2 Limit Switch and Level Sensor Locations.....................................................4 - 67
8-3 Limit Switch Functions..................................................................................4 - 68
Hydraulic Pumps
9-1 Function Pumps...........................................................................................4 - 71
9-2 Drive Pump...................................................................................................4 - 72
9-3 Auxiliary Pump.............................................................................................4 - 75
Manifolds
10-1 Function Manifold Components, S-100 and S-105 Models (serial number 136)......................................................................................4 - 77
10-2 Function Manifold Components, S-100 and S-105 Models (after serial number 136)..............................................................................4 - 81
10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models..............4 - 85
10-4 Proportional Valves - Function Manifold.......................................................4 - 86
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TABLE OF CONTENTS Section 4
Repair Procedures, continued
10-5 Function Manifold Components, S-120 and S-125 Models (before serial number 431)...........................................................................4 - 87
10-6 Function Manifold Components, S-120 and S-125 Models (from serial number 431 to 574)...................................................................4 - 91
10-7 Function Manifold Components, S-120 and S-125 Models (after serial number 574)..............................................................................4 - 95
10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models..............4 - 99
10-9 Proportional Valves - Function Manifold.....................................................4 - 100
10-10 Platform Manifold Components, S-100 and S-120 Models........................4 - 101
10-11 Platform Manifold Components, S-105 and S-125 Models........................4 - 103
10-12 Proportional Valves - Platform Manifolds...................................................4 - 105
10-13 Platform Rotate Counterbalance Valve Manifold Components..................4 - 105
10-14 Turntable Rotation Manifold Components..................................................4 - 106
10-15 Steer and Axle Extend/Retract Manifold Components - View 1.................4 - 107
10-16 Steer and Axle Extend/Retract Manifold Components - View 2.................4 - 109
10-17 Valve Adjustments - Steer and Axle Extend/Retract Manifold...................4 - 113
10-18 Traction Manifold Components (S-100/105 before serial number 291) (S-120/125 before serial number 1195).....................................................4 - 115
10-19 Traction Manifold Components (S-100/105 after serial number 290) (S-120/125 after serial number 1194)........................................................4 - 119
10-20 Valve Adjustments - Traction Manifold.......................................................4 - 123
10-21 Valve Coils.................................................................................................4 - 123
Fuel and Hydraulic Tanks
11-1 Fuel Tank...................................................................................................4 - 126
11-2 Hydraulic Tank...........................................................................................4 - 127
Turntable Rotation Components
12-1 Turntable Rotation Hydraulic Motor and Drive Hub....................................4 - 129
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TABLE OF CONTENTS Section 4
Repair Procedures, continued Axle Components
13-1 Steer Sensors.............................................................................................4 - 133
13-2 Yoke and Hub.............................................................................................4 - 135
13-3 Drive Motor.................................................................................................4 - 137
13-4 Drive Hub...................................................................................................4 - 138
13-5 Steering Cylinders......................................................................................4 - 139
13-6 Extendable Axles........................................................................................4 - 140
Section 5
Diagnostic Codes
Introduction..............................................................................................................5 - 1
Diagnostic Code Chart.............................................................................................5 - 3
Control System Fault Codes....................................................................................5 - 9
Deutz TD 2.9 L4 Engine Fault Codes....................................................................5 - 13
Perkins 854F-34T Engine Fault Code....................................................................5 - 28
Software.................................................................................................................5 - 37
Section 6
Schematics
Introduction..............................................................................................................6 - 1
Circuit Numbering....................................................................................................6 - 2
Wire Color Legend...................................................................................................6 - 4
Limit Switches..........................................................................................................6 - 8
Relay Layout..........................................................................................................6 - 10
Drive Chassis Controller Pin Legend.....................................................................6 - 11
Platform Controller Pin Legend..............................................................................6 - 12
Turntable Controller Pin Legend............................................................................6 - 13
Engine Relay and Fuse Panel Legend Deutz TD2011 and Perkins 1104D Models..................................................6 - 14
Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models..............................6 - 15
Engine Relay and Fuse Panel Legend - Perkins 854F Models.............................6 - 16
Telematics Connector Pin Legend.........................................................................6 - 17
Electrical Symbols Legend.....................................................................................6 - 18
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TABLE OF CONTENTS Section 6
Schematics
Hydraulic Symbols Legend....................................................................................6 - 19
Safety Circuit Schematic........................................................................................6 - 21
Engine Options- Perkins and Cummins (S-100/105 before serial number 219) (S-120/125 before serial number 933).........................................................6 - 23
Engine Options- Perkins (S-100/105 from serial number 219 to 247) (S-120/125 from serial number 933 to 984).................................................6 - 25
Engine Options- Perkins (S-100/105 from serial number 248) (S-120/125 from serial number 985)............................................................6 - 27
Engine Options- Perkins (S-100/105/120/125 from serial number 874)..............................................6 - 29
Engine Options- Cummins (S-100/105 from serial number 219 to 247) (S-120/125 from serial number 933 to 984).................................................6 - 31
Engine Options- Cummins (S-100/105 from serial number 248) (S-120/125 from serial number 985)............................................................6 - 33
Electrical Schematic - Generator Options..............................................................6 - 35
Electrical Schematic - 12 kW Generator (welder option).......................................6 - 37
Electrical Schematic (ES105C, ES125G) (S-100/105 before serial number 231) (S-120/125 before serial number 921)...........................located at end of manual
Electrical Schematic (ES0427) (S-100/105 from serial number 231 to 809) (S-120/125 from serial number 921 to 2709).................located at end of manual
Electrical Schematic (ES0509) (S100/105 from serial number 810) (S120/125 from serial number 2710)..............................located at end of manual
Perkins 1104D-44T Engine Electrical Schematic..................................................6 - 39
Perkins 854F-34T Engine Electrical Schematic.....................................................6 - 41
Perkins 854F-34T Engine Electrical Harness........................................................6 - 43
Deutz TD2.9 Engine Electrical Schematic.............................................................6 - 45
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TABLE OF CONTENTS Section 6
Schematics,continued
Deutz TD2.9 Engine Electrical Harness.................................................................6 - 47
Hydraulic Schematic - 12 kW Generator (welder option)......................................6 - 49
Hydraulic Schematic, S-100 • S-105 (serial number 136)......................................................................................6 - 51
Hydraulic Schematic, S-100 • S-105 (from serial number 137 to 290)...................................................................6 - 53
Hydraulic Schematic, S-100 • S-105 (from serial number 291 to serial number 738)............................................6 - 55
Hydraulic Schematic, S-100 • S-105 (from serial number 739).6 - 57
Hydraulic Schematic, S-120 • S-125 (from serial number 404 to serial number 430)............................................6 - 59
Hydraulic Schematic, S-120 • S-125 (from serial number 431 to serial number 1194)..........................................6 - 61
Hydraulic Schematic, S-120 • S-125 (from serial number 1195 to serial number 2634)........................................6 - 63
Hydraulic Schematic, S-120 • S-125 (from serial number 2635 to serial number 3145)........................................6 - 65
Hydraulic Schematic, S-120 • S-125 (from serial number 3146 to serial number S12514D-921)..........................6 - 67
Hydraulic Schematic, S-120 • S-125 (from serial number S12514D-921)..............................................................6 - 69
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Section 2 • Specifications
Specifications Machine Specifications, S-120 and S-125 Models Stowed dimensions
Turning radius, inside, axles retracted
S-120
S-125
39 ft 11 in 12.17 m
39 ft 11 in 12.17 m
42 ft 8 in 13 m
46 ft 9 in 14.25 m
Width, axles retracted
8 ft 2 in 249 cm
Width, axles extended
Length, transport position Length, stowed
Turning radius, outside, axles extended Turning radius, inside, axles extended
13 ft 2 in 4.01 m
13 ft 2 in 4.01 m
18 ft 10 in 5.74 m
18 ft 10 in 5.74 m
8 ft 6 in 2.59 m
8 ft 6 in 2.59 m
Turntable rotation (degrees)
360° continuous
Platform rotation
160°
8 ft 2 in 249 cm
Maximum allowable side force (ANSI and CSA)
150 lbs 667 N
11 ft 335 cm
11 ft 335 cm
Maximum allowable side force (CE)
90 lbs 400 N
10 ft 1 in 308 cm
10 ft 1 in 308 cm
44,340 lbs 20,112 kg
44,640 lbs 20,248 kg
15 3/4 in 40 cm
15 3/4 in 40 cm
Platform height, maximum
120 ft 36.6 m
125 ft 38.1 m
Working height, maximum
126 ft 38.4 m
131 ft 39.9 m
Horizontal reach maximum
75 ft 22.9 m
80 ft 24.4 m
Maximum load capacity
750 lb 340 kg
500 lb 227 kg
Turntable tailswing, axles retracted
66 in 168 cm
66 in 168 cm
Turntable tailswing axles extended
48 in 122 cm
48 in 122 cm
Wheelbase
12 ft 366 cm
12 ft 366 cm
22 ft 2 in 6.75 m
22 ft 2 in 6.75 m
Height, stowed maximum Weight Ground clearance Operational dimensions
Turning radius, outside, axles retracted
Part No. 102916
Controls
12V DC proportional
Platform dimensions Length
96 in 244 cm
Width
36 in 91 cm
Tires and wheels Tire size
445/65D22.5, FF
Tire ply rating
18
Tire weight, new foam-filled (minimum)
815 lbs 370 kg
Overall tire diameter
46.5 in 118 cm
Wheel diameter
22.5 in 57 cm
Wheel width
13 in 33 cm
Wheel lugs
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs 570 Nm
Lug nut torque, lubricated
320 ft-lbs 434 Nm
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Section 2 • Specifications
SPECIFICATIONS Fluid capacities Hydraulic tank
55 gallons 208 liters
Hydraulic system (including tank)
80 gallons 303 liters
Fuel tank
40 gallons 151 liters
Coolant capacity
20 quarts 18.9 liters
Drive hubs
47 oz 1.4 liters
Turntable rotation drive hub
93 oz 2.8 liters
Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5
For operational specifications, refer to the Operator's Manual.
Performance Specifications, S-120 and S-125 Models Drive speeds High drive speed, 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, 32.6 - 36.6 sec 18 ft / 5.5 m non-stowed > 80 ft Braking distance, maximum High range on paved surface Gradeability (boom stowed)
4 to 6 ft 1.2 to 1.8 m
See Operators Manual
Boom function speeds, maximum from platform controls Jib boom up (S-125 models)
28 to 32 seconds
Jib boom down (S-125 models)
28 to 32 seconds
Boom up Boom fully retracted Boom extended to >4 ft / >1.2 m (time between fully lowered and a fully raised position)
80 to 88 seconds 100 to 110 seconds
Boom extended to >80 ft / >24.4 m (time between 53° envelope limit and a fully raised position)
50 to 55 seconds
Boom extended to >100 ft / >30.5 m (time between 68° envelope limit and a fully raised position)
24 to 28 seconds
Boom down Boom fully retracted Boom extended to >4 ft / >1.2 m (time between fully raised and a fully lowered position)
2 - 2
80 to 88 seconds 100 to 110 seconds
Boom extended to >80 ft / >24.4 m (time between fully raised and the 50° envelope limit)
50 to 55 seconds
Boom extended to >100 ft / >30.5 m (time between fully raised and the 65° envelope limit)
24 to 28 seconds
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Section 2 • Specifications
SPECIFICATIONS Boom extend vertical, 0 to 120 ft / 0 to 36.6 m
170 to 190 seconds
Boom retract vertical, 120 ft to 0 / 36.6 m to 0
Machine Specifications, S-100 and S-105 Models
170 to 190 seconds
Stowed dimensions
S-100
S-105
39 ft 11 in 12.17 m
39 ft 11 in 12.17 m
42 ft 8 in 13 m
46 ft 14 m
Width, axles retracted
8 ft 2 in 249 cm
8 ft 2 in 249 cm
Width, axles extended
11 ft 335 cm
11 ft 335 cm
10 ft 1 in 308 cm
10 ft 1 in 308 cm
39,700 lbs 18,007 kg
40,000 lbs 18,143 kg
151/2 in 39 cm
151/2 in 39 cm
Platform height, maximum
100 ft 30.5 m
105 ft 32 m
Working height, maximum
106 ft 32.3 m
111 ft 33.8 m
Horizontal reach maximum
75 ft 22.9 m
80 ft 24.4 m
Maximum load capacity
750 lb 340 kg
500 lb 227 kg
Turntable tailswing, axles retracted
66 in 168 cm
66 in 168 cm
Turntable tailswing axles extended
48 in 122 cm
48 in 122 cm
Wheelbase
12 ft 366 cm
12 ft 366 cm
Turning radius, outside, axles retracted
21 ft 7 in 6.58 m
21 ft 7 in 6.58 m
Turning radius, inside, axles retracted
13 ft 7 in 4.14 m
13 ft 7 in 4.14 m
Length, transport position
Turntable rotate, 360° boom horizontal and fully retracted
170 to 190 seconds
Turntable rotate, 360° boom horizontal and extended >0 ft / >0 m
63 to 70 seconds drive enable to drive enable
Turntable rotate, 360° boom fully raised and
109 to 120 seconds
Length, stowed
Height, stowed maximum Weight Ground clearance Operational dimensions
120 ft / 36.6 m
LSB9AS 65 O
LSB14AO 68 O
110 ft / 33.5 m 100 ft / 30.5 m
LSB2RS 101 ft (30.8 m)
LSB2RO 102 ft (31.1 m)
90 ft / 27.4 m
LSB4EO 100 ft (30.5 m)
80 ft / 24.4 m
LSB13AO 53 O
70 ft / 21.3 m
LSB8AS 50 O LSB4ES 75.5 ft (23 m)
60 ft / 18.3 m
LSB3EO 75 ft (22.9 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS 11 O
LSB1DO 10 O
20 ft / 6.1 m
10 ft / 3 m
LSB3RO 3 ft (0.9 m)
0 ft / 0 m
70 ft / 21.3 m
60 ft / 18.3 m
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
20 ft / 6.1 m
10 ft / 3 m
0 ft / 0 m
-10 ft / -3 m
Part No. 102916
LSB3RS 3.5 ft (1.1 m)
S-100 • S-105 • S-120 • S-125
2-3
October 2015
Section 2 • Specifications
SPECIFICATIONS Turning radius, outside, axles extended Turning radius, inside, axles extended
19 ft 10 in 6.05 m
19 ft 10 in 6.05 m
9 ft 2.74 m
9 ft 2.74 m
Turntable rotation (degrees)
360° continuous
Platform rotation
160°
Maximum allowable side force (ANSI and CSA)
150 lbs 667 N
Maximum allowable side force (CE)
90 lbs 400 N
Controls
12V DC proportional
Platform dimensions Length
96 in 244 cm
Width
36 in 91 cm
Tires and wheels Tire size
IN385/65D22.5, FF 18
Tire ply rating Tire weight, new foam-filled (minimum)
Hydraulic tank
55 gallons 208 liters
Hydraulic system (including tank)
80 gallons 303 liters
Fuel tank
40 gallons 151 liters
Coolant capacity
20 quarts 18.9 liters
Drive hubs
47 oz 1.4 liters
Turntable rotation drive hub
93 oz 2.8 liters
Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5
For operational specifications, refer to the Operator's Manual.
622 lbs 282 kg
Overall tire diameter
43.1 in 109.5 cm 22.5 in 57 cm
Wheel diameter Wheel width
11.75 in 30 cm 10 @ 3/4 -16
Wheel lugs Lug nut torque, dry
420 ft-lbs 570 Nm
Lug nut torque, lubricated
320 ft-lbs 434 Nm
2 - 4
Fluid capacities
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Performance Specifications, S-100 and S-105 Models Drive speeds High drive speed, 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, 32.6 - 36.6 sec 18 ft / 5.5 m non-stowed > 80 ft Braking distance, maximum High range on paved surface Gradeability (boom stowed)
4 to 6 ft 1.2 to 1.8 m
See Operator's Manual
Boom function speeds, maximum from platform controls Jib boom up (S-105 models)
28 to 32 seconds
Jib boom down (S-105 models)
28 to 32 seconds
Boom extend, boom fully raised 0 to 100 ft / 0 to 30.5 m
120 to 140 seconds
Boom retract, boom fully raised 100 ft to 0 / 30.5 m to 0
120 to 140 seconds
Turntable rotate, 360° boom horizontal and fully retracted
170 to 190 seconds
Turntable rotate, 360° boom horizontal and extended >0 ft / >0 m
63 to 70 seconds drive enable to drive enable
Turntable rotate, 360° boom fully raised and extended >80 ft / >24.4 m
109 to 120 seconds drive enable to drive enable 18 to 22 seconds
Platform rotate, 160°
Boom up Boom fully retracted Boom extended to >4 ft / >1.2 m (time between fully lowered and a fully raised position) Boom extended to >80 ft / >24.4 m (time between 53° envelope limit and a fully raised position)
80 to 88 seconds 100 to 110 seconds 120 ft / 36.6 m
50 to 55 seconds
100 ft / 30.5 m
Boom down Boom fully retracted Boom extended to >4 ft / >1.2 m (time between fully raised and a fully lowered position) Boom extended to >80 ft / >24.4 m (time between fully raised and the 50° envelope limit)
110 ft / 33.5 m
90 ft / 27.4 m
80 to 88 seconds 100 to 110 seconds
LSB13AO 53
80 ft / 24.4 m
LSB8AS 50
70 ft / 21.3 m
50 to 55 seconds
LSB3EO 75 ft (22.9 m)
60 ft / 18.3 m
LSB4ES 75.5 ft (23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS 11
LSB1DO 10
20 ft / 6.1 m
10 ft / 3 m
LSB3RO 3 ft (0.9 m)
LSB3RS 3.5 ft (1.1 m)
0 ft / 0 m
70 ft / 21.3 m
60 ft / 18.3 m
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
20 ft / 6.1 m
10 ft / 3 m
S-100 • S-105 • S-120 • S-125
0 ft / 0 m
-10 ft / -3 m
Part No. 102916
2-5
October 2015
Section 2 • Specifications
SPECIFICATIONS
Hydraulic Specifications
Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the differences in base additive chemistry. When incompatible fluids are mixed, insoluble materials may form and deposit in the hydraulic system, plugging hydraulic lines, filters, control valves and may result in component damage.
Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation prevention, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Cleanliness level, minimum
ISO 15/13 250 ppm
Water content, maximum Recommended Hydraulic Fluid Hydraulic oil type
Note: Do not operate the machine when the ambient air temperature is consistently above 120°F / 49°C.
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic fluids
Hydraulic Fluid Temperature Range
Mineral based
Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A
Biodegradable
Petro Canada Environ MV 46
2
UCON Hydrolube HP-5046
3
Fire resistant
Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Product Support before use.
1
4
-40 -22 -4 14 32 -40 -30 -20 -10 -0
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
50 10
68 20
86 104 122 30 40 50
F C
Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV
optional oil cooler may be required.
2 - 6
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade
Chevron 5606A Hydraulic Oil Fluid Properties 32
ISO Grade
15
Viscosity index
200
Viscosity index
300
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C
7.5 33.5
Brookfield Viscosity cP @ -4°F / -20°C cP @ -22°F / -30°C
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C cSt @ -40°F / -40°C
5.5 15.0 510
1040 3310
Flash point
375°F / 190°C
Pour point
-58°F / -50°C
Maximum continuous operating temperature
171°F / 77°C
Note: An hydraulic oil heating system is recommended when the ambient temperature is consistently below 0°F / -18°C .
Flash point
180°F / 82°C
Pour point
-81°F / -63°C
Maximum continuous operating temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil heating system is used.
Note: Do not operate the machine when the ambient temperature is below -20°F / -29°C with Rando HD Premium MV.
Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32°F / 0°C may result in component damage.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2-7
October 2015
Section 2 • Specifications
SPECIFICATIONS
Petro-Canada Environ MV 46 Fluid Properties
Hydraulic Component Specifications
ISO Grade
46
Viscosity index
154
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C
8.0 44.4
Flash point
482°F / 250°C
Pour point
-49°F / -45°C
Maximum continuous operating temperature
180°F / 82°C
Drive pump Type: bi-directional variable displacement piston pump Displacement 0 to 2.8 cu in 0 to 46 cc Flow rate @ 2350 rpm, maximum
28.5 gpm 108 L/min
Drive pressure, maximum
3625 psi 250 bar
Charge pump Type: gerotor
UCON Hydrolube HP-5046 Fluid Properties ISO Grade Viscosity index
46 192
Displacement
0.85 cu in 13.9 cc
Flow rate @ 2350 rpm
9 gpm 34 L/min
Charge pressure @ 2350 rpm Neutral position
315 psi 21.7 bar
Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F / -18°C
22 46 1300
Function pump
Flash point
None
Front Section
Pour point
-81°F / -63°C
Maximum continuous operating temperature
189°F / 87°C
2 - 8
Type:
variable displacement piston pump
Displacement 0 to 1.71 cu in 0 to 28 cc Flow rate @ 2350 rpm, maximum
S-100 • S-105 • S-120 • S-125
17.4 gpm 65.9 L/min
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS Rear Section
Steer/Axle manifold
Displacement 0 to 1.1 cu in 0 to 18 cc
Axle extend relief pressure
Flow rate @ 2350 rpm, maximum
11.2 gpm 42.4 L/min
Drive manifold
Pressure, maximum continuous
3350 psi 231 bar
Standby pressure
250 psi 17 bar
Hot oil relief pressure: S-100/105 before serial number 291 S-120/125 before serial number 1195
250 psi 17.2 bar
Hot oil relief pressure: S-100/105 after serial number 290 S-120/125 after serial number 1194
280 psi 19.3 bar
Brakes
Auxiliary pumps Type:
1800 psi 124 bar
fixed displacement gear pump
Displacement
0.15 cu in 2.47 cc
Function manifold Function relief pressure (measured at test port)
2600 psi 179.3 bar
Platform relief pressure (measured at test port 2)
3000 psi 207 bar
Brake release pressure
174-189 psi 12-13 bar
Drive motors Displacement per revolution, high speed
0.8 cu in 13.3 cc
Displacement per revolution, low speed
2.7 cu in 45 cc
Jib and platform manifolds Platform rotate and platform level flow regulator
0.3 gpm 1.14 L/min
Jib manifold flow regulator
2 gpm 7.6 L/min
Part No. 102916
S-100 • S-105 • S-120 • S-125
2-9
October 2015
Section 2 • Specifications
SPECIFICATIONS Hydraulic filters High pressure filter Beta 3 ≥ 200 High pressure filter bypass pressure
102 psi 7 bar
Medium pressure filter Beta 3 ≥ 200 Medium pressure filter bypass pressure Hydraulic tank return filter Drive motor case drain return filter
2 - 10
25 psi 1.7 bar
10 micron with 25 psi / 1.7 bar bypass Beta 10 ≥ 2
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz Engine F4L 913
Injection system
Displacement Number of cylinders Bore and stroke Horsepower
249.3 cu in 4.086 liters
4 4.02 x 4.92 inches 102 x 125 mm 77 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
18:1
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Low idle rpm Frequency
1300 rpm 385.7 Hz
High idle rpm Frequency
2350 rpm 570.4 Hz
Valve clearance, cold
Injection pump make
IMSA
Injection pump pressure
8702 psi 600 bar
Injector opening pressure
3626 psi 250 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Alternator output 55A, 12 VDC 3/8 to 1/2 inch Fan belt deflection 9 to 12 mm
Battery - Engine starting 12V, Group 31 Type Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 175 minutes Battery - Control system
Intake
0.006 in 0.15 mm
Exhaust
0.006 in 0.15 mm
12V DC, Group 4D Type Quantity 1 Cold cranking ampere 1020A Reserve capacity @ 25A rate 300 minutes
Lubrication system Oil pressure Oil capacity (including filter)
40 to 60 psi 2.75 to 4.14 bar 14.3 quarts 13.5 liters
Oil viscosity requirements Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 11
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz %NGINE BF4L 2011
Oil temperature switch
Displacement Number of cylinders Bore and stroke
189.6 cu in 3.1 liters
4 3.7 x 4.409 inches 94 x 112 mm
Horsepower Continuous @ 2500 rpm Net intermittent @ 2500 rpm
69.1 72.8
Firing order
1-3-4-2
Low idle rpm Frequency
1500 rpm 382.5 Hz
High idle rpm Frequency
2350 rpm 599.25 Hz
Compression ratio
17.5:1
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor
centrifugal mechanical
Valve clearance, cold Intake
0.012 in 0.3 mm
Exhaust
0.020 in 0.5 mm
Lubrication system 40 to 60 psi 2.8 to 4.1 bar
Oil pressure, hot (at 2000 rpm) Oil capacity (including filter)
10.5 quarts 9.9 liters
Oil viscosity requirements Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
2 - 12
Torque
8-18 ft-lbs 11-24 Nm
Oil temperature switch point 275°F 135°C Oil pressure switch Torque
8-18 ft-lbs 11-24 Nm
Oil pressure switch point
7 psi 0.48 bar
Fuel injection system Injection pump make
Bosch
Injection pump pressure, maximum
15,000 psi 1034 bar
Injector opening pressure
3046 psi 210 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Starter motor Current draw, normal load
140-200A
Cranking speed 200-250 rpm Battery - Engine starting 12V, Group 31 Type Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 175 minutes Battery - Control system 12V DC, Group 4D Type Quantity 1 Cold cranking ampere 1020A Reserve capacity @ 25A rate 300 minutes Alternator output
80A @ 14V DC
3/8 to 1/2 inch Fan belt deflection 9 to 12 mm
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz %NGINE TD2011L04i Displacement Number of cylinders Bore and stroke
Oil temperature switch 220.9 cu in 3.62 liters
4 3.78 x 4.92 inches 96 x 125 mm
Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point 275°F 135°C Oil pressure switch Installation torque
8-18 ft-lbs 11-24 Nm
Induction system turbocharged
Pressure switch point
22 psi 1.5 bar
Firing order
1-3-4-2
Fuel injection system
Low idle
1300 rpm
High idle
2450 rpm
Compression ratio
17.5:1
Horsepower net intermittent @ 2400 rpm
74hp 55KW
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor
centrifugal mechanical
Injection pump pressure, maximum
15,000 psi 1034 bar
Injector opening pressure
3046 psi 210 bar
Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load
Valve Clearance, cold Intake
0.012 in 0.3 mm
Exhaust
0.020 in 0.5 mm
Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2.8 to 4.1 bar Oil capacity (including filter)
Motorpal
12.8 quarts 12.1 liters
140-200 A
Cranking speed 250-350 rpm Battery - Engine starting and control system Type 6V DC Quantity 2 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Alternator output
80A @ 14V DC
3/8 to 1/2 inch Fan belt deflection 9 to 12 mm
Oil viscosity requirements 5W-30 -22°F to 86°F / -30°C to 30°C (synthetic) -4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 13
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz %NGINE TD 2.9
Oil temperature switch
Displacement Number of cylinders Bore and stroke
177 cu in 2.9 liters
4 3.6 x 4.3 inches 92 x 110 mm
Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point 275°F 135°C Oil pressure switch Installation torque
8-18 ft-lbs 11-24 Nm
Induction system turbocharged
Pressure switch point
22 psi 1.5 bar
Firing order
1-3-4-2
Fuel injection system
Low idle
1000 rpm
High idle
2500 rpm
Compression ratio
17.4:1
Horsepower net intermittent @ 2600 rpm
74.2hp 55KW
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor
electronic
Motorpal
Injection pump pressure, maximum
15,000 psi 1034 bar
Injector opening pressure
3046 psi 210 bar
Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine.
Lubrication system
Starter motor
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2.8 to 4.1 bar
Current draw, normal load
Oil capacity (including filter)
Battery - Engine starting and control system
9.4 quarts 8.9 liters
140-200 A
Cranking speed 250-350 rpm
-22°F to 86°F / -30°C to 30°C 5W-30 (synthetic)
Type 12V DC, Group 31 Quantity 1 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes
-4°F to 104°F / -20°C to 40°C
10W-40
Alternator output
Above 5°F / -15°C
15W-40
3/8 to 1/2 inch Fan belt deflection 9 to 12 mm
Oil viscosity requirements
Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.
2 - 14
S-100 • S-105 • S-120 • S-125
95A @ 14V DC
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins %NGINE 1104D-44T Displacement
Oil temperature switch 268.5 cu in 4.4 liters
Installation torque
8-18 ft-lbs 11-24 Nm 8 psi 0.55 bar
Number of cylinders
4
Pressure switch point
Bore and stroke
4.13 x 5 inches 105 x 127 mm
Oil Sensor Settings
Horsepower net intermittent @ 2200 rpm
68 ph / 50.7KW 74 hp / 55.2 KW
Induction system turbocharged Firing order
1-3-4-2
Low idle
1300 rpm
High idle
2450 rpm
Compression ratio
18.2:1
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor
centrifugal mechanical
10 ohms 120 ohms
Fuel injection system
Motorpal
Transfer pump pressure 10-12 psi / 0.69-0.83 bar Injector pressure
(4264+116 psi) / (294+8 bar)
Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load
115 A
Cranking speed 200-250 rpm Battery - Auxiliary power units
Valve Clearance, cold Intake
0.008 in 0.2 mm
Exhaust
0.018 in 0.45 mm
Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2.8 to 4.1 bar Oil capacity (including filter)
0 psi 50 psi
10.4 quarts 9.8 liters
6V DC Type Quantity 2 Battery capacity, maximum 285AH Reserve capacity @ 25A rate 745 Minutes Battery - Engine starting and control system 12V DC, Group 31 Type Quantity 1 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes
Oil viscosity requirements 5W-20 -22°F to 86°F / -30°C to 30°C (synthetic) -4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 15
October 2015
Section 2 • Specifications
SPECIFICATIONS Perkins 1104D-44T Perkins Engine coolant
Capacity (engine only)
Displacement
9.5 quarts 9 liters
Number of cylinders
Coolant temperature switch Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F 110°C
Temperature Sensor Settings
%NGINE 854F-34T
Bore and stroke Horsepower net intermittent @ 2500 rpm
4 3.89 x 4.33 inches 99 x 110 mm 74 hp / 55.2 KW
Induction system turbocharged
Firing order 215°F 37 ohms Standby 102°C speed Low idle 170°F 78 ohms 82°C High idle Alternator output
207 cu in 3.4 liters
1-3-4-2 1000 rpm 1500 rpm 2500 rpm
85A @ 12V DC
Compression ratio
3/8 to 1/2 in
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder.
Fan belt deflection
9 to 12 mm
Governor
17.0:1
Electronic
Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2.8 to 4.1 bar Minimum oil pressure Oil capacity (including filter)
12 psi 0.82 bar 7.7 quarts 7.3 liters
Oil viscosity requirements -22°F to 86°F / -30°C to 30°C
5W-20
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.
2 - 16
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS Oil temperature switch
Perkins 854F-34T cont. Engine coolant
Installation torque
18.4 ft-lbs 25 Nm
Pressure switch point
12 psi 0.82 bar
Coolant temperature switch
0 psi
10 ohms
Installation torque
18.4 ft-lbs 25 Nm
50 psi
120 ohms
Maximum continuous temperature
226°F 108°C
Oil Sensor Settings
Fuel injection system Transfer pump pressure 10-12 psi / 0.69-0.83 bar Injector pressure
23000 psi / (1600 bar)
Fuel requirement
16.5 quarts 15.6 liters
Temperature Sensor Settings 215°F 37 ohms 102°C 170°F 78 ohms 82°C Alternator output
For fuel requirements, refer to the engine Operator Manual for your engine.
120A @ 12V DC
3/8 to 1/2 in Fan belt deflection 9 to 12 mm
Glow plugs Initial load (0-10 sec) Continuous load (>10 sec)
Capacity (50/50 extended life)
80A 40A
Starter motor Current draw, normal load
68 A
Cranking speed 130-200 rpm Battery - Auxiliary power units 6V DC Type 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
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 17
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins Engine 1004-42
Injection system
Displacement
258 cu in 4.23 liters
Number of cylinders
4
Bore & stroke
4.06 x 5 inches 103.1 x 127 mm
Horsepower
81 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
18.5:1
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Low idle rpm Frequency
1300 rpm 303.3 Hz
High idle rpm Frequency
2350 rpm 548.3 Hz
Valve clearance, cold Intake
0.008 in 0.20 mm
Exhaust
0.018 in 0.45 mm
Lubrication system Oil pressure Oil capacity (including filter)
51 psi 3.45 bar 8.9 quarts 8.4 liters
Injection pump make
Zexel
Injector opening pressure
2204 psi 152 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Alternator output 55A, 12V DC 3/8 to 1/2 inch Fan belt deflection 9 to 12 mm
Battery - System Type 12V, Group 27TM Quantity 1 AH rating 109AH Cold cranking ampere 630A Reserve capacity @ 25A rate 160 minutes Battery - Engine starting 12V, Group 4D Type Quantity 1 AH rating 190AH Cold cranking ampere 1020A Reserve capacity @ 25A rate 325 minutes Cooling system Engine capacity
9.5 quarts 9 liters
System capacity
20 quarts 18.9 liters
Oil viscosity requirements Unit ships with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
2 - 18
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins %NGINE 1104C-44
Lubrication system
Displacement
268.5 cu in 4.4 liters
Oil pressure, hot 40 to 60 psi (at 2000 rpm) 2.8 to 4.1 bar
Number of cylinders
4
Oil capacity (including filter)
Bore and stroke
4.13 x 5 inches 105 x 127 mm
Oil viscosity requirements
Horsepower Gross intermittent @ 2400 rpm Net intermittent @ 2400 rpm
86 83
Firing order
1-3-4-2
Low idle rpm Frequency
1300 rpm 316.3 Hz
Low Idle with belt-driven generator option Frequency
1400 rpm 340.7 Hz
High idle rpm Frequency
2350 rpm 571.8 Hz
Compression ratio
18.2:1
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor
centrifugal mechanical
Valve clearance, cold Intake
0.008 in 0.2 mm
Exhaust
0.018 in 0.45 mm
Part No. 102916
7.3 quarts 6.9 liters
Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil pressure sending unit Torque
8-18 ft-lbs 11-24 Nm
Oil pressure switch point
8 psi 0.55 bar
Fuel injection system Injection pump make
Bosch
Injector opening pressure
2200 psi 152 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine.
S-100 • S-105 • S-120 • S-125
2 - 19
October 2015
Section 2 • Specifications
SPECIFICATIONS Battery - Engine starting Type 12V, Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 175 minutes Battery - Control system Type 12V DC, Group 4D Quantity 1 Cold cranking ampere 1020A Reserve capacity @ 25A rate 300 minutes Starter motor Current draw, normal load
140-200A
Cranking speed 200-250 rpm Engine coolant Capacity
14 quarts 13.2 liters
Coolant temperature sending unit Torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F 110°C
Alternator output
85A @ 13.8V DC
3/8 inch Fan belt deflection 10 mm
Perkins %NGINE 804D-33T Displacement Number of cylinders Bore and stroke
203 cu in 3.33 liters
4 3.7 x 4.72 inches 94 x 120 mm
Horsepower Gross intermittent @ 2500 rpm
83 / 62 kW
Induction system turbocharged Firing order
1-3-4-2
Low idle
1300 rpm 316 Hz
High idle
2350 rpm 572 Hz
Compression ratio
19.5:1
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor
centrifugal mechanical
Valve clearance, cold Intake
0.0098 in 0.25 mm
Exhaust
0.0098 in 0.25 mm
Lubrication system Oil pressure, hot 40 to 60 psi (at 2000 rpm) 2.8 to 4.1 bar Oil capacity (including filter)
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10.6 quarts 10 liters
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS Oil viscosity requirements
Starter motor
Below 86°F / 30°C
5W-30
Current draw, normal load
200A 250 rpm
-4°F to 104°F / -20°C to 40°C
10W-30
Cranking speed
Above 14°F / -10°C
15W-40
Engine coolant
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. Oil pressure sending unit Installation torque
8-18 ft-lbs 11-24 Nm
Oil pressure switch point
8 psi 0.55 bar
Fuel injection system Injection pump make
Bosch
Injector opening pressure
2200 psi 152 bar
Capacity
12.5 quarts 11.8 liters
Coolant temperature sending unit Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F 110°C
Alternator output
90A @ 12V DC
3/8 to 1/2 in Fan belt deflection 9 to 12 mm
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Auxiliary power units Type 6V DC Quantity 2 AH rating 285AH Reserve capacity @ 25A rate 745 minutes Battery - Engine starting and control system Type 12V DC, Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes
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Section 2 • Specifications
SPECIFICATIONS
Cummins %NGINE B3.3T
Fuel injection system
Displacement Number of cylinders Bore and stroke Horsepower
199 cu in 3.26 liters
4 3.74 x 4.53 inches 95 x 115 mm 80 @ 2200 rpm 60 kW @ 2200 rpm
Firing order
1-2-4-3
Low idle
1300 rpm 368 Hz
High idle
2350 rpm 666 Hz
Compression ratio
17:1
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Valve clearance, cold Intake
0.014 in 0.35 mm
Exhaust
0.020 in 0.5 mm
Lubrication system Oil pressure, hot (at 2000 rpm)
31 to 72 psi 2 to 5 bar 9 quarts 8.5 liters
Oil capacity (including filter)
Injection pump make Injection pressure
Zexel 12,000 psi 827 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Auxiliary power units Type 6V DC Quantity 2 AH rating 285AH Reserve capacity @ 25A rate 745 minutes Battery - Engine starting and control system Type 12V DC, Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Starter motor Current draw, maximum
550A
Engine cranking speed, minimum
130 rpm
Engine coolant Capacity
9.1 quarts 8.6 liters
Alternator output 120A, 12V DC 3/8 to 1/2 inch Fan belt deflection 10 to 12.5 mm
Oil viscosity requirements Below 68°F / 20°C
5W-30
-10° to 68°F / -23° to 20°C
10W-30
Above 14°F / -10°C
15W-40
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
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Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Cummins %NGINE B3.9L
Injection system
Displacement Number of cylinders Bore and stroke Horsepower
238 cu in 3.9 liters
4 4.02 x 4.72 inches 102 x 120 mm 75 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
16.5:1
Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Low idle rpm Frequency
1300 rpm 368.3 Hz
High idle rpm Frequency
2350 rpm 665.8 Hz
Valve clearance, cold Intake
0.010 in 0.254 mm
Exhaust
0.020 in 0.508 mm
Lubrication system Oil pressure Oil capacity (including filter)
50 psi 3.45 bar 9.5 quarts 9 liters
Injection pump make
Bosch
Injection pump pressure
5500 psi 379.2 bar
Injector opening pressure
3480 psi 240 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Alternator output 63A, 12V DC Battery - System Type 12V, Group 27TM Quantity 1 AH rating 109AH Cold cranking ampere 630A Reserve capacity @ 25A rate 160 minutes Battery - Engine starting 12V, Group 4D Type Quantity 1 AH rating 190AH Cold cranking ampere 1020A Reserve capacity @ 25A rate 325 minutes Cooling system Engine capacity
8.8 quarts 8.3 liters
System capacity
20 quarts 18.9 liters
Oil viscosity requirements Unit ships with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
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Section 2 • Specifications
SPECIFICATIONS
Cummins %NGINE B4.5L
Fuel injection system
Displacement Number of cylinders Bore and stroke Horsepower
275 cu in 4.5 liters
4 4.02 x 5.42 inches 102 x 138 mm 80 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
18:1
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Low idle rpm Frequency
1300 rpm 368.3 Hz
High idle rpm Frequency
2350 rpm 665.8 Hz
Valve clearance, cold Intake
0.010 in 0.254 mm
Exhaust
0.020 in 0.508 mm
Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter)
50 psi 3.45 bar 9.5 quarts 9 liters
Oil viscosity requirements Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
Injection pump make Injection pump pressure
Delphi
3480 to 3680 psi 240 to 254 bar
Injector opening pressure
3480 psi 240 bar
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Engine starting Type 12V, Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 175 minutes Battery - Control system 12V DC, Group 4D Type Quantity 1 Cold cranking ampere 1020A Reserve capacity @ 25A rate 300 minutes Starter motor Current draw, no load
125A
Brush length, minimum
0.72 in 18.3 mm
Engine coolant Capacity
17 quarts 16 liters
Coolant temperature sending unit Torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F 110°C
Alternator output 95A, 12V DC 3/8 to 1/2 inch Fan belt deflection 10 to 12.5 mm
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Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Machine Torque Specifications Platform rotator
Manifold Plug Torque Specifications
1-8 center bolt, GR 5, dry
640 ft-lbs 868 Nm
Plug torque
1-8 center bolt, GR 5, lubricated
480 ft-lbs 651 Nm
SAE No. 4
14 ft-lbs / 18.9 Nm
3/8
35 ft-lbs* 47.5 Nm
SAE No. 6
23 ft-lbs / 31.2 Nm
SAE No. 8
36 ft-lbs / 48.8 Nm
Turntable rotate assembly
SAE No. 10
62 ft-lbs / 84.1 Nm
Rotate bearing mounting bolts, lubricated 180 ft-lbs 244 Nm
SAE No. 12
84 ft-lbs / 113.9 Nm
-16 bolts, GR 8, lubricated *use blue thread-locking compound
Rotate drive hub mounting bolts, dry Rotate drive hub mounting bolts, lubricated *use blue thread-locking compound Rotate drive motor mounting bolts, dry Rotate drive motor mounting bolts, lubricated
SAE No. 2
50 in-lbs / 6 Nm
380 ft-lbs 515 Nm 280 ft-lbs* 380 Nm 110 ft-lbs 149 Nm 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 Nm
Drive hub oil plug, O-ring seal
13 ft-lbs 18 Nm
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Section 2 • Specifications
SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications
SAE O-ring Boss Port
Your machine is equipped with Parker SealLokTM fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Seal-LokTM Fittings (hose end - ORFS)
Torque
SAE Dash size
-4
10 ft-lbs / 13.6 Nm
-6
30 ft-lbs / 40.7 Nm
-8
40 ft-lbs / 54.2 Nm
-10
60 ft-lbs / 81.3 Nm
-12
85 ft-lbs / 115 Nm
-16
110 ft-lbs / 150 Nm
-20
140 ft-lbs / 190 Nm
-24
180 ft-lbs / 245 Nm
(tube fitting - installed into Aluminum) (all types) SAE Dash size
-4
14 ft-lbs / 19 Nm
-6
23 ft-lbs / 31.2 Nm
-8
36 ft-lbs / 54.2 Nm
-10
62 ft-lbs / 84 Nm
-12
84 ft-lbs / 114 Nm
-16
125 ft-lbs / 169.5 Nm
-20
151 ft-lbs / 204.7 Nm
-24
184 ft-lbs / 249.5 Nm
Adjustable Fitting
JIC 37° Fittings Thread Size
Non-adjustable fitting
a jam nut
(swivel nut or hose connection) SAE Dash Size
Torque
SAE O-ring Boss Port
Flats
-4
7/16-20
2
-6
9/16-18
1 1/4
-8
3/4-16
1
-10
7/8-14
1
-12
1 1/16-12
1
-16
1 5/16-12
1
-20
1 5/8-12
1
-24
1 7/8-12
1
(tube fitting - installed into Steel)
SAE Dash size
Torque
-4
ORFS / 37° (Adj) ORFS / (Non-Adj) 37° (Non-Adj)
15 ft-lbs / 20.3 Nm 26 ft-lbs / 35.3 Nm 22 ft-lbs / 30 Nm
-6
ORFS / (Adj / Non-adj) 37° (Adj / Non-adj)
35 ft-lbs / 47.5 Nm 29 ft-lbs / 39.3 Nm
-8
ORFS / (Adj / Non-adj) 37° (Adj / Non-adj)
60 ft-lbs / 81.3 Nm 52 ft-lbs / 70.5 Nm
-10 ORFS / 37° (Adj) 37° (Non-Adj)
100 ft-lbs / 135.6 Nm 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 types)
305 ft-lbs / 413.5 Nm
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Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Torque Procedure
JIC 37° fittings
Seal-LokTM fittings
1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Note: The O-rings used in the Parker Seal Lok® fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612).
1 Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, approximately 30 in-lbs / 3.4Nm. 2 Using a permanent ink marker, make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting. Refer to illistration 1.
2 Lubricate the O-ring before installation. 3 Be sure that the face seal O-ring is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table. 6 Operate all machine functions and inspect the hoses and fittings and related components to
Part No. 102916
Illustration 1 a hex nut b reference mark c body hex fitting
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October 2015
Section 2 • Specifications
SPECIFICATIONS 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to illustration 2. Note: Using the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. 5 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks.
Note: The marks indicate the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened.
Illustration 2 a body hex fitting b reference mark c second mark
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Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD LUBED in-lbs
20 28
1/4
DRY
Nm
80 90
in-lbs
9 10.1
100 120
LUBED ft-lbs
18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8
1 1 1/8 1
1 /4 1 1/2
13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640
LUBED Nm
in-lbs
Nm
ft-lbs
11.3 13.5
110 120
DRY
Nm
ft-lbs
17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223
A574 High Strength Black Oxide Bolts LUBED
Grade 8
17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190
DRY
Nm
in-lbs
12.4 13.5
140 160
LUBED
23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969
18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670
Nm
in-lbs
Nm
ft-lbs
15.8 18 DRY
Nm
ft-lbs
24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620
25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560
Nm
130 140
14.7 15.8 LUBED
33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826
21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000
Nm
28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size (mm) 5 6 7
LUBED in-lbs
16 19 45
Nm
1.8 3.05 5.12
LUBED 8 10 12 14 16 18 20 22 24
ft-lbs
5.4 10.8 18.9 30.1 46.9 64.5 91 124 157
Nm
7.41 14.7 25.6 40.8 63.6 87.5 124 169 214
Part No. 102916
Class 8.8
DRY in-lbs
21 36 60
LUBED Nm
in-lbs
Nm
ft-lbs
2.4 4.07 6.83
DRY ft-lbs
7.2 14.4 25.1 40 62.5 86.2 121 166 210
41 69 116
Nm
4.63 7.87 13.2
LUBED
9.88 19.6 34.1 54.3 84.8 117 165 225 285
14 27.9 48.6 77.4 125 171 243 331 420
Nm
19.1 37.8 66 105 170 233 330 450 570
Class 10.9
DRY in-lbs
54 93 155
LUBED Nm
in-lbs
Nm
ft-lbs
6.18 10.5 17.6
DRY ft-lbs
18.8 37.2 64.9 103 166 229 325 442 562
58 100 167
Nm
6.63 11.3 18.9
DRY in-lbs
78 132 223
LUBED
25.5 50.5 88 140 226 311 441 600 762
20.1 39.9 69.7 110 173 238 337 458 583
Nm
27.3 54.1 94.5 150 235 323 458 622 791
Class 12.9 LUBED Nm
in-lbs
Nm
ft-lbs
8.84 15 25.2
DRY ft-lbs
26.9 53.2 92.2 147 230 317 450 612 778
S-100 • S-105 • S-120 • S-125
68 116 1.95
Nm
7.75 13.2 22.1
LUBED
36.5 72.2 125 200 313 430 610 830 1055
23.6 46.7 81 129 202 278 394 536 682
Nm
32 63.3 110 175 274 377 535 727 925
DRY in-lbs
91 155 260
Nm
10.3 17.6 29.4
DRY ft-lbs
31.4 62.3 108 172 269 371 525 715 909
Nm
42.6 84.4 147 234 365 503 713 970 1233
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SPECIFICATIONS
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Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine.
Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every two years as specified on the Maintenance Inspection Report.
Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Failure to perform each procedure as presented and scheduled could result in death, serious injury or substantial machine damage.
Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Immediately tag and remove from service a damaged or malfunctioning machine.
With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Repair any machine damage or malfunction before operating machine. Use only Genie approved replacement parts. Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection. Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Boom in the stowed position • Turntable rotated with the boom between the circle-end (yellow arrow) wheels • Turntable secured with the turntable rotation lock pin • Key switch in the off position with the key removed • Wheels chocked • All external AC power supply disconnected from the machine
Part No. 102916
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 a potentially hazardous situation 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.
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Section 3 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend
Pre-delivery Preparation Report
Note: The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.
The pre-delivery preparation report contains checklists for each type of scheduled inspection.
Indicates that tools will be required to perform this procedure.
Indicates that new parts will be required to perform this procedure.
Indicates that a cold engine will be required to perform this procedure.
Make copies of the Pre-delivery Preparation report to use for each inspection. Store completed forms as required. Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, and two years. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Inspection Checklist Daily or every 8 hours
Indicates that a warm engine will be required to perform this procedure.
Quarterly or every 250 hours Six months or every 500 hours Annual or every 1000 hours
Indicates that dealer service will be required to perform this procedure.
Two years or every 2000 hours
A A+B A+B+C A+B+C+D A+B+C+D+E
Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements.
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Part No. 102916
Pre-Delivery Preparation Fundamentals
Instructions
It is the responsibility of the dealer to perform the Pre-delivery Preparation.
Make copies of this form to use for each Pre-Delivery Preparation.
The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.
Use the operator’s manual on your machine.
A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.
The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual.
Repairs to the machine may only be made by a qualified service technician, according to the manufacturer’s specifications.
If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box.
Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual.
Legend Y = yes, completed N = no, unable to complete R = repaired Comments
Pre-Delivery Preparation Pre-operation inspection completed Maintenance items completed Function tests completed
Model Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Terex South Dakota, Inc USA 500 Oak Wood Road PO Box 1150 Watertown, SD 57201-6150 (605) 882-4000
Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. Rev D
Inspector company
Y
N
R
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Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company
Instructions • Make copies of this report to use for each inspection. • Select the appropriate checklist(s) for the type of inspection to be performed.
Checklist A Y N R A-1 Inspect the manuals and decals A-2 Pre-operation inspection A-3 Perform function tests A-4 Engine maintenance Perkins models A-5Engine maintenance Cummins models A-6 Hydraulic filter condition indicator Perform after 40 hours: A-7 30 Day Service Perform every 50 hours: A-8 Engine MaintenancePerkins models Perform after 50 hours: A-9 Engine MaintenanceDeutz models Perform every 100 hours: A-10 Grease rotation bearing A-11 Grease axles Perform after 150 hours: A-12 Replace drive hub oil
Daily or 8 hour Inspection: A Quarterly or 250 hour Inspection: A+B Semi-annual or 500 hour Inspection: A+B+C
Checklist B Y N R B-1 Batteries B-2 Electrical wiring B-3 Oil cooler and fins Deutz models B-4 Inspect air filter B-5 Hydraulic oil analysis B-6 Engine maintenance Deutz models B-7 Engine maintenance Cummins models B-8 Exhaust system B-9 Lug nut torque B-10 Drive hub oil level B-11 Drive brakes B-12 Engine RPM B-13 Key switches B-14 Ground control override B-15 Platform self-leveling B-16 Limit switches B-17 Fuel and hydraulic tank venting systems B-18 Engine idle select operation B-19 Test the drive brakes B-20 Drive speed - stowed position B-21 Drive speed - raised or extended position B-22 Inspect the Boom Extend/Retract Cables
Annual or 1000 hour Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E • Place a check in the appropriate box after each inspection procedure is completed. • Use the step-by-step procedures in this section to learn how to perform these inspections.
Comments
• If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired
Part No. 102916
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Section 3 • Scheduled Maintenance Procedures
October 2015
MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company
Instructions • Make copies of this report to use for each inspection. • Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: A Quarterly or 250 hour Inspection: A+B Semi-annual or 500 hour Inspection: A+B+C
Checklist C Y N R C-1 Engine maintenance Deutz models C-2 Engine maintenance Cummins models C-3 Engine maintenance Perkins models C-4 Replace air filter element C-5 Grease platform overload (if equipped) C-6 Test the platform overload (if equipped) Checklist D - Rev A D-1 Boom wear pads D-2 Extendable axle wear pads D-3 Free-wheel configuration D-4 Turntable rotation bearing bolts D-5 Rotation gear backlash D-6 Drive hub oil D-7 Turntable bearing wear D-8 Engine maintenance Deutz models D-9 Engine maintenance Perkins models D-10 Engine maintenance Cummins models D-11 Replace the hydraulic filter elements
Checklist E Y N R E-1 Replace hydraulic oil E-2 Engine maintenance Cummins models E-3 Engine maintenance Deutz models Perform every two years: E-4 Engine maintenance Perkins models E-5 Engine maintenance Deutz models Perform every 3000 hours: E-6 Engine maintenance Perkins models E-7 Engine maintenance Deutz models Perform every 4000 hours: E-8 Engine maintenance Perkins models Perform every 6000 hours: E-9 Engine maintenance Perkins models E-10 Engine maintenance Deutz models Perform every 12000 hours: E-11 Engine maintenance Perkins models E-12 Engine maintenance Deutz models Perform every 10 years: E-13 Replace the Boom Extend/Retract cables
Annual or 1000 hour Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E • Place a check in the appropriate box after each inspection procedure is completed. • Use the step-by-step procedures in this section to learn how to perform these inspections. • If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box.
Comments
Legend Y = yes, acceptable N = no, remove from service R = repaired
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Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures A-1 Inspect the Manuals and Decals Genie requires that this procedure be performed daily. Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions.
3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage. Result: The machine is equipped with all required decals, and all decals are legible and in good condition. Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced. 4 Always return the manuals to the storage container after use. Note: Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed.
1 Check to make sure that the operator's and safety manuals are present and complete in the storage container on the platform. 2 Examine the pages of each manual to be sure that they are legible and in good condition. Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition. Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced.
Part No. 102916
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-2 Perform Pre-operation Inspection
A-3 Perform Function Tests
Genie requires that this procedure be performed daily.
Genie requires that this procedure be performed daily.
Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required.
Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.
Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.
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Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.
S-100 • S-105 • S-120 • S-125
Part No. 102916
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-4 Perform Engine Maintenance Perkins Models
A-5 Perform Engine Maintenance Deutz Models
Engine specifications require that this procedure be performed every 8 hours or daily, whichever comes first.
Engine specifications require that this procedure be performed every 8 hours or daily, whichever comes first. All Models:
• Engine oil level - check • Coolant level - check/add
• Engine oil level - check
• Fuel system filter/water separator - drain
• Fuel system filter/water separator - drain
• Alternator Belt - Inspect/Adjust/Replace
• Engine tightness - check for leaks
• Air filter discharge valve - clean
• Exhaust system - check for leaks
• Engine tightness - check for leaks
• Air filter discharge valve - clean
• Exhaust system - check for leaks Required maintenance procedures and additional engine information are available in the Perkins 1004 User's Handbook (Perkins part number TPD 1349E) OR the Perkins 845F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 800D Series User's Handbook (Perkins part number SEBU8324-00). Perkins 1004 User's Handbook Genie part number Perkins 854 Series User's Handbook Genie part number Perkins 800D Series User's Handbook Genie part number
Part No. 102916
61376 218708 None
TD 2.9 Models: • Coolant level - check/add Required maintenance procedures and additional engine information are available in the Deutz F4L913 Operation Manual (Deutz part number 0297-7341) OR the Deutz BF4L2011 Operation Manual (Deutz part number 0297-9929) OR the Deutz TD 2.9 Operation Manual (Deutz part number 0312-3893) OR the Deutz TD 2011 Operation Manual (Deutz part number 0312-3547). Deutz F4L913 Operation Manual Genie part number
62446
Deutz BF4L2011 Operation Manual Genie part number
84794
Deutz TD 2.9 Operation Manual Genie part number
1251561
Deutz TD 2011 Operation Manual Genie part number
139320
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-6 Perform Engine Maintenance Cummins Models
A-7 Check the Hydraulic Filter Condition Indicators
Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first.
Genie requires that this procedure be performed daily.
Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 and B3.9L Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3T Operation and Maintenance Manual (Cummins part number 3666417-00). Cummins B4.5 and B3.9L Operation and Maintenance Manual Genie part number Cummins B3.3T Operation and Maintenance Manual Genie part number
3 - 10
107527
139324
Note: Perform this procedure after the machine reaches operating temperature. The amount of time this takes will vary, depending on ambient air temperature. Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation. The filter condition indicators will show when the hydraulic flow is bypassing a clogged filter. If the filters are not frequently checked and replaced, impurities will remain in the hydraulic system and cause component damage. Note: There are four hydraulic filters on the machine: one tank return filter, one medium pressure filter and two high pressure filters. All the filters have condition indicators on them, except the medium pressure filter. 1 Start the engine from the ground controls. 2 Press and release the engine idle select button to change the engine rpm to high idle.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES Tank return filter
Medium and high pressure filters
Note: The tank return filter indicator needle may operate in the red area when hydraulic oil is below 50° F / 10° C.
Note: The medium and high pressure filters are mounted to the engine side bulkhead.
Note: If the return filter indicator needle is not operating in the green area after performing previous daily procedures, continue running engine until hydraulic oil temperature is at least 50° F / 10° C. 3 Open the ground control side turntable cover and inspect the filter condition indicator gauge.
4 Inspect the filter condition indicators.
b
a c
a
a b c
a
filter condition indicator gauge
Result: The needle on the gauge should be operating in the green area. If the needle is in the red area, this indicates that the hydraulic filter is being bypassed and the filter needs to be replaced. See D-11, Replace the Hydraulic Filter Elements.
Part No. 102916
high pressure filters filter condition indicators medium pressure filter
Result: The filter condition indicators should be operating with the plungers in the green area. If any of the indicators display the plunger in the red area, this indicates that a hydraulic filter is being bypassed and the filter needs to be replaced. See D-11, Replace the Hydraulic Filter Elements.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-8 Perform 30 Day Service
A-9 Perform Engine Maintenance Perkins Models
The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage. After this interval, refer to the maintenance checklists for continued scheduled maintenance. 1 Perform the following maintenance procedures:
• A-10
Grease the Turntable Rotation Bearing and Rotate Gear
• B-9
Inspect the Tires, Wheels, and Lug Nut Torque
• B-10
Check the Drive Hub Oil Level and Fastener Torque
• D-4
Check the Turntable Rotation Bearing Bolts
• D-11
Replace the Hydraulic Filter Elements
Engine specifications require that this procedure be performed every 50 hours or weekly, whichever come first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 1004 User's Handbook (Perkins part number TPD 1349E) OR the Perkins 854 Series User's Handbook (Perkins part number SEBU8726) OR the Perkins 800D Series User's Handbook (Perkins part number SEBU8324-00). Perkins 1004 User's Handbook Genie part number
61376
Perkins 854 Series User's Handbook Genie part number
218708
Perkins 800D Series User's Handbook Genie part number
None
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Part No. 102916
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
A-10 Perform Engine Maintenance Deutz Models
Engine specifications require that this one-time procedure be performed after the first 50 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz F4L913 Operation Manual (Deutz part number 0297-7341) OR the Deutz BF4L2011 Operation Manual (Deutz part number 0297-9929) OR the Deutz TD 2.9 Operation Manual (Deutz part number 0312-3893) OR the Deutz TD 2011 Operation Manual (Deutz part number 0312-3547).
Part No. 102916
Deutz F4L913 Operation Manual Genie part number
62446
Deutz BF4L2011 Operation Manual Genie part number
84794
Deutz TD 2.9 Operation Manual Genie part number
1251561
Deutz TD 2011 Operation Manual Genie part number
139320
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
A-11 Grease the Turntable Rotation Bearing and Rotate Gear
Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage. 1 Remove the turntable rotation gear cover retaining fasteners and remove the gear cover from the machine. 2 Open the ground controls side turntable side cover. 3 Locate the grease fitting below the ground control box. 4 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches (10 to 13 cm) at a time and repeat this step until the entire bearing has been greased. 5 Apply grease to each tooth of the drive gear, located under the turntable. 6 Install the turntable rotation gear cover and retaining fasteners onto the machine. Bodily injury hazard. Contact with the turntable rotation gear could result in serious injury. Do not operate the machine if the turntable rotation gear cover is not installed.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-12 Grease the Extendable Axles
A-13 Replace the Drive Hub Oil
Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist.
Genie specifications require that this one-time procedure be performed after the first 150 hours of operation.
Frequent lubrication to the front and rear extendable axles helps to ensure the smooth operation of the axles over the lifetime of the product. Two grease fittings are added at each extending axle. One to direct grease to the top sliding wear pad and one to direct grease to the bottom sliding wear pad.
Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil after the first 150 hours may cause the machine to perform poorly and continued use may cause component damage. Drive Hubs: 1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point.
a
2 Remove both plugs and drain the oil into a suitable container. Refer to capacity specifications 3 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other side. a
b
a b
Top wear pad grease fitting Side wear pad grease fitting
1 Locate the grease fittings on the extendable axles covers. 2 Thoroughly pump grease into each grease fitting. When grease is pumped into each fitting, a hose directs this lubrication to the top or bottom wear pad. 3 Cycle the extending axles in and out. Genie recommends that the extending axles be cycled in and out at least once a week.
Part No. 102916
a
drive hub plugs
4 Fill the hub with oil from either plug hole until the oil level is even with the bottom of both plug holes. Install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs. 6 Check the torque of the drive hub mounting bolts. Refer to Specifications, Machine Torque Specifications.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES Turntable Rotate Drive Hub: 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, Machine Torque Specifications. 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Remove the ground control side fixed turntable cover. Refer to Repair Procedure, How to Remove a Fixed Turntable Cover. 3 Tag, disconnect and plug the turntable rotate drive motor hoses at the turntable rotate drive motor and the turntable rotate drive brake hoses at the turntable rotate drive brake. Cap the fittings. 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. Component damage hazard. Hoses can be damaged if they are kinked or pinched.
5 Remove the plug from the side of the drive hub. Drain the oil from the hub into a suitable container. 6 Install the drive hub assembly onto the machine. Lubricate and torque the drive hub mounting bolts to specification. Refer to Specifications, Machine Specifications. 7 Fill the drive hub with oil from the side hole until the oil level is even with the bottom of the hole. Apply pipe thread sealant to the plug. Install the plug. Refer to Specifications, Machine Specifications. 8 Install the turntable rotate drive motor hoses into the turntable rotate drive motor and install the turntable rotate drive brake hose into the turntable rotate drive brake. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 9 Adjust the turntable rotation gear backlash. See D-5, Check the Turntable Rotation Gear Backlash. 10 Install the ground control side fixed turntable cover onto the machine and tighten the retaining fasteners
4 Remove the turntable rotate drive hub mounting bolts and pivot bolt. Remove the turntable rotate drive hub with a suitable lifting device of ample capacity. Crushing hazard. The turntable rotate drive hub may become unbalanced and fall when it is removed from the machine if it is not properly supported.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
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Section 3 • Scheduled Maintenance Procedures
Checklist B Procedures B-1 Inspect the Batteries
3 Be sure that the battery retainers and cable connections are tight.
Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first.
5 Put on protective clothing and eye wear.
4 Fully charge the batteries. Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize.
Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. There are 2 batteries on the machine. One starts the engine and the other powers the control system. The batteries are charged by the alternator through a battery separator. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. 1 Open the engine side cover. 2 Be sure that the battery cable connections are free of corrosion.
6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display an adjusted specific gravity of 1.277 +/- 0.007. The battery is fully charged. Proceed to step 11. Result: One or more battery cells display a specific gravity of 1.269 or below. Proceed to step 8. 8 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours. 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results.
Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.
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Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows:
B-2 Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display a specific gravity of 1.277 +/- 0.007. The battery is fully charged. Proceed to step 11. Result: One or more battery cells display a specific gravity from 1.269 to 1.218. The battery is still useable, but at a lower performance so will need to be recharged more often. Proceed to step 11.
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Result: One or more battery cells display a specific gravity from 1.217 to 1.173. The battery is approaching the end of its life. Proceed to step 11. Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is 1.172 or less. Replace the battery.
1 Open the engine side turntable cover. 2 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
11 Check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 12 Install the vent caps and neutralize any electrolyte that may have spilled. a
b a b
engine pivot plate anchor hole engine pivot plate retaining fastener
3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.
12 Start the engine from the ground controls and raise the boom above the turntable covers. Component damage hazard. Be sure the hydraulic supply hoses to the function and drive pumps are not kinked before starting the engine.
Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 5 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires:
13 Inspect the turntable area for burnt, chafed and pinched cables.
· Engine wiring harness · Battery area wiring 6 Open the ground controls side turntable cover.
14 Lower the boom to the stowed position and turn the engine off.
7 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: 8
· Inside of the ground control box · Hydraulic manifold wiring · Battery area wiring · Hydraulic oil cooler wiring Inspect for a liberal coating of dielectric grease in the following locations:
· All wire harness connectors to ground control box · Wire harness connectors 9 Open the hydraulic manifold box covers at both sides of the drive chassis. 10 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: · Hydraulic manifold wiring 11 Inspect for a liberal coating of dielectric grease in the following location:
15 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: · Cable track on the boom · Cables on the boom, jib boom and jib boom pivot area · Jib boom/platform rotate manifold · Platform control box · Inside of the platform control box 16 Inspect for a liberal coating of dielectric grease in the following location: · All wire harness connectors to platform control box 17 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 18 Swing the engine pivot plate in towards the machine. 19 Install the bolt that was just removed into the original hole to secure the engine pivot plate.
· Wire harness connectors to DCON module
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S-100 • S-105 • S-120 • S-125
Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-3 Check the Engine Oil Cooler and Cooling Fins - Deutz Models (does not include TD 2.9 models)
Maintaining the oil cooler in good condition is essential for good engine performance. Operating a machine with a damaged oil cooler may result in engine damage. Also, restricting air flow through the oil cooler will affect the performance of the cooling system.
material. Cooling and blower fins 5 Inspect the fan blower fins for physical damage. 6 Clean the fan blower fins of debris and foreign material. 7 Using a flashlight, inspect the head cooling passages and fins for physical damage or foreign material. 8 If needed, clean the cylinder head cooling passages and fins of debris and foreign material. 9 Install the engine side cover and tighten the
Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 1 Open the engine side turntable cover. Oil cooler 2 Remove the retaining fasteners from the engine side cover. Remove the cover. 3 Inspect the oil cooler for leaks and physical damage. 4 Clean the oil cooler of debris and foreign
Part No. 102916
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-4 Inspect the Engine Air Filter Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Note: Perform this procedure with the engine off.
2 Release the latches from the end cap of the air filter canister. Remove the end cap. 3 Remove the filter element. 4 Clean the inside of the canister and the canister end cap with a damp cloth. 5 Inspect the filter element. If needed, blow from the inside out using low pressure dry compressed air, or tap out dust, taking care not to damage the element. 6 Install the filter element. 7 Install the end cap onto the canister. Secure the clamps. Note: Be sure the discharge slot is pointing down.
1 Open the engine side cover. Empty the dust discharge valve by pressing together the sides of the discharge slot. Clean the discharge slot as needed.
a
b
c
a clamp b cannister end cap c dust discharge valve
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Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-5 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil.
Part No. 102916
B-6 Perform Engine Maintenance Deutz Models
Engine specifications require that this procedure be performed every 250 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz F4L913 Operation Manual (Deutz part number 0297-7341) OR the Deutz BF4L2011 Operation Manual (Deutz part number 0297-9929) OR the Deutz TD 2.9 Operation Manual (Deutz part number 0312-3893) OR the Deutz TD 2011 Operation Manual (Deutz part number 0312-3547). Deutz F4L913 Operation Manual Genie part number
62446
Deutz BF4L2011 Operation Manual Genie part number
84794
Deutz TD 2.9 Operation Manual Genie part number
1251561
Deutz TD 2011 Operation Manual Genie part number
139320
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
B-7 Perform Engine Maintenance Cummins Models
Engine specifications require that this procedure be performed every 250 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 and B3.9L Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3T Operation and Maintenance Manual (Cummins part number 3666417-00). Cummins B4.5 and B3.9L Operation and Maintenance Manual Genie part number
107527
Cummins B3.3T Operation and Maintenance Manual Genie part number
139324
To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-8 Check the Exhaust System
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns.
a
b a b
engine pivot plate anchor hole engine pivot plate retaining fastener
2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 4 Be sure that all fasteners are tight.
Cummins and Perkins models:
5 Inspect all welds for cracks.
1 Be sure that all fasteners are tight.
6 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints.
2 Inspect all welds for cracks. 3 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. Deutz models: 1 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
7 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 8 Swing the engine pivot plate in towards the machine. 9 Install the bolt that was just removed into the original hole to secure the engine pivot plate. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-9 Inspect the Tires, Wheels and Lug Nut Torque
B-10 Check the Drive Hub Oil Level and Fastener Torque
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.
Maintaining the tires and wheels in good condition, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion.
Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage.
Note: The tires on these machines are foam filled and do not need air added to them.
Drive hubs: 1 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other side. a
1 Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracked welds. 3 Check each lug nut for proper torque. Refer to Specifications, Machine Torque Specifications. a
drive hub plugs
2 Remove both plugs and check the oil level. Result: The oil level should be even with the bottom of the plug holes. 3 If necessary, add oil until the oil level is even with the bottom of the plug holes. 4 Install the plugs in the drive hub. 5 Check the torque of the drive hub mounting fasteners. Refer to Specifications, Machine Torque Specifications. 6 Repeat this procedure for each drive hub.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES Turntable Rotate Drive Hub: 1 Remove the fixed turntable cover at the ground controls side of the machine. 2 Remove the power to platform plug panel upper retaining fasteners and loosen the lower retaining fasteners. Do not disconnect the wiring.
a
c
b
3 Support the cover with a suitable lifting device. Protect the cover from damage. 4 Remove the cover retaining fasteners. Remove the cover from the machine. Crushing hazard. The turntable cover may become unbalanced and fall when it is removed from the machine if it is not properly supporte 5 Remove the plug located on the top of the drive brake and check the oil level. Result: The oil level should be even with the bottom of the plug hole.
Part No. 102916
a plug b turntable rotate drive hub c drive brake
6 If necessary, add oil until the oil level is even with the bottom of the plug hole. 7 Install the plug into the drive hub.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-11 Confirm the Proper Brake Configuration
2 Be sure the free-wheel valve on the drive pump is closed (clockwise). Note: The free-wheel valve is located on the drive pump.
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.
b
d
Proper brake configuration is essential to safe operation and good machine performance. Hydrostatic brakes and hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. 1 Check each drive hub disconnect cap to be sure it is in the engaged position. disengaged position
c
a
a drive pump b screwdriver c lift pump d free-wheel valve
Note: The free-wheel valve should always remain closed.
engaged position
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-12 Check and Adjust the Engine RPM
Deutz models: 1 Start the engine from the ground controls. 2 Push one of the LCD screen buttons shown until engine rpm is displayed.
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage.
Result: Refer to Specifications, Deutz Engine Specification. Skip to step 5 if the low idle rpm is correct. 3 Loosen the locknut on the low idle adjustment screw.
Note: Does not apply to these models. The engine RPM is controlled by the ECM and can only be adjusted by re-programming the ECM. If RPM or service is required, please contact Genie Product Support. Deutz TD 2.9 L4 model Perkins 854F-34T model Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.
Plus
Minus
Previous
a
low idle adjustment screw
Part No. 102916
a
a
low idle adjustment screw
Enter
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 4 Adjust the low idle adjustment screw until low idle is 1500 rpm. Tighten the locknut.
2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.
5 Push and hold the function enable/high speed button. Note the engine rpm on the display.
3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.
Result: Refer to Specifications, Deutz Engine Specification.
Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
If the high idle is correct, disregard adjustment step 6. 6 Loosen the yoke lock nut. Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle. Cummins and Perkins models: 1 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
4 Start the engine from the ground controls. Component damage hazard. Be sure the hydraulic supply hoses to the function and drive pumps are not kinked before starting the engine. 5 Push one of the LCD screen buttons shown until engine rpm is displayed. Result: Refer to Specifications, Perkins Engine Specification. a
a
b a b
engine pivot plate anchor hole engine pivot plate retaining fastener
c
b
Perkins models a low idle adjustment screw b solenoid boot c yoke lock nut
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES Skip to step 7 if the low idle rpm is correct. 6 Loosen the low idle lock nut. Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the low idle lock nut and confirm the rpm. 7 Push and hold the function enable/high speed button. Note the engine rpm on the display. Result: Refer to Specifications, Cummins Engine Specification.
If the high idle is correct, disregard adjustment step 8. 8 Perkins models: Loosen the yoke lock nut. Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Cummins models: Turn the high idle solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle. 9 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 10 Swing the engine pivot plate in towards the machine. 11 Install the bolt that was just removed into the original hole to secure the engine pivot plate.
a
b
Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
c
Cummins models a low idle adjustment screw b solenoid cable c rpm solenoid
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-13 Test the Key Switches
STOP
00000
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential to safe machine operation. Failure of either key switch to function properly could cause a hazardous operating situation. There are two key switches on the machine - the Main key switch and the Service Bypass/Recovery key switch.
Run Service Bypass Recovery
The Main key switch controls machine operation from the ground or platform controls.
1 Open the ground controls side turntable side cover.
When the Service Bypass/Recovery key switch is turned to the service bypass position, the primary boom can be raised while the axles are retracted. This feature of the machine is especially helpful for storage purposes or when loading the machine for transport.
2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.
Note: When the boom is raised with the axles retracted, the boom cannot be rotated past either circle-end wheel. When the Service Bypass/Recovery key switch is turned and held to the recovery position, the auxiliary power units will turn on and fully retract the boom and then lower the boom. This feature of the machine is especially helpful if the operator in the platform cannot lower the boom, if the platform controls become inoperative or for returning the machine to a safe position when the safety switches have been tripped. Note: Perform this procedure with the axles retracted and the boom in the stowed position.
3 At the ground controls, turn the service bypass/recovery key switch to the run position. 4 Turn the main key switch to ground control, start the engine and then turn the key switch to platform control. 5 Check any machine function from the ground controls. Result: The machine functions should not operate. 6 Turn the main key switch to ground control. 7 Check any machine function from the platform controls. Result: The machine functions should not operate. 8 Turn the main key switch to the off position. Result: The engine should stop and no functions should operate. 9 Turn the main key switch to ground control and start the engine.
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Section 3 • Scheduled Maintenance Procedures
10 Attempt to raise the primary boom. Result: The boom should not raise. Note: The primary boom will not raise until the axles are fully extended. 11 Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. Note: The main key switch should remain in the ground control position. 12 Turn the service bypass/recovery key switch to the service bypass position. 13 Raise the boom. Result: The boom should raise. 14 Remove the key from the service bypass/recovery key switch and insert the key into the main key switch. 15 Turn the main key switch to the off position. 16 Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. 17 Turn and hold the service bypass/recovery key switch to the recovery position. Result: The boom should return to the stowed position.
B-14 Test the Ground Control Override Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button at the platform controls is in the on or off position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. 1 Push in the red Emergency Stop button at the platform controls to the off position. 2 Start the engine from the ground controls. 3 At the ground controls, operate each boom function through a partial cycle. Result: All boom functions should operate. Note: The boom will not raise past horizontal and the boom will not extend more than 12 inches / 30.5 cm unless both axles are fully extended.
18 Turn the service bypass/recovery key switch to the run position. 19 Remove the key from the service bypass/recovery key switch and insert the key into the main key switch. 20 Turn the main key switch to the off position. 21 Close the turntable side cover.
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Section 3 • Scheduled Maintenance Procedures
B-15 Test the Platform Self-leveling Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained level by the communication between the platform level sensor and the turntable level sensor. If the platform becomes out of level, the computer at the ground controls will open the appropriate solenoid valve(s) at the platform manifold to maintain a level platform. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel. 1 Start the engine from the platform controls and extend the axles. 2 Turn the key switch to ground controls.
5 Push and hold a function enable/speed select button and fully raise the boom. Result: The platform should remain level at all times to within ±2 degrees. Note: If the platform becomes out of level, the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls. The platform level up/down buttons will only work in the direction that will level the platform. Level the platform until the indicator light turns off. 6 Push and hold a function enable/speed select button and fully lower the boom. Result: The platform should remain level at all times to within ±2 degrees. Note: If the platform becomes out of level, the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls. The platform level up/down buttons will only work in the direction that will level the platform. Level the platform until the indicator light turns off.
3 Push and hold a function enable/speed select button and fully retract the boom. 4 Push and hold a function enable/speed select button and adjust the platform to a level position using the platform level up/down buttons.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-16 Test the Safety Envelope and Circuits Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Testing the machine safety envelope is critical to safe machine operation. If the boom is allowed to operate when a safety switch is not functioning correctly, the machine stability is compromised and may tip over. Note: Refer to Repair Procedure, Limit Switch and Level Sensor Locations for diagram showing the location of switches in this procedure. 1 Start the engine from the ground controls.
7 Pull out the red Emergency Stop button to the on position and restart the engine. 8 Disconnect the 68° proximity switch LSB14AO and install a wire jumper between pin 3 and pin 4 of the Deutsch connector. Result: ">68 deg" should be present on the display screen at the ground controls. 9 Activate the function enable/high RPM button and extend the boom to 101 feet / 30.8 m. Result: The engine should stop and the boom extend function should be disabled. Result: If the engine does not stop and the boom continues to extend, the LSB2RS switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section. Bodily injury hazard. If the boom extends to more than 101 feet / 30.8 m without stopping the engine, stop immediately and retract the boom until the boom is extended to less than 100 feet / 30.5 m. Failure to retract the boom could result in death or serious injury.
2 Raise the boom to approximately 60°. Note: For S-100 or S-105 models, proceed to step 30. 101 feet / 30.8 m Length Safety Switch, LSB2RS: 3 Extend the boom to more than 80 feet / 24.4 m. Machines before SN 2710: Machines after SN 2709:
10 Using auxiliary power, retract the boom until the boom is extended to approximately 95 feet / 29 m.
5 Push in the red Emergency Stop button to the off position.
11 Remove the wire jumper installed in step 8 and connect the Deutsch connector to LSB14AO.
4 Proceed to step 8.
6 Plug in the LSB2RS test jumper between the lower limit switch and the function manifold (J2 and J4 connectors on the ground control box).
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES S-100/105 models before SN 806:
20 Measure the angle of the boom.
S-120/125 models before SN 2710:
Result: The angle of the boom should be greater than 65°.
12 Proceed to step 15.
21 Using auxiliary power, raise the boom until the boom angle is greater than 68°.
S-100/105 Models after SN 805: S-120/125 Models after SN 2709: 13 Push in the red Emergency Stop button to the off position. 14 Remove the LSB2RS test jumper between the lower limit switch and the function manifold (J2 and J4 connectors on the ground control box). 15 Pull out the red Emergency Stop button to the on position and restart the engine. 65° Angle Safety Switch, LSB9AS: 16 Raise the boom to the maximum angle. 17 Fully extend the boom. 18 Disconnect the 68° proximity switch LSB14AO and install a wire jumper between pin 3 and pin 4 of the Deutsch connector. 19 Activate the function enable/high RPM button and lower the boom to 65°.
22 Remove the wire jumper installed in step 18 and connect the Deutsch connector to LSB14AO. 23 With the key switch off, press and hold the button and turn the key switch to the on position. Release the button after five seconds and press the buttons. button until clear all safety switch 24 Press the faults appears. 25 Select yes, then press the 26 Press the
button.
button until exit appears.
27 Select yes, then press the
button.
28 Restart the engine. 50° Angle Safety Switch, LSB8AS: 29 Lower the boom to approximately 60°.
Result: The engine should stop and the boom down function should be disabled.
30 Extend the boom to approximately 95 feet / 28.96 m.
Result: If the engine does not stop and the boom continues to lower to less than 65°, the LSB9AS switch is out of adjustment or the wiring is faulty and will need to be replaced or repaired. See Repair Section.
31 Disconnect the 53° proximity switch LSB13AO and install a wire jumper between pin 3 and pin 4 of the Deutsch connector.
Bodily injury hazard. If the boom lowers to less than 65° without stopping the engine, stop immediately and raise the boom until the boom is elevated to greater than 68°. Failure to raise the boom could result in death or serious injury.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 32 Activate the function enable/high RPM button and lower the boom to 50°. Result: The engine should stop and the boom down function should be disabled. Result: If the engine does not stop and the boom continues to lower to less than 50°, the LSB8AS switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section. Bodily injury hazard. If the boom lowers to less than 50° without stopping the engine, stop immediately and raise the boom until the boom is elevated togreater than 53°. Failure to raise the boom could result in death or serious injury. 33 Measure the angle of the boom. Result: the angle of the boom should be greater than 50°. 34 Using auxiliary power, raise the boom until the boom angle is greater than 53°. 35 Remove the wire jumper installed in step 31 and connect the Deutsch connector to LSB13AO.
38 Select yes, then press the 39 Press the
button until exit appears.
40 Select yes, then press the
button.
41 Restart the engine, retract the boom so it is extended less than 75 feet / 22.9 m and then lower the boom sufficient to gain access to LSB3EO. Note: LSB3EO is located on top of boom tube number 2 at the platform end of the machine. 76 feet / 23.2 m Length Safety Switch, LSB4ES: 42 Disconnect the 75 feet / 22.9 m safety switch LSB3EO. 43 Start the engine and activate the function enable/high RPM button and extend the boom to 76 feet / 23.2 m. Result: The engine should stop and the boom extend function should be disabled. Result: If the engine does not stop and the boom continues to extend, the LSB4ES switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section.
36 With the key switch off, press and hold the button and turn the key switch to the on position. Release the button after five seconds and press the buttons. button until clear all safety switch 37 Press the faults appears.
Part No. 102916
button.
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. If the boom extends to more than 76 feet / 23.2 m without stopping the engine, stop immediately and retract the boom until the boom is extended to less than 75 feet / 22.9 m. Failure to retract the boom could result in death or serious injury.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 44 Using auxiliary power, retract the boom until the boom is extended to less than 75 feet / 22.9 m. 45 Re-connect the harness plug to LSB3EO. 46 With the key switch off, press and hold the button and turn the key switch to the on position. Release the button after five seconds and press the buttons. button until clear all safety switch 47 Press the faults appears. 48 Select yes, then press the 49 Press the
54 Place the arm removed in step 53 back on the LSB6S switch 180° opposite its original position. Rotate the head of the switch 45° clockwise and activate the function enable/high RPM button and attempt to extend the boom. Result: The boom extend function should be disabled. Result: If the boom extends, the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired. See Repair Section. Bodily injury hazard. If the boom extends at all, stop immediately and retract the boom until the boom is extended to less than 2 feet / 0.6 m. Failure to retract the boom could result in death or serious injury.
button.
button until exit appears.
50 Select yes, then press the
button.
Cable Break Safety Switch, LSB6S: 51 Start the engine and activate the function enable/high RPM button and retract the boom until the boom is extended to less than 2 feet / 0.6 m. 52 Remove the boom end cover from the pivot end of the boom. 53 Remove the arm from the cable break limit switch LSB6S.
55 Activate the function enable/high RPM button and attempt to retract the boom. Result: The boom retract function should be enabled. Result: If the boom does not retract, the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired. See Repair Section.
Note: LSB6S is located at the end of the boom tubes at the pivot end of the boom.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 56 Allow the switch to return to its neutral position, then rotate the head of the switch 45° counter clockwise and activate the function enable/high RPM button and attempt to extend the boom. Result: The boom extend function should be disabled. Result: If the boom extends, the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired. See Repair Section.
62 Place a metal washer over the target area of the axle extend proximity switch LSAX1EO and place a metal washer over the target area of the axle extend proximity switch LSAX2EO to close the contacts. Result: The axle extend indicator light at the ground and platform controls should be illuminated. a
Bodily injury hazard. If the boom extends at all, stop immediately and retract the boom until the boom is extended to less than 2 feet (0.6 m). Failure to retract the boom could result in death or serious injury. 57 Reinstall the arm onto LSB6S in its original position. Axle Extend Safety Switch, LSAX1ES and LSAX2ES and 3 feet / 0.9 m Safety Switch, LSB3RS and 11° Angle Safety Switch, LSB7DS: 58 Fully retract and lower the boom to the stowed position.
Proximity switch a target area
63 Activate the function enable/high RPM button and attempt to extend the boom. Result: The boom should not extend to more than 3 feet / 0.9 m. Result: If the boom extends to more than 3 feet / 0.9 m, the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section.
59 Retract both axles approximately 1 foot / 0.3 m. 60 Remove the access cover from each axle. 61 Disconnect the square-end axle extend safety switch LSAX1ES and install a wire jumper between pin 3 and pin 4 of the deutsch connector.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. If the boom extends to more than 3 feet / 0.9 m, stop immediately and retract the boom until the boom is extended to less than 2 feet / 0.6 m. Failure to retract the boom could result in death or serious injury.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES 64 Activate the function enable/high RPM button and attempt to raise the boom.
67 Activate the function enable/high RPM button and attempt to extend the boom.
Result: The boom should not raise to more than 11°.
Result: The boom should not extend to more than 3 feet / 0.9 m.
Result: If the boom continues to raise, the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section.
Result: If the boom extends to more than 3 feet / 0.9 m, the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section.
Bodily injury hazard. If the boom raises to more than 11°, stop immediately and lower the boom until the boom is less than 11°. See Repair Section. Failure to retract the boom could result in death or serious injury. 65 Remove the wire jumper installed in step 61 and connect the Deutsch connector to LSAX1ES. 66 Disconnect the circle-end axle extend safety switch LSAX2ES and install a wire jumper between pin 3 and pin 4 of the Deutsch connector.
Bodily injury hazard. If the boom extends to more than 3 feet / 0.9 m, stop immediately and retract the boom until the boom is extended to less than 2 feet / 0.6 m. Failure to retract the boom could result in death or serious injury. 68 Activate the function enable/high RPM button and attempt to raise the boom. Result: The boom should not raise to more than 11°. Result: If the boom continues to raise, the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired. See Repair Section. Bodily injury hazard. If the boom raises to more than 11°, stop immediately and lower the boom until the boom is less than 11°. Failure to lower the boom could result in death or serious injury. 69 Remove the wire jumper installed in step 66 and connect the Deutsch connector to LSAX2ES.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems
Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. Free-breathing fuel and hydraulic tank caps are essential for good machine performance and service life. A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the caps be inspected more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, well-ventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. 1 Remove the cap from the fuel tank.
2 Check for proper venting. Result: Air passes through the fuel tank cap. Procced to step 4. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3. Note: When checking for positive tank cap venting, air should pass freely through the cap. 3 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 2. 4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. 6 Check for proper venting. Result: Air passes through the hydraulic tank cap. Procced to step 8. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 7. Note: When checking for positive tank cap venting, air should pass freely through the cap. 7 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-18 Test the Engine Idle Select Operation Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.
6 Turn the key switch to platform controls. 7 At the platform controls, press the engine idle select button until high idle (rabbit symbol) is selected. Result: The engine should change to high idle. a
b
c
A properly operating engine idle select function is essential to good engine performance and safe machine operation. There are three settings. Low idle (turtle symbol) allows the operator to control multiple boom and/or drive functions simultaneously, though at reduced speed. This setting maintains a consistent low idle.
d
High idle (rabbit symbol) allows the operator to control multiple boom and/or drive functions simultaneously. This setting maintains a consistent high idle. Foot switch activated high idle (rabbit and foot switch symbols) should be used for normal machine operation. This selection activates high idle only when the foot switch is pressed down. 1 Turn the key switch to ground controls. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Start the engine from the ground controls. 4 Push and release the rpm select button until high rpm is selected (rabbit symbol).
a b c d
foot switch activated high idle indicator light low idle indicator light high idle indicator light engine rpm select button
8 Press the engine idle select button until low idle (turtle symbol) is selected. Result: The engine should change to low idle. 9 Press the engine idle select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected. Result: The engine should not change to high idle. 10 Press down the foot switch. Result: The engine should change to high idle.
Result: The engine should change to high idle. 5 Push and release the rpm select button until low rpm is selected (turtle symbol). Result: The engine should return to low idle.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-19 Test the Drive Brakes
B-20 Test the Drive Speed Stowed Position
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulically-released individual wheel brakes can appear to operate normally when they are actually not fully operational. Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Refer to Maintenance Procedure, Confirm the Proper Brake Configuration.
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Note: Select a test area that is firm, level and free of obstructions. Note: Perform this procedure with the boom in the stowed position.
Note: Select a test area that is firm, level and free of obstructions.
1 Create start and finish lines by marking two lines on the ground 36 feet / 11 m apart.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected. then lower the boom into the stowed position.
3 Press the engine rpm select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected, then lower the boom into the stowed position. 4 Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use when crossing the test line. 5 Bring the machine to top drive speed before reaching the test line. Release the drive controller when your reference point on the machine crosses the test line. 6 Measure the distance between the test line and your machine reference point. Refer to Section Specifications, Machine Specifications.
Part No. 102916
4 Choose a point on the machine; i.e., contact patch of a tire as a visual reference for use when crossing the start and finish lines. 5 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 6 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section Specifications, Machine Specifications.
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-21 Test the Drive Speed Raised or Extended Position
7 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section Specifications, Machine Specification. 8 Lower the boom below horizontal. 9 Extend the boom approximately 4 feet (1.2 m).
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.
10 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.
Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range.
11 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.
Note: Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 36 feet (11 m) apart.
12 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section Specifications, Machine Specification. 13 Raise the boom to a horizontal position.
2 Start the engine from the platform controls.
14 Extend the boom until the raise boom LED and envelope alarm are activated.
3 Press the engine idle select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected.
15 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.
4 Raise the boom until the engine rpm switches to low speed.
16 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.
5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 6 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.
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17 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section Specifications, Machine Specification.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-22 Inspect the Boom Extend/Retract Cables
Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube on the S-100 and S-105, and the numbers 2 and 3 boom tubes on the S-120 and S-125. Inspecting for foreign objects, damage and/ or improper adjustment of the boom extend/retract cables on a regular basis is essential to good machine performance and safe machine operation. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise.
3 Visually inspect the cables and components through both inspection holes for the following: • Frayed or broken wire strands • Kinks or crushed cables • Corrosion • Paint or foreign materials on the cables • Split or cracked cable ends • Cables are on all pulleys • Cables have equal tension
• Cables at end of adjustment range
• No Broken or damaged pulleys • No Unusual or excessive pulley wear • All fasteners in place and secure Note: A flashlight and inspection mirror may be necessary to thoroughly inspect the above items. Note: A pulley groove gauge should be used to check the condition of the pulleys. 4 Replace the cables if any damage is found.
Note: Perform this procedure with the boom in the stowed position and the engine off.
5 At the pivot end of the boom, visually inspect for the following:
1 Remove the boom end cover from the pivot end of the boom.
• The red locking bracket is securely installed over the cable adjustment bolts 6 Install the plastic cover at the pivot end of the boom and access panels on the sides of the boom.
a
b
7 Start the engine from the platform controls. 8 Extend the boom approximately 2 feet (0.6 m).
b a b c
c
boom end cover side access covers cable ends (located underneath the boom)
2 Remove the retaining fasteners from the access covers located on the side of the boom at the platform end of the machine. Remove the covers.
Part No. 102916
9 Retract the boom. While retracting the boom, visually inspect the number 2 and number 3 boom tubes. Result: The number 2 should not move more than 1/2 inch (13 mm) before the number 3 boom tube begins to retract. Note: If the number 2 boom tube moves more than inch (13 mm) before the number 3 boom tube begins to retract, the boom extend/retract cables need to be adjusted. See Repair Procedure 4-5, How to Adjust the Boom Extend/Retract Cables.
1/2
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Section 3 • Scheduled Maintenance Procedures
Checklist C Procedures C-1 Perform Engine Maintenance Deutz Models
C-2 Perform Engine Maintenance Cummins Models
Engine specifications require that this procedure be performed every 500 hours.
Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first.
All Models:
Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage.
• Engine oil and filter - change TD 2.9 Models: • Primary fuel filter - replace • V-belts - inspect/adjust/replace • Air intake pipe - check • Cooling system - check TD 2011L04i Models: • Valve clearance - check at first oil change Required maintenance procedures and additional engine information are available in the Deutz F4L913 Operation Manual (Deutz part number 0297-7341) OR the Deutz BF4L2011 Operation Manual (Deutz part number 0297-9929) OR the Deutz TD 2.9 Operation Manual (Deutz part number 0312-3893) OR the Deutz TD 2011 Operation Manual (Deutz part number 0312-3547). Deutz F4L913 Operation Manual Genie part number
62446
Deutz BF4L2011 Operation Manual Genie part number
84794
Deutz TD 2.9 Operation Manual Genie part number
1251561
Deutz TD 2011 Operation Manual Genie part number
139320
3 - 46
Required maintenance procedures and additional engine information are available in the Cummins B4.5 and B3.9L Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3T Operation and Maintenance Manual (Cummins part number 3666417-00). Cummins B4.5 and B3.9L Operation and Maintenance Manual Genie part number
107527
Cummins B3.3T Operation and Maintenance Manual Genie part number
139324
To access the engine:
1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable.
S-100 • S-105 • S-120 • S-125
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-3 Perform Engine Maintenance Perkins Models
C-4 Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be performed every 500 hours.
Engine specifications require that this procedure be performed every 500 hours or annually.
854F Models:
1104D Models:
• Engine oil and filter - change
• Engine oil and filter - change
• Fuel system primary filter (water separator)
• Fuel system primary filter (water separator)
element - replace
element - replace
• Fuel system secondary filter - replace
• Fuel system secondary filter - replace
• Fan clearance - check
• Hoses and clamps - inspect/replace
Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477). Perkins 854F Operation and Maintenance Manual Genie part number 1263971 Perkins 1004 Serial User's Handbook Genie part number
61376
Perkins 800D Serial User's Handbook Genie part number
None
Part No. 102916
• Radiator - clean • V-belts - inspect/adjust/replace Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477). Perkins 854F Operation and Maintenance Manual Genie part number 1263971 Perkins 1004 Serial User's Handbook Genie part number
61376
Perkins 800D Serial User's Handbook Genie part number
None
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-5 Replace the Engine Air Filter Element
C-6 Grease the Platform Overload Mechanism (if equipped)
Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first.
Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist.
Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Note: Perform this procedure with the engine off. 1 Release the latches on the air cleaner cap. Remove the end cap from the air cleaner canister. 2 Remove the filter element. 3 Use a damp cloth to wipe the filter sealing surface and the inside of the outlet tube. Make sure that all contaminant is removed before the filter is inserted.
Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage. 1 Locate the grease fittings on each pivot pin of the platform overload assembly. 2 Thoroughly pump grease into each grease fitting using a multipurpose grease.
4 Check new filter element gasket for damage before installing. 5 Install the new filter element. 6 Install the end cap on the canister and secure. Note: Be sure the discharge slot is pointing down.
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S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-7 Test the Platform Overload System (if equipped)
Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over. Note: Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Remove all weight, tools and accessories from the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an inaccurate test.
4 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown. Refer to Illustration 1. Result: The platform overload indicator light should be off at both the ground and platform controls. Result: The platform overload indicator lights are on and the alarm is sounding. Calibrate the platform overload system. Refer to Repair Procedure, Calibrate the Platform Overload System (if equipped). 5 Carefully move the test weight to each remaining location. Result: The platform overload indicator light should be off at both the ground and platform controls. Result: The platform overload indicator lights are on and the alarm is sounding. Calibrate the platform overload system. Refer to Repair Procedure, Calibrate the Platform Overload System (if equipped). 6 Using a suitable lifting device, place an additional weight onto the platform: S-100 and S-120- 75 lbs / 34 kg S-105 and S-125- 50 lbs / 22.7 kg. Result: The alarm should sound. The platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls. Result: The alarm is not sounding and the platform overload indicator light is not flashing and platform overload is not displayed on the LCD screen at the ground controls. Calibrate the platform overload system. Refer to Repair Procedure, Calibrate the Platform Overload System (if equipped). Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES 11 Lift the test weights off the platform floor using a suitable lifting device. Result: The platform overload indicator light and alarm should turn off at both the ground and platform controls.
Illustration 1
7 Carefully move the test weights to each remaining location in the platform. Result: The alarm should sound. The platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls. Result: The alarm is not sounding and the platform overload indicator light is not flashing and platform overload is not displayed on the LCD screen at the ground controls. Calibrate the platform overload system. Refer to Repair Procedure, Calibrate the Platform Overload System (if equipped). Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.
Note: There may be an approximate 2 second delay before the overload indicator light and alarm turn off. 12 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 13 Turn the key switch to platform control. 14 Test all machine functions from the platform controls. Result: All platform control functions should operate. Note: If the platform overload system is not operating properly, refer to Repair Procedure, Calibrate the Platform Overload System (if equipped).
8 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Note: Machine functions should still operate with auxiliary power at the ground controls.
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S-100 • S-105 • S-120 • S-125
Part No. 102916
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Section 3 • Scheduled Maintenance Procedures
Checklist D Procedures D-1 Check the Boom Wear Pads
6 Remove the boom end cover retaining fasteners at the pivot end of the boom. Remove the boom end cover from the machine.
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
7 Remove the boom side inspection cover retaining fasteners from the boom at the pivot end of the boom. Remove the boom inspection cover from the machine to access boom 3 wear pads.
Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions. 1 Start the engine from the ground controls. 2 Raise the end of the boom to a comfortable working height (chest high). Stop the engine. 3 Remove the protective covers from the platform end of each boom tube. 4 Measure each wear pad. Boom wear pad specifications Minimum thickness
1/2
inch 12.7 mm
8 Measure each wear pad at the pivot end of the boom. Boom wear pad specifications Minimum thickness
1/2
inch 12.7 mm
9 Replace any wear pad if it is less than specification. If a wear pad is not less than specification, shim as necessary to obtain minimum clearance with zero binding. 10 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding of the boom tubes. Note: Always maintain squareness between the outer and inner boom tubes.
5 Replace any wear pad if it is less than specification. If a wear pad is not less than specification, shim as necessary to obtain minimum clearance with zero binding. Note: The minimum shim clearance for the boom wear pads is .030 in / .76 mm and the maximum allowable shim clearance is .090 in / 2.29 mm. Note: If the wear pads are still within specification, refer to Repair Procedure, How to Shim the Boom.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-2 Check the Extendable Axle Wear Pads
3 Replace any wear pad if it is less than specification. If a wear pad is not less than specification, shim as necessary to obtain minimum clearance and no drag.
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining the axle wear pads in good condition is essential to safe machine operation. Wear pads are placed on axle tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions.
Note: If the wear pads are still within specification. Refer to Repair Procedure, How to Shim the Extendable Axles. Note: Keep axle lubricated. See A-11, Grease the Extendable Axles. 4 Extend and retract the axles through the entire range of motion to check for tight spots that may cause binding or scraping of the axle tubes. Note: Always maintain squareness between the outer and inner axle tubes.
Note: Be sure that the axles are fully extended before attempting this procedure. 1 Start the engine from the platform controls and extend the axles. 2 Measure each wear pad. Extendable axle wear pad specifications Minimum thickness
3 - 52
7/16
inch 11.1 mm
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-3 Check the Free-wheel Configuration
5 Manually rotate each wheel at the square-end of the machine. Result: Each wheel at the square-end of the machine should rotate with minimum effort.
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge may cause death or serious injury and property damage. Collision hazard. Select a work site that is firm and level. Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. 1 Chock both of the wheels at the circle-end of the machine to prevent the machine from rolling. 2 Place a lifting jack of ample capacity (35,000 lbs / 16000 kg) under each of the steer yokes at the square-end of the machine. 3 Lift the wheels off the ground and place blocks under the drive chassis for support.
6 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Lower the machine. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. 7 Chock both of the wheels at the square-end of the machine to prevent the machine from rolling. 8 Place a lifting jack of ample capacity (35,000 lbs / 16000 kg) under each of the steer yokes at the circle-end of the machine. 9 Lift the wheels off the ground and place blocks under the drive chassis for support. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the circle-end of the machine. 11 Manually rotate each wheel at the circle-end of the machine. Result: Each wheel at the circle-end of the machine should rotate with minimum effort.
4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the square-end of the machine. disengaged position
engaged position
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-4 Check the Turntable Rotation Bearing Bolts
12 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Lower the machine. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage.
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
All models: 13 Be sure the free-wheel valve on the drive pump is closed (clockwise). Note: The free-wheel valve is located on the drive pump, and should always remain closed.
Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Raise the boom to a horizontal position. 2 Install a safety chock onto the hydraulic lift cylinder extension rod. Carefully lower the boom onto the lift cylinder safety chock. Crushing hazard. Keep hands away from the cylinder and all moving parts when lowering the boom.
b c
a
d
Note: The lift cylinder safety chock is available through Genie (Genie part number 75097).
a drive pump b screwdriver c lift pump d free-wheel valve
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S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
3 Be sure that each turntable rotation bearing mounting bolt above the turntable is torqued in sequence. Refer to Specifications, Machine Torque Specifications.
18
23 28
1 6 11 16
13 3 30
21 26 4 9
25 20 15 10
14 19 24 29
8
5
D-5 Check the Turntable Rotation Gear Backlash
27 22
7 17 12
2
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Properly adjusted turntable rotation gear backlash is essential for good machine performance and service life. Improperly adjusted turntable rotation gear backlash will cause the machine to perform poorly and continued use will cause component damage. The turntable rotation drive hub is mounted on the swing chassis behind the fixed side cover at the ground controls side. Note: Be sure to check the backlash with the machine fully stowed and the counterweight at the square end of the machine. Note: Select a test area that is firm, level and free of obstructions.
Bolt torque sequence
4 Raise the boom to a horizontal position. 5 Remove the safety chock and lower the boom to the stowed position. 6 Be sure that each turntable rotation bearing mounting bolt under the drive chassis is torqued in sequence. Refer to Specifications, Machine Torque Specifications.
1 Rotate the turntable until the boom is centered between the circle end wheels. 2 Apply approximately 20 lbs / 89 N of side force to the platform, moving the platform to one side as far as it will go.
Note: The turntable rotation bearing bolt torque sequence is the same from above the turntable and below the drive chassis.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES 3 Using a feeler guage, measure the gap between the swing hub pinion gear and the turntable rotation bearing at the center tooth. The gap should be meaured on one side of the pinion gear on the center tooth.
5 Apply approximately 20 lbs / 89 N of side force to the platform, moving the rotator to the left as far as it will go. Move the tape measure so the straight edge on the rotator measures 0 inches / 0 m.
Note: The pinion gear can be accessed on the outside of the chassis under the pinion gear guard.
6 Apply approximately 20 lbs / 89 N of side force to the platform, moving the rotator to the right as far as it will go.
Result: The gap is between .010 inch / .254 mm and .022 inch / .559 mm. The backlash is within tolerance. Result: The gap is less than .010 inch / .254 mm or more than .022 inch / .559 mm. The backlash needs to be adjusted. Refer to Repair Procedure, Turntable Rotation Hydraulic Motor and Drive Hub. 4 After the backlash has been set, place a tape measure approximately two feet long / 0.6 m, perpendicular to the boom, on the ground under the rotator.
7 Note the distance on the tape measure the rotator has moved. Result: The rotator movement does not exceed 2 inches / 51 mm. The backlash is in tolerence. Result: The side-to-side rotator movement exceeds 2 inches / 51 mm. The turntable drive hub may need service. Contact Genie Industries Service Department.
Note: Fasten a straight edge on the side of the rotator using tape so one end is just above the tape measure.
3 - 56
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-6 Replace the Drive Hub Oil
4 Fill the hub with oil from either plug hole until the oil level is even with the bottom of both plug holes. Install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs.
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
6 Check the torque of the drive hub mounting bolts. Refer to Specifications, Machine Torque Specifications.
Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage.
Turntable Rotate Drive Hub: 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, Machine Torque Specifications.
Drive Hubs:
1 Secure the turntable from rotating with the turntable rotation lock pin.
1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point.
2 Remove the ground control side fixed turntable cover. Refer to Repair Procedure, How to Remove a Fixed Turntable Cover.
2 Remove both plugs and drain the oil into a suitable container. Refer to capacity specifications 3 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other side.
3 Tag, disconnect and plug the turntable rotate drive motor hoses at the turntable rotate drive motor and the turntable rotate drive brake hoses at the turntable rotate drive brake. Cap the fittings.
a
a
Part No. 102916
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. Component damage hazard. Hoses can be damaged if they are kinked or pinched.
drive hub plugs
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
a b c h d f
e
g
f
a b c d e f g h
drive motor brake drain plug drive hub drain plug drive hub pivot bolt mounting bolt adjustment bolt with lock nut drive brake
7 Fill the drive hub with oil from the side hole until the oil level is even with the bottom of the hole. Apply pipe thread sealant to the plug. Install the plug. Refer to Specifications, Machine Specifications. 8 Install the turntable rotate drive motor hoses into the turntable rotate drive motor and install the turntable rotate drive brake hose into the turntable rotate drive brake. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 9 Adjust the turntable rotation gear backlash. See D-5, Check the Turntable Rotation Gear Backlash. 10 Install the ground control side fixed turntable cover onto the machine and tighten the
4 Remove the turntable rotate drive hub mounting bolts and pivot bolt. Remove the turntable rotate drive hub with a suitable lifting device of ample capacity. Crushing hazard. The turntable rotate drive hub may become unbalanced and fall when it is removed from the machine if it is not properly supported. 5 Remove the plug from the side of the drive hub. Drain the oil from the hub into a suitable container. 6 Install the drive hub assembly onto the machine. Lubricate and torque the drive hub mounting bolts to specification. Refer to Specifications, Machine Torque Specifications.
3 - 58
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-7 Inspect for Turntable Bearing Wear
a
b
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life. Continued use of a worn turntable bearing could create an unsafe operating condition, resulting in death or serious injury and component damage. Note: Perform this procedure with the machine on a firm, level surface and the boom in the stowed position. 1 Grease the turntable bearing. Refer to maintenance procedure, Grease the Turntable Bearing and Rotate Gear. 2 Torque the turntable bearing bolts to specification. Refer to maintenance procedure, Check the Turntable Rotation Bearing Bolts. 3 Start the machine from the ground controls and raise the boom to full height. Do not extend the boom. 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under, or inline with, the boom and no more than 1 inch / 2.5 cm from the bearing. Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing.
c
d
a turntable b dial indicator c drive chassis d turntable rotation bearing
5 Adjust the dial indicator needle to "zero" position. 6 Lower the primary boom and jib to the horizontal position and fully extend the boom. 7 Note the reading on the dial indicator. Result: The measurement is less than 0.118 inch / 3.0 mm. The bearing is good. Result: The measurement is more than 0.118 inch / 3.0 mm. The bearing is worn and needs to be replaced. 8 Fully retract the boom. Fully raise the boom and jib. Visually inspect the dial indicator to be sure the needle returns to the "zero" position. 9 Remove the dial indicator and rotate the turntable 90°. 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90° apart. 11 Lower the boom to the stowed position and turn the machine off. 12 Remove the dial indicator from the machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-8 Perform Engine Maintenance Deutz Models
D-9 Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
Engine specifications require that this procedure be performed every 1000 hours.
All Models: • Fuel system primary filter (water separator) element - replace
• Engine valve lash - inspect/adjust 854F Models: • Water pump - inspect
• Fuel system secondary filter - replace
Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477).
• Hoses and clamps - inspect/replace • Glow plugs - check • V-belts - re-tension/renew TD 2011L04i Models: • Engine valve lash - inspect/adjust Required maintenance procedures and additional engine information are available in the Deutz F4L913 Operation Manual (Deutz part number 0297-7341) OR the Deutz BF4L2011 Operation Manual (Deutz part number 0297-9929) OR the Deutz TD 2.9 Operation Manual (Deutz part number 0312-3893) OR the Deutz TD 2011 Operation Manual (Deutz part number 0312-3547). Deutz F4L913 Operation Manual Genie part number
62446
Deutz BF4L2011 Operation Manual Genie part number
84794
Deutz TD 2.9 Operation Manual Genie part number
1251561
Deutz TD 2011 Operation Manual Genie part number
139320
3 - 60
1104D Models:
Perkins 854F Operation and Maintenance Manual Genie part number 1263971 Perkins 1004 Serial User's Handbook Genie part number
61376
Perkins 800D Serial User's Handbook Genie part number
None
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-10 Perform Engine Maintenance Perkins Models
D-11 Perform Engine Maintenance Cummins Models
Engine specifications require that this procedure be performed every 1500 hours.
Engine specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
854F Models: • Engine crankcase breather - replace Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477). Perkins 854F Operation and Maintenance Manual Genie part number 1263971 Perkins 1004 Serial User's Handbook Genie part number Perkins 800D Serial User's Handbook Genie part number
61376 None
Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 and B3.9L Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3T Operation and Maintenance Manual (Cummins part number 3666417-00). Cummins B4.5 and B3.9L Operation and Maintenance Manual Genie part number
107527
Cummins B3.3T Operation and Maintenance Manual Genie part number
139324
To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 61
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-12 Replace the Hydraulic Filter Elements
Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Replacement of the hydraulic tank return filter is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often.
3 Remove each filter with an oil filter wrench. 4 Apply a thin layer of clean oil to the new oil filter gaskets. 5 Install the new hydraulic return filter element and tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. 6 Use a permanent ink marker to write the date and number of hours from the hour meter on the filters. 7 Start the engine from the ground controls. 8 Inspect the filters and related components to be sure that there are no leaks.
Tank Return Filter: Burn hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Note: Perform this procedure with the engine off. 1 Open the ground controls side turntable side cover and locate the tank return filters. 2 Place a suitable container under the hydraulic tank return filters.
3 - 62
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES Medium and High Pressure Hydraulic Filters:
4 Remove the filter element from the housing. 5 Inspect the housing seal and replace it if necessary.
Burn hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Note: The medium pressure filter is for the charge pump and the high pressure filters are for the drive circuit. Note: Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the three filters mounted to the bulkhead.
6 Install the new medium pressure filter element into the housing and tighten it securely. 7 Install the new high pressure filter elements into the housings and tighten them securely. 8 Clean up any oil that may have spilled during the installation procedure. 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings. 10 Start the engine from the ground controls. 11 Inspect the filter housings and related components to be sure that there are no leaks.
a b
a b
high pressure filters medium pressure filter
2 Place a suitable container under the filters. 3 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures E-1 Test or Replace the Hydraulic Oil
2 Close the two hydraulic shut-off valves located at the hydraulic tank. Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.
Genie specifications require that this procedure be performed every 2000 hours or 2 years, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more frequently. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. Note: Perform this procedure with the boom in the stowed position and the axles extended. 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 ground controls side turntable side cover. Refer to Repair Procedure, How to Remove a Hinged Turntable Cover.
3 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container. Refer to Specifications, Hydraulic Specifications. 4 Remove the ground controls support bracket retaining fasteners and remove the ground control box assembly from the machine. Component damage hazard. Be sure to properly support the ground control box. Do not allow the ground control box to hang by the wiring or cables. 5 Tag and disconnect the wires from the horn. Remove the horn retaining fasteners and remove the horn from the machine. 6 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic tank shut-off valves. Cap the fittings. 7 Tag, disconnect and plug the supply hose for the auxiliary power unit. Cap the fitting on the hydraulic tank. 8 Tag, disconnect and plug the case drain hose at the return filter. Cap the fitting on the return filter head. 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 head.
open
3 - 64
closed
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES 10 Remove the hydraulic tank breather filter from the tank. 11 Remove the hydraulic tank strap retaining fasteners and remove the hydraulic tank straps from the machine. 12 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. 13 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall if it is not properly supported and secured to the overhead crane when it is removed from the machine.
24 Install the two suction hoses and the supply hose for the auxiliary power unit onto the machine. 25 Install the case drain hose onto the return filter head. 26 Install the T-fitting and 2 hoses connected to it to the hydraulic tank return filter head. 27 Fill the tank with hydraulic oil until the level is within the top 2 inches / 5 cm of the sight gauge. Do not overfill. 28 Apply pipe thread sealant to the threads of the hydraulic tank filter mount. 29 Install a new tank breather filter onto the filter mount and tighten it securely by hand.
14 Remove the hydraulic tank return filter from the hydraulic tank return filter head.
30 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter.
15 Remove the case drain filter from the case drain filter head.
31 Install a new tank case drain return filter onto the filter mount and tighten it securely by hand.
16 Remove the suction strainers from the tank and clean them using a mild solvent.
32 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter.
17 Rinse out the inside of the tank using a mild solvent. 18 Install the suction strainers using pipe thread sealant on the pipe threads. 19 Install the drain plug using pipe thread sealant on the pipe threads. Note: Always use pipe thread sealant on all pipe threads. 20 Install the hydraulic tank onto the machine.
33 Install a new tank return filter onto the filter mount and tighten it securely by hand. 34 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter. 35 Clean up any oil that may have spilled during the procedure. 36 Open the hydraulic tank shut-off valves. Component damage hazard. Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank. Refer to Repair Procedure, How to Prime the Pumps.
21 Install the hydraulic tank retaining straps and install the hydraulic tank retaining fasteners. 22 Install the horn and horn retaining fasteners onto the machine. Connect the wiring. 23 Install the ground control box assembly and assembly retaining fasteners onto the machine.
Part No. 102916
37 Install the turntable side cover.
S-100 • S-105 • S-120 • S-125
3 - 65
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-2 Perform Engine Maintenance Cummins Models
E-3 Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be performed every 2000 hours or 2 years, whichever comes first.
Engine specifications require that this procedure be performed every 2000 hours.
Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 and B3.9L Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3T Operation and Maintenance Manual (Cummins part number 3666417-00). Cummins B4.5 and B3.9L Operation and Maintenance Manual Genie part number
107527
Cummins B3.3T Operation and Maintenance Manual Genie part number
139324
All Models: • Aftercooler core - inspect • Alternator - inspect • Engine mounts - inspect • Starting Motor - inspect • Turbocharger - inspect 1104D Models: • Water pump - inspect Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477). Perkins 854F Operation and Maintenance Manual Genie part number 1263971
To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable.
Perkins 1004 Serial User's Handbook Genie part number
61376
Perkins 800D Serial User's Handbook Genie part number
None
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 66
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-4 Perform Engine Maintenance Deutz Models
E-5 Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be performed every 2 years.
Engine specifications require that this procedure be performed every 3000 hours.
All Models:
1104D Models:
• Extended Life Coolant (ELC) - replace
• Fuel Injector - test/change
TD 2011L04i Models:
854F Models:
• Alternator belt - replace
• Diesel Particulate Filter - clean
• Glow plugs - replace
• Radiator cap - inspect/replace
Required maintenance procedures and additional engine information are available in the Deutz TD 2011 Series Operation Manual (Deutz part number 0312-3547) OR the Deutz TD 2.9 Series Operation Manual (Deutz part number 0312-3893) OR the Deutz F4L913 Series Operation Manual (Deutz part number 0297-7341) OR the Deutz B4L2011 Series Operation Manual (Deutz part number 0297-9929).
• Alternator Belt - Inspect/Adjust/Replace Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477).
Deutz TD 2011 Series Operation Manual Genie part number
139320
Deutz TD 2.9 Series Operation Manual Genie part number
1251561
Deutz F4L913 Series Operation Manual Genie part number
Perkins 1004 Serial User's Handbook Genie part number
61376
62446
Deutz B4L2011 Series Operation Manual Genie part number
Perkins 800D Serial User's Handbook Genie part number
None
84794
Part No. 102916
Perkins 854F Operation and Maintenance Manual Genie part number 1263971
S-100 • S-105 • S-120 • S-125
3 - 67
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-6 Perform Engine Maintenance Deutz Models
E-7 Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be performed every 3000 hours.
Engine specifications require that this procedure be performed every 4000 hours.
TD 2011L04i Models:
All Models:
• Injection valve - replace
• Aftercooler core - clean/test
• Aftercooler Core - clean/test
Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477).
• Charge air cooler entry - drain lube oil/ condensate • Turbocharge compressor outlet - clean TD 2.9 Models: • V-belt and tensioning pulley - replace Required maintenance procedures and additional engine information are available in the Deutz TD 2011 Series Operation Manual (Deutz part number 0312-3547) OR the Deutz TD 2.9 Series Operation Manual (Deutz part number 0312-3893) OR the Deutz F4L913 Series Operation Manual (Deutz part number 0297-7341) OR the Deutz B4L2011 Series Operation Manual (Deutz part number 0297-9929). Deutz TD 2011 Series Operation Manual Genie part number
139320
Deutz TD 2.9 Series Operation Manual Genie part number
1251561
Deutz F4L913 Series Operation Manual Genie part number
62446
Deutz B4L2011 Series Operation Manual Genie part number
84794
3 - 68
Perkins 854F Operation and Maintenance Manual Genie part number 1263971 Perkins 1004 Serial User's Handbook Genie part number
61376
Perkins 800D Serial User's Handbook Genie part number
None
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-8 Perform Engine Maintenance Deutz Models
E-9 Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be performed every 6000 hours.
Engine specifications require that this procedure be performed every 12000 hours or 6 years, whichever come first.
TD 2011L04i Models:
All Models:
• Toothed belt - replace
• Extended Life Coolant (ELC) - replace
Required maintenance procedures and additional engine information are available in the Deutz TD 2011 Series Operation Manual (Deutz part number 0312-3547) OR the Deutz TD 2.9 Series Operation Manual (Deutz part number 0312-3893) OR the Deutz F4L913 Series Operation Manual (Deutz part number 0297-7341) OR the Deutz B4L2011 Series Operation Manual (Deutz part number 0297-9929).
Required maintenance procedures and additional engine information are available in the Perkins 854F Operation and Maintenance Manual (Perkins part number SEBU8726-00) OR the Perkins 1004 Serial User's Handbook (Perkins part number TPD 1349E) OR the Perkins 800D Serial User's Handbook (Perkins part number TPD 1477).
Deutz TD 2011 Series Operation Manual Genie part number
139320
Perkins 854F Operation and Maintenance Manual Genie part number 1263971
Deutz TD 2.9 Series Operation Manual Genie part number
1251561
Perkins 1004 Serial User's Handbook Genie part number
61376
Deutz F4L913 Series Operation Manual Genie part number
62446
Perkins 800D Serial User's Handbook Genie part number
None
Deutz BF4L2011 Series Operation Manual Genie part number
84794
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 69
Section 3 • Scheduled Maintenance Procedures
October 2015
CHECKLIST E PROCEDURES
E-10 Replace the Boom Extend/Retract Cables
Genie specifications require that this procedure be performed every 10 years. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube on the S-100 and S-105, and the numbers 2 and 3 boom tubes on the S-120 and S-125. Replacement of the boom extend/retract cables is essential to good machine performance and safe machine operation. The boom extend/ retract functions should operate smoothly and be free of hesitation, jerking and unusual noise. 1 Replace the boom extend cables. Refer to Repair Procedure, How to Replace the Boom Extend/Retract Cables.
3 - 70
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine.
Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order. Symbols Legend
Repair any machine damage or malfunction before operating the machine.
Before Repairs Start: Read, understand and obey the safety rules and operating instructions in the Genie S-100 & Genie S-105 Operator’s Manual and the Genie S-120 & Genie S-125 Operator’s Manual.
Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Be sure that all necessary tools and parts are available and ready for use.
Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.
Use only Genie approved replacement parts. Unless otherwise specified, perform each repair procedure with the machine in the following configuration:
• Machine parked on a firm, level surface
• Boom in the stowed position
• Turntable rotated with the boom between the circle-end wheels
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.
• Turntable secured with the turntable rotation lock pin
• Key switch in the off position with the key removed
• Wheels chocked
• All external AC power supply disconnected from the machine
Part No. 102916
Used to indicate the presence of a potentially hazardous situation 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.
S-100 • S-105 • S-120 • S-125
4-1
October 2015
Section 4 • Repair Procedures
Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be changed to alter the machine operating parameters. The key switch must be in the off position before entering the programming mode. Use the
or
buttons to scroll through the screens.
button (to increase) or the button (to decrease) or to select To change parameter values, use the a setting. Press the button to save the new value to memory. An audible beep will indicate a save to memory. You must exit the programming mode for the changes to take effect. To Exit Programming Mode: se the scroll button U to scroll through the menu until the screen displays exit, then 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. Screen or Menu
Operator
Machine Status Unit of Measure and Language
4 - 2
Procedure Default
Hour meter (on power up) Engine speed Engine oil pressure PSI (English) Engine oil pressure kPa (metric) Engine temperature °F (English) Engine temperature °C (metric) Primary boom angle sensor Turntable level sensor X° Turntable level sensor Y° Platform angle Battery voltage
With key switch on,
press the
and at same time.
Description
the
With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press
Range or Selection
Engine temperature is not displayed until engine is above 100°F / 38°C
Hydraulic pressure PSI (English) Hydraulic pressure kPa (metric) Boom angle Axle status Metric/English measurements
Use +/- buttons to change
Language selection
English, German, French, Spanish, Portuguese, Italian, Dutch and Swedish. Deutz 2.9L Turbo (D2.9T) Deutz TD2011L0.4i (DL04i) Perkins 1104D-44T (P1104) Perkins 854F (P854T)
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
DISPLAY MODULE
Screen or Menu
Drive Functions
Procedure With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press .
Description 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
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
Boom up speed stowed % Boom down speed stowed % Boom up speed % <75 ft Boom down speed % <75 ft Boom up speed % >75 ft Boom down speed % >75 ft Boom up speed % >100 ft Boom down speed % >100 ft Boom extend speed % Boom retract speed % Turntable rotate speed % <75 ft Turntable rotate speed % >75 ft Jib boom up/down speed %
Part No. 102916
S-100 • S-105 • S-120 • S-125
Range or Selection 100% max and 10% min, 100 % (default) 100% max and 10% min, 90% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 125% max and 25% min, 100% (default) 125% max and 25% min, 100% (default) 100% max and 0% min, 50% (default) 120% max and 10% min, 100% (default) 120% max and 10% min, 100% (default) 80% max and 10% min, 80% (default) 80% max and 10% min, 80% (default) 35% max and 10% min, 29% (default) 35% max and 10% min, 29% (default) 25% max and 10% min, 20% (default) 25% max and 10% min, 20% (default) 60% max and 10% min, 60% (default) 40% max and 10% min, 35% (default) 120% max and 75% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default)
4-3
October 2015
Section 4 • Repair Procedures
DISPLAY MODULE
Screen or Menu
Procedure
Description
Range or Selection
Lift Function Ramp Settings
With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press
Boom up/down ramp acceleration % Boom up/down ramp deceleration % Boom extend/retract ramp acceleration % Turntable rotate ramp acceleration % Turntable rotate ramp deceleration % Jib up/down ramp deceleration %
5000 max and 100 min, 5000 (5.0 sec) (default) 2600 max and 100 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) 3000 max and 0 min, 250 (0.25 sec) (default)
Valve Calibration
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
(yes/no)
Reset boom up/down valve defaults Reset boom extend/retract valve defaults Reset turntable rotate valve defaults Allow boom up/down speed calibration Allow turntable rotate speed calibration Reset drive joystick defaults Reset boom up/down joystick defaults Reset boom extend/retract joystick defaults reset turntable rotate joystick defaults Reset steer joystick defaults
(yes/no)
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)
Level Sensor Calibration
4 - 4
With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press
S-100 • S-105 • S-120 • S-125
(yes/no) (yes/no) (yes/no) (yes/no) (yes/no) (yes/no) (yes/no) (yes/no) (yes/no)
(yes/no)
Part No. 102916
October 2015
Section 4 • Repair Procedures
DISPLAY MODULE
Screen or Menu
Default Reset
Procedure With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press
Description
Range or Selection
Reset drive functions
(yes/no)
Reset boom function speeds
(yes/no)
Reset lift function ramps
(yes/no)
Reset all (Contact Genie Industries
(yes/no)
Service Department before using this option)
Clear all safety switch faults
(yes/no)
Overload Recovery
With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press
Clear Overload Recovery
A passcode is required to clear the message
Options
With key switch off, press and hold the button and turn the key switch to the on position. Release the button and press
Limit boom height to 100 ft / 80 ft AC generator Alarm
(100 ft / 80 ft) (none, belt, hyd) (no, motion, travel, descent, travel and descent)(0, 1, 2, 3, 4, 5) (no, drive cutout while not stowed, lifting or driving) (yes/no) (none/prox) (none/pltfs) (yes/no) (yes/no) (yes/no) (yes/no)
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)
(yes/no) (o to 10 seconds, 2 is the default.
shown only when hyd gen is selected)
Part No. 102916
S-100 • S-105 • S-120 • S-125
4-5
October 2015
Section 4 • Repair Procedures
Platform Controls The platform controls contains two printed circuit boards: The membrane circuit board is mounted to the underside of the control box lid which contains the LEDs and touch-sensitive buttons for machine functions. The membrane circuit board sends the input from the operator to the platform controls ECM circuit board. The ECM circuit board sends the data to the turntable control box for processing.
b
a
c
e
The platform controls ECM circuit board communicates with the turntable controls. The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment. The operating parameters of the joysticks are stored in memory at the turntable controls. If a joystick controller error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. See 1-3, How to Calibrate a Joystick Controller.
d a platform ECM circuit board b boom extend/retract joystick controller c drive/steer joystick controller d membrane circuit board e boom up/down and turntable rotate left/right joystick controller
Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion.
4 - 6
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
1-1 Circuit Boards
7 Locate the ECM circuit board mounted to the inside of the platform control box. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Note: When an ECM circuit board is replaced, the joystick controllers will need to be calibrated. See 1-3, How to Calibrate a Joystick Controller.
How to Remove the ECM Circuit Board
Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.
1 Push in the Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box mounting fasteners. Remove the platform control box from the machine. Component damage hazard. Cables can be damaged if they are kinked or pinched.
8 Remove the ECM circuit board mounting fasteners. 9 Carefully remove the ECM circuit board from the platform control box.
3 Locate the cables that connect to the bottom of the control box. Number each cable and its location at the control box.
How to Remove the Membrane Circuit Board
4 Disconnect the cables from the bottom of the platform control box.
1 Push in the Emergency Stop button to the off position at both the ground and platform controls.
5 Remove the control cable plug retaining fasteners from the bottom of the platform control box.
2 Remove the platform control box lid retaining fasteners. Open the control box lid.
6 Remove the platform control box lid retaining fasteners. Open the control box lid.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4-7
October 2015
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS 3 Locate the membrane circuit board mounted to the inside of the platform control box lid. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 4 Carefully disconnect the two ribbon cables from the membrane circuit board. 5 Remove the membrane circuit board 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 functions similar to toggle switches, but do not have any moving parts. 1 Push in the Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box lid retaining fasteners. Open the control box lid. 3 Carefully disconnect the two ribbon cables from the membrane circuit board. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.
4 - 8
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B 4 Close the control box lid. 5 Remove the decal from the platform control box. 6 Carefully remove the membrane decal from the platform control box while guiding the ribbon cables out of the control box lid. 7 Remove any decal adhesive from the control box lid with a mild solvent. Note: Do not allow any solvent to come in contact with the membrane circuit board. 8 Install the new membrane decal while guiding the ribbon cables through the control box lid. Note: Be sure that all LED locations on the membrane decal align with the LED's on the membrane circuit board. 9 Install a new platform controls decal over the membrane decal. 10 Open the control 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 be calibrated before the threshold, max-out or ramp rate can be set. Note: It is possible to reset multiple joystick defaults before exiting the programming mode. Note: After each joystick is calibrated, check the display at the ground control box. There should be no calibration faults shown on the display. If calibration faults exist, repeat steps 1 through 8 for that joystick controlled function. Note: Contact Genie Product Support Department before using the reset all joystick default option. Note: Perform this procedure with the engine off. The calibration procedure for each joystick begins on the next page.
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Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
Drive functions:
Steer functions:
Note: If the calibration fault is already displayed at the ground box begin with step 6.
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.
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.
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 enter button twice.
3 Press the minus button enter button twice.
twice, then press the
twice, then press the
to scroll through the 4 Use the scroll button menu until reset drive joystick defaults is displayed. Press the button to select yes, then press the button.
4 Use the scroll button to scroll through the menu until reset steer joystick defaults is displayed. Press the button to select yes, then press the button.
5 Exit programming mode.
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 .
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.
6 Do not start the engine.
7 Locate the drive/steer joystick.
7 Locate the drive/steer joystick.
8 Move the drive/steer joystick full stroke in the forward direction and hold for 5 seconds, then return to the center or neutral position.
8 Move the drive/steer joystick full stroke in the left direction and hold for 5 seconds, then return to the center or neutral position.
9 Move the drive/steer joystick full stroke in the reverse direction and hold for 5 seconds, then return to the center or neutral position.
9 Move the drive/steer joystick full stroke in the right 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: 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.
Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1.
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Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
Primary boom extend/retract functions:
Primary boom up/down functions:
Note: If the calibration fault is already displayed at the ground box begin with step 6.
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.
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.
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 enter button twice.
twice, then press the
3 Press the minus button enter button twice.
twice, then press the
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.
4 Use the scroll button to scroll through the menu until reset primary boom up/down joystick defaults is displayed. Press the button to select yes, then press the button.
5 Exit programming mode.
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 .
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.
6 Do not start the engine.
7 Locate the primary boom/turntable rotate joystick.
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.
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 primary boom extend/retract joystick full stroke in the retract 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: 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.
Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1.
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Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
Turntable rotate 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 enter button twice.
twice, then press the
4 Use the scroll button to scroll through the menu until reset turntable rotate 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 joystick full stroke in the left direction and hold for 5 seconds, then return to the center or neutral position. 9 Move the boom/turntable joystick full stroke in the right direction and hold for 5 seconds, then return to the center or neutral position.
How to Reset a Proportional Valve Coil Default Note: Use this procedure for any software version other than 2.00. For software version 2.00 refer to the following procedure. Note: This procedure only needs to be performed if a proportional valve has been replaced. Note: After the valve coil defaults have been set, each machine function threshold and default function speed must be set. See How to Set the Function Thresholds and Default Function Speeds. 1 Turn the key switch to the off 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 enter button twice.
twice, then press the
4 Use the scroll button to scroll through the menu until the function valve that needs to be reset is displayed. Press the button to select yes, then press the button to save the setting. Note: Choices are: Propel (drive) valve reset; Boom up/down valve reset; Boom extend/retract valve reset; or TT rotate valve reset. 5 Push one of the LCD screen buttons shown until exit is displayed. 6 Press the plus button or minus button select yes and then press the enter button
to .
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.
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PLATFORM CONTROLS
How to Reset a Proportional Valve Coil Default (software version 2.00) Note: Software version 2.00 requires the use of Web GPI to perform this procedure. Refer to Diagnostic Code, Software. Note: This procedure only needs to be performed if a proportional valve has been replaced. Note: After the valve coil defaults have been set, each machine function threshold and default function speed must be set. See How to Set the Function Thresholds and Default Function Speeds. 1 Open Web GPI and connect to the TCON. 2 Select the valve screen of the proportional valve you want to reset. Note: Choices are: Propel (drive) valve reset; Boom up/down valve reset; Boom extend/retract valve reset; or TT rotate valve reset. 3 Press "set Defaults" and enter the level 2 password (obtained from field service personnel). 4 Enter "0" (zero) into the threshold boxes. 5 Press "send" and enter the level 2 password (obtained from field service personnel). 6 Disconnect from the TCON and proceed with calibration.
How to Set the Function Thresholds and Function Speeds Note: Before the threshold and default function speeds can be set, the boom function proportional valve coil defaults must be set first. See How to Reset a Proportional Valve Coil Default. Note: If a boom function proportional valve coil has not been replaced and just want to reset the function speed to original factory settings, begin with step 10. 1 Start the engine from the platform controls. 2 Press down the foot switch. Note: Be sure the engine rpm is set to foot switch activated high idle. Function threshold: 3 Select a joystick controlled function that needs to have the threshold set. 4 Slowly move the joystick off center in either 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. 5 While holding the joystick in position, press the engine start button at the platform controls to set the joystick controller threshold. 6 Slowly move the joystick off center in the opposite direction just until the machine function starts to move, then move the joystick very slowly towards the neutral or center position just before the machine function stops. Do not let go of the joystick.
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Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
7 While holding the joystick in position, press the engine start button at the platform controls to set the joystick controller threshold. 8 Repeat steps 3 through 7 for each joystick controlled machine function (boom up/down and turntable rotate left/right, boom extend/ retract, and drive forward/reverse). 9 Once all the joystick controllers have been calibrated, push in the Emergency Stop button at the platform controls to save the settings in memory. Note: The red Emergency Stop button at the platform controls must be pushed in to the off position following calibration of the joystick controllers to save the settings in memory. 10 At the ground controls, turn the key switch to the off position, wait a moment and then turn the key switch to platform controls. 11 Check the display at the ground controls to be sure there are no calibration faults. Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure. Function speeds: Note: Be sure the machine is in the stowed position and the boom is rotated between the circle end tires. Note: Perform this procedure with the machine parked on a firm, level surface which is free of obstructions. 12 Start the engine from the platform controls. 13 Select a boom function that needs the function speed set. 14 Boom up/down functions: Starting in the stowed position, move the joystick full stroke in the up direction. When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center.
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Boom extend/retract functions: Raise the boom until the low-speed drive function is enabled. Move the joystick full stroke in the extend direction. When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center.
Turntable rotate functions: Raise the boom until the low-speed drive function is enabled. Move the joystick full stroke to the left (cw) until the drive enable light turns 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 controls must be pushed in to the off position following calibration of the joystick controllers to save the settings in memory. 16 At the ground controls, turn the key switch to the off position, wait a moment and then turn the key switch to platform controls. 17 Check the display at the ground controls to be sure there are no calibration faults. Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure.
How to Adjust the Function Speeds 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.
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Part No. 102916
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Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
2 Press and hold the enter button on the ground control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. 3 Press the plus button minus button twice.
twice, then press the
4 Press the scroll button until the function to be adjusted is displayed. 5 Press the plus button to increase the speed to decrease the or press the minus button speed. 6 Press the enter button memory.
to save the setting in
ground control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. 3 Press the plus button scroll button twice.
twice, then press the
4 Press the scroll button until the function to be adjusted is displayed. 5 Press the plus button to increase the ramp rate or press the minus button to decrease the ramp rate. 6 Press the enter button memory.
to save the setting in
7 Push one of the LCD screen buttons shown until exit is displayed.
7 Push one of the LCD screen buttons shown until exit is displayed. 8 Press the plus button to select yes and then press the enter button .
8 Press the plus button to select yes and then press the enter button
.
9 Continue to perform this procedure until the machine function speed meets specification. Refer to Specifications for function speeds.
Specifications
How to Adjust the Function Ramp Rate Setting
Turntable rotate accelerate 2 seconds decelerate 0.25 second
The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for 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 position at both the ground and platform controls. 2 Press and hold the enter button
Part No. 102916
Ramp rate (factory settings)
Primary boom up/down accelerate decelerate
3 seconds 0..25 second
Primary boom extend/retract accelerate decelerate
2 seconds 0.25 second
Jib boom up/down accelerate decelerate
2 seconds 0.25 second
Drive accelerate
2 seconds
on the
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Section 4 • Repair Procedures
Platform Components 2-1 Platform
2-2 Platform Leveling Cylinder
How to Remove the Platform
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 close the appropriate platform level proportional valve on the platform manifold to maintain a level platform. The platform leveling cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.
1 Separate the foot switch quick disconnect plug. 2 Support the platform with an appropriate lifting device. 3 Locate the cables that connect to the bottom of the control box. Number each cable and its location at the platform control box. 4 Disconnect the cables from the bottom of the platform control box. 5 Remove the platform control box mounting fasteners. Remove the platform control box and set it aside. 6 Remove the air line to platform bracket retaining fasteners (if equipped). 7 Remove the weld cables from the platform (if equipped). Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 8 Remove the platform mounting fasteners and remove the platform from the machine. Crushing hazard. The platform may become unbalanced and fall when it is removed from the machine if it is not properly supported.
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How to Remove the Platform Leveling Cylinder 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 Extend the boom until the platform leveling cylinder barrel-end pivot pin is accessible. 2 Raise the boom slightly and place blocks under the platform. 3 Lower the boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS 4 Tag, disconnect and plug the hydraulic hoses from the platform leveling cylinder at the bulkhead fittings located inside the boom tube at the platform end and connect them together using a connector. Cap the bulkhead fittings on the boom tube.
8 Use a soft metal drift to remove the rod-end pivot pin. Crushing hazard. The platform (S-100 and S-120 models) or jib boom (S-105 and S-125 models) will fall when the platform leveling cylinder rod-end pivot pin is removed if it is not properly supported.
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.
Crushing hazard. The platform leveling cylinder will fall if it is not properly supported when the rodend pivot pin is removed.
5 Remove the pin retaining fastener from the platform leveling cylinder rod-end pivot pin. Do not remove the pin. 6 Remove the external snap ring from the barrelend pivot pin. Do not remove the pin. 7 Support the platform leveling cylinder with a suitable lifting device. Protect the cylinder rod from damage.
Component damage hazard. The platform leveling cylinder rod can become damaged if it is allowed to fall. 9 Use a soft metal drift to remove the barrel-end pivot pin. 10 Carefully pull the platform leveling cylinder out of the boom. Component damage hazard. Hoses can be damaged if they are kinked or pinched.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS
How to Bleed the Platform Leveling Cylinder
2-3 Platform Rotator
Note: Do not start the engine. Use auxiliary power for all machine functions in this procedure.
The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees.
Note: The boom must remain below 10° to properly perform this procedure. 1 Raise the boom to a horizontal position. 2 Activate auxiliary power.
How to Remove the Platform Rotator Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position.
3 Push the platform level up and down buttons through two complete platform leveling cycles to remove any air that might be in the system.
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 platform. See Repair Procedure, How to Remove the Platform. 2 Disconnect the electrical connector from the platform angle sensor.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS 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 Remove the platform manifold mounting fasteners. Lay the platform manifold to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. 5 Remove the power to platform cover plate from the electrical outlet box. Do not disconnect the wiring. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
8 Support the platform mounting weldment, but do not apply any lifting pressure. 9 Remove the eight mounting bolts from the platform mounting weldment. 10 Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly supported. 11 Support the platform rotator. Do not apply any lifting pressure. S-100 and S-120 models: 12 Support the rod end of the platform leveling cylinder. Protect the cylinder rod from damage. 13 Remove the pin retaining fastener from the platform level cylinder rod-end connecting link pivot pin and the platform rotator pivot pin. Do not remove the pins. 14 Use a soft metal drift to remove both pins and remove the platform rotator from the machine.
6 Remove the power to platform electrical outlet box from the platform and lay it to the side. 7 Remove the weld cable from the platform (if equipped). Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
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Crushing hazard. The platform rotator may become unbalanced and fall if it is not properly supported. Component damage hazard. The platform angle sensor is a very sensitive instrument. It can be damaged internally if the platform rotator is dropped or sustains any physical shock, even if the damage is not visible.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS S-105 and S-125 models: 12 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins. Do not remove the pins. 13 Support the jib boom leveling arms with a suitable lifting device.
2 Connect a clear hose to the top bleed valve. Place the other end of the hose in a container to collect any drainage. Secure the container to the boom. 3 Slowly open the top bleed valve on the rotator. Do not remove the bleed valve from the platform rotator.
14 Use a soft metal drift to remove both pins and remove the platform rotator from the machine.
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.
Crushing hazard. The jib boom leveling arms may fall if they are not properly supported when the jib boom leveling arm pivot pin is removed. Component damage hazard. The platform angle sensor is a very sensitive instrument. It can be damaged internally if the platform rotator is dropped or sustains any physical shock, even if the damage is not visible.
a
How to Bleed the Platform Rotator Note: Do not start the engine. Use auxiliary power for all machine functions in this procedure.
d
S-105 (Before serial number 251) and S-125 models (Before serial number 999): 1 At the ground controls, simultaneously hold the auxiliary power button and the platform rotate right button until the platform is fully rotated to the right.
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S-100 • S-105 • S-120 • S-125
c
b
a top bleed valve b bottom bleed valve c clear hose d container
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS 4 Hold the platform rotate left button until the platform is fully rotated. Continue holding the button until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 5 Connect the clear hose to the bottom bleed valve and slowly open the valve. Do not remove the bleed valve. 6 Hold the platform rotate right button until the platform is fully rotated. Continue holding the button until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform full right then left and inspect the bleed valves for leaks. 9 Clean up any oil that may have spilled during this procedure. S-100, S-120, S-105 (after serial number 250) and S-125 models (after serial number 998): 1. Rotate the platform full right, then full left until air is completely out of the rotator. Bleeding the valve is not necessary.
2-4 Platform Level Sensor The platform level sensor is mounted to the side of the platform rotator. The platform level sensor is monitored by the control system to maintain a level platform throughout boom range of motion. If a platform level sensor is replaced, it must be calibrated prior to machine operation.
How to Calibrate the Platform Level Sensor Note: Perform this procedure with the machine on a firm, level surface and in the stowed position. 1 Secure a digital level to one of the side railings of the platform. 2 Start the machine and level the platform to gravity. Push the red Emergency stop button in to stop the engine. 3 Press and hold the enter button on the ground control panel while pulling out the red Emergency Stop button. 4 Press the plus button , then press the enter button twice before again pressing the plus button . 5 Press the enter button three timees until Platform Level to Gravity is displayed on the LCD screen. 6 Press the plus button 7 Press the enter button memory.
once. to save the setting in
8 Push one of the LCD screen buttons shown until platform level sensor mv per degree is displayed.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS 9 Confirm that the number shown on the display is the same as that shown on the data sheet supplied with the new platform level sensor. Result: If the number shown on the display is the same as that shown on the data sheet supplied with the new platform level sensor, continue to step 10. Result: If the number shown on the display is not the same as that shown on the data sheet supplied with the new platform level sensor, continue to step 9. button or the minus 10 Press the plus button to correct the display to match the data sheet. Then press the enter button to save the setting in memory. 11 Push one of the LCD screen buttons shown until exit is displayed. 11 Press the plus button to select yes and then press the enter button .
2-5 Platform Overload System The platform overload system is designed to prevent the machine from continuing to operate when the load in the platform exceeds maximum rated capacity. Refer to the machine serial label for maximum capacity information. If maximum platform capacity is exceeded, the alarm will sound at the platform controls and the platform overload indicator lights will flash at both the ground and platform controls. The ground and platform controls will become disabled. Before normal machine operation can continue, the excess load will need to be removed from the platform. If the excess load cannot be removed or if the operator at the platform controls is unable to correct the overloaded condition, another person at the ground controls can operate the machine using auxiliary power. There will be limited control of boom functions from the ground controls when using auxiliary power. Auxiliary power can be used to correct the overloaded platform condition in order to resume normal, safe operation of the machine.
How to Calibrate the Platform Overload System (if equipped) Calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over. Note: Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Remove all weight, tools and accessories from the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an incorrect calibration. 4 Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the enter of the platform floor. 5 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to 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 6. Result: The alarm is sounding. The platform overload indicator light is flashing at the platform controls and “PLATFORM OVERLOAD” should be displayed on the LCD screen at the ground controls. Slowly tighten the load spring adjustment nut in a clockwise direction in 10° increments until the overload indicator light turns off, and the alarm does not sound. Proceed to step 8.
6 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to 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. Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10° increments until the overload indicator light flashes at both the platform and ground controls, and the alarm sounds. Proceed to step 7. Result: The alarm should be sounding. The platform overload indicator light should be flashing at the platform controls and “PLATFORM OVERLOAD” should be displayed on the LCD screen at the ground controls. Repeat this procedure beginning with step 5. 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 lights and alarm responds.
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.
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Section 4 • Repair Procedures
PLATFORM COMPONENTS 7 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to 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. Repeat this procedure beginning with step 5. Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 8 Add an additional test weight to the platform. S-105 and S-125- 10 lb / 4.5 kg S-100 and S-120- 12 lb / 5.4 kg. Result: The alarm should be sounding. The platform overload indicator light should be flashing at the platform controls and “PLATFORM OVERLOAD” should be displayed on the LCD screen at the ground controls. Proceed to step 9. 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. Remove the additional 10 lb / 4.5 kg test weight. Repeat this procedure beginning with step 6.
9 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 12 Using a suitable lifting device, lift the test weight off the platform floor. 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. Note: There may be a 2 second delay before the overload indicator lights and alarm turn off. 13 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 14 Turn the key switch to platform control. 15 Test all machine functions from the platform controls. Result: All platform control functions should operate normally.
Note: There may be a 2 second delay before the platform overload indicator light and alarm responds.
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S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
2-6 Platform Overload Recovery Message (software V3.14 and later) If the ground controls LCD screen displays OVERLOAD RECOVERY, the emergency lowering system has been used while the platform was overloaded.
How to Clear the Platform Overload Recovery Message Note: This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine. Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.
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. Then press the buttons in following sequence: (plus)(plus)(plus)(minus) and press the enter button to accept. Note: The passcode buttons (plus)(plus)(plus)(minus) must be entered in the proper sequence before the enter button is pressed. 6 Press the enter or previous button on the LCD screen until EXIT is displayed. 7 Press the plus button or minus button to select YES and then press the enter button. 8 Turn the key switch to the off position.
Plus
Minus
Previous
Enter
1 Turn the key switch to platform control. Start the engine and level the platform. 2 Press and hold the enter button on the ground sontrol panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
Jib Boom Components, S-105 / S-125 Models 3-1 Jib Boom, S-105 and S-125 Models
5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
How to Remove the Jib Boom Note: Perform this procedure with the boom in the stowed position. 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 platform. See Repair Procedure, How to Remove the Platform. 2 Remove the platform mounting weldment and the platform rotator. See Repair Procedure, How to Remove the Platform Rotator. 3 Remove the hose and cable cover retaining fasteners from the jib boom leveling arm. Remove the hose and cable cover from the machine.
6 Support the barrel end of the cylinder with a suitable lifting device. 7 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. 8 Use a soft metal drift to remove the pin and let the cylinder hang down. 9 Attach a lifting strap from an overhead crane to the jib boom. 10 Remove the pin retaining fastener from the jib boom pivot pin. 11 Use a soft metal drift to remove the pin and remove the jib boom from the primary boom.
4 Support the jib boom with a suitable lifting device.
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S-100 • S-105 • S-120 • S-125
Crushing hazard. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported.
Part No. 102916
October 2015
Section 4 • Repair Procedures
JIB BOOM COMPONENTS, S-105 AND S-125 MODELS 12 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 13 Slide both of the jib boom leveling arms off of the jib boom pivot pin and lay them off to the side.
18 Remove the pin retaining fastener from the platform leveling cylinder rod-end pivot pin. 19 Use a soft metal drift to remove the platform leveling cylinder rod-end pivot pin. Crushing hazard. The platform leveling cylinder may fall if it is not properly supported when the rodend pivot pin is removed.
14 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder.
Crushing hazard. The jib boom bellcrank may fall if it is not properly supported when the platform leveling cylinder rod-end pivot pin is removed.
15 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. Remove the jib boom lift cylinder from the jib boom bellcrank. Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported. 16 Attach a lifting strap from an overhead crane to the jib boom bellcrank.
20 Remove the pin retaining fastener from the jib boom bellcrank pivot pin. 21 Use a soft metal drift to remove the jib boom bellcrank pivot pin. Remove the jib boom bellcrank from the machine.
17 Support the rod end of the platform leveling cylinder with a suitable lifting device. Protect the cylinder rod from damage.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Crushing hazard. The jib boom bellcrank may become unbalanced and fall if it is not properly supported when it is removed from the machine.
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October 2015
Section 4 • Repair Procedures
JIB BOOM COMPONENTS, S-105 AND S-125 MODELS
3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models
2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
How to Remove the Jib Boom Lift Cylinder Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Lower the jib boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks.
3 Remove the hose and cable cover retaining fasteners from the jib boom leveling arm. Remove the hose and cable cover from the machine. 4 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 5 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out and lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 6 Support the jib boom lift cylinder with a suitable lifting device. 7 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pivot pin. 8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. Remove the jib boom lift cylinder from the machine. Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported.
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S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Boom Components
S-100 and S-105 Models Pivot end a
b
c
a b c
Number 1 Number 2 Number 3
Platform end
S-120 and S-125 Models Pivot end a
b
c
d
a b c d
Part No. 102916
Platform end
Number 0 Number 1 Number 2 Number 3
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
4-1 Cable Track
4 Tag and disconnect the black electrical connector from the bottom of the control box.
The cable track and boom cable tube guides cables and hoses running up the boom. The cable track can be repaired link by link without removing the cables and hoses that run through it. Removing the entire cable track assembly may be necessary when performing major repairs that involve removing the boom.
6 Remove the cable track mounting fasteners from the cable track support at the engine side of the machine.
How to Remove the Boom Cable Track 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. Note: Perform this procedure with the boom fully stowed. 1 Remove the hose and cable cover retaining fasteners from the jib boom leveling arm. Remove the hose and cable cover from the machine. 2 Remove the protective coil sleeve from the hose and cable bundle at the platform end of the boom cable tube. 3 Tag, disconnect and plug all hydraulic hoses from the boom cable tube to the platform manifold. Note: If your machine is equipped with an airline to platform option and/or weld cable option, the airline and/or cable must be disconnected from the platform before the cable track is removed.
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5 Remove the platform-end boom cable tube mounting fasteners at the engine side of the machine.
7 Remove the wear pad mounting weldment from the cable track support bracket at the engine side of the machine. 8 Remove the hose and cable clamp from the cable track support bracket at the engine side of the machine. 9 Place blocks between the cable track and the boom cable tube for support. 10 Strap together the boom cable tube, blocks of wood, and the cable track at the engine side of the machine. Component damage hazard. Cables, hoses, boom cable tube and cable track can be damaged if they are kinked or pinched. 11 Remove the limit switch cover retaining fasteners from the top of the number 2 boom tube at the platform end of the machine. Remove the limit switch cover. 12 Tag and disconnect the wiring connectors from the proximity and limit switches on top of the number 2 boom tube at the platform end of the machine.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 13 Remove the cable track roller guide mounting fasteners from the ground controls side of the machine at the platform end. 14 Remove the roller guide from the cable track guide bracket at the engine side of the machine.
If not removing the boom from the machine, proceed to step 19. 18 Tag, disconnect and plug the primary extension cylinder hydraulic hoses on the side of the number 2 boom tube at the ground controls side of the machine. Cap the fittings.
15 Tag, disconnect and plug the hydraulic hoses from the bottom of the bulkhead fittings on the cable track support at the ground controls side of the machine. 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. 16 Remove the bulkhead fitting locknuts from the bulkhead fittings on the cable track support at the ground controls side of the machine. Remove and cap the fittings. 17 Tag and disconnect the wiring connectors. Note: The wiring connectors that need to be disconnected are located next to the hose fittings that were removed in step 16.
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. 19 Remove the cable track mounting fasteners from the cable track support at the ground controls side of the machine. 20 Remove the side panels from the boom cable tube located under the cable track at the ground controls side of the machine. 21 Remove the hose and cable cover mounting fasteners from the pivot end of the boom at the ground controls side of the machine. Remove the cover. 22 Remove the hose and cable clamps from the hoses and cables located below the boom pivot on the inside of the turntable riser at the ground controls side of the machine. 23 Tag and disconnect the electrical cables from the cable track to the ground controls side of the machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS If not removing the boom from the machine, proceed to step 25. 24 Pull the hydraulic hoses from the boom cable tube located under the cable track at the ground controls side of the machine.
28 Attach a lifting strap from an overhead crane to each end of the cable track assembly. Carefully lift the assembly from the boom and set it on a structure capable of supporting it. Crushing hazard. If the cable track assemblies are not properly secured together, the cable track assemblies may become unbalanced and fall when it is removed from the machine.
25 Place blocks between the cable track and the cable track tube at the ground controls side of the machine. Secure the cable track and the cable track tube together. Component damage hazard. Cables, hoses, boom cable tube and cable track can be damaged if they are kinked or pinched. 26 Attach a lifting strap from an overhead crane to the cable track assembly at the engine side of the boom. Lift the cable track assembly over the boom and carefully set the assembly on top of the longer boom cable tube at the ground controls side of the machine. Crushing hazard. If the cable track assemblies are not properly secured together, the cable track may become unbalanced and fall when it is removed from the machine. 27 Strap both cable track assemblies together. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. Component damage hazard. Cable tracks can be damaged if they are twisted.
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Component damage hazard. Cables, 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 Service Parts Department. Before serial number 881 (S-120/125) and 210 (S-100/105): Use part number 62320 which includes a 1-link section of cable track. If the cable track has been replaced using cable track kit, Genie part number 102054, use part number 102214. If unsure which cable track is on the machine, contact Genie Industries Service Department.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS After serial number 880 (S-120/125) and 209 (S-100/105): Use part number 102214 which includes a 3-link section of cable track. 1 Visually inspect the cable track and determine which section needs to be replaced. 2 Remove the snap-on cable track spacers. 3 Remove the external snap rings from the pivot pins at each end of the 3-link section to be removed. 4 Lift up the hoses and cables and carefully remove the damaged 3-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 5 Remove the snap-on spacers from the replacement section of cable track. 6 Lift up the hoses and cables and carefully insert the new 3-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 7 Connect the ends of the replacement cable track section to the existing cable track using the pivot pins and external snap rings. Note: Be sure that the pivot pins are installed from the inside out so the external snap rings are on the outside of the cable track. 8 Install the cable track snap-on spacers.
4-2 Boom How to Shim the Boom 1 Measure each upper, side and lower wear pad. 1 Boom wear pad specifications /2 inch 12.7 mm Minimum thickness
Note: If a wear pad is not less than specification, perform the following procedure. 2 Remove the retaining fasteners from the appropriate black plastic boom tube cover at the platform end of the boom. Remove the cover. 3 Extend the boom until the wear pads are accessible. 4 Loosen the wear pad mounting fasteners. 5 Fit as many shims as can be installed by hand. 6 Tighten the mounting fasteners. 7 Remove the boom end cover retaining fasteners at the pivot end of the boom. Remove the boom end cover from the machine. 8 Remove the boom side inspection cover retaining fasteners from the boom at the pivot end of the boom. Remove the boom inspection cover from the machine to access boom 3 wear pads. 9 Loosen the wear pad mounting fasteners. 10 Fit as many shims as can be installed by hand. 11 Tighten the mounting fasteners. 12 Replace the covers. 13 Extend and retract the boom through an entire cycle. Check for tight spots that may cause binding of the boom.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
How to Remove the Boom 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 serious injury and significant component damage. Dealer service is strongly recommended.
8 Remove the boom storage area cover retaining fasteners. Remove the cover from the machine. 9 Place support blocks under the boom lift cylinder. 10 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom lift cylinder may fall when the rod-end pivot pin is removed if the boom lift cylinder is not properly supported by the overhead crane.
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.
Crushing hazard. The boom may fall when the rod-end pivot pin is removed if the boom is not properly supported by the overhead crane.
1 Remove the platform. See Repair Procedure, How to Remove the Platform. 2 Remove the platform rotator. See Repair Procedure, How to Remove the Platform Rotator.
11 Carefully raise the boom with the overhead crane until the rod end of the boom lift cylinder can be removed.
3 S-105 and S-125 models: Remove the Jib Boom. See 3-1, How to Remove the Jib Boom.
12 Carefully lower the rod end of the boom lift cylinder down onto the support blocks.
4 Remove the cable track. See Repair Procedure, How to Remove the Boom Cable Track.
13 Lower the boom with the overhead crane to a horizontal position.
5 Raise the boom approximately 4 feet / 1.2 m.
14 Remove the boom end cover retaining fasteners from the pivot end of the boom. Remove the cover.
6 Attach a lifting strap from an overhead crane to the rod end of the boom lift cylinder. 7 Attach an overhead 10 ton / 10,000 kg crane to the platform end of the boom for support. Do not lift the boom.
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15 Locate the cable break limit switch above the primary boom extension cylinder at the pivot end of the boom.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 16 Tag and disconnect the wiring connector from the cable break limit switch. 17 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 not allow oil to squirt or spray. 18 Attach a second overhead 10 ton / 10,000 kg crane to the pivot end of the boom for support. Do not apply any lifting pressure. 19 Remove the pin retaining fastener from the boom pivot pin. Do not remove the pin.
How to Disassemble the Boom, S-120 and S-125 Models Note: Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced. The primary boom extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Primary Extension Cylinder. 1 Remove the boom. See 4-2, How to Remove the Boom. 2 Remove the retaining fasteners from the access covers on both sides of the boom at the pivot end. Remove the access covers. a
20 Use a soft metal drift to remove the boom pivot pin. Component damage hazard. Be careful not to damage the boom envelope limit switch(s) located on the inside of the engine side turntable riser when removing the boom assembly. The boom envelope switch(s) can be damaged even if the damage is not visible. 21 Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it.
a
side access 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.
Crushing hazard. The boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead cranes.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 10 Remove the pulley pivot pins, cable guards and pulleys. a
Note: When installing the pulleys, be sure that the side of the pulley with the taller flange is facing the center of the boom tube. 11 Locate the number 3 boom tube extension cable clevis pins on both sides of the number 2 boom tube at the pivot end of the boom.
b
12 Remove the cotter pin and clevis pin from both cables. Note: When installing a clevis pin, always replace the cotter pin with a new one.
a b
cable break limit switch cable pulley
13 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin.
5 Disconnect the wiring connector from the cable break limit switch.
14 Remove the cable break actuator mounting plate retaining fasteners. Remove the lower plate from the machine.
6 Tag, disconnect and plug the hydraulic hoses from the primary boom extension cylinder. Cap the fittings on the cylinder.
15 Remove the upper plate and actuator pivot pin. Do not remove the cable break limit switch from the mounting plate.
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.
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.
7 Remove the fasteners from the inner cable track mounting bracket at the primary boom extension cylinder. 8 Lay the inner cable track and hoses down and out of the way.
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.
9 Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the pivot end of the boom.
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S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 24 Support and slide the primary boom extension cylinder out of the boom assembly while guiding the cables out of the boom and place it on a structure capable of supporting it. Crushing hazard. The primary boom extension cylinder may become unbalanced and fall when it is removed from the boom if it is not properly supported and attached to the overhead crane.
a
a
red cable adjustment locking bracket
Component damage hazard. Cables can be damaged if they are kinked or pinched. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
18 Remove the two cable adjustment bolts.
25 Remove the retaining fasteners from the limit switch cover on top of the number 2 boom tube at the platform end of the machine.
19 Remove the cable-end block mounting plate fasteners. Remove the cable-end block mounting plate from the machine.
26 Carefully remove the cover with proximity and limit switches from the top of the number 2 boom tube at the platform end of the boom.
20 Remove the trunnion pin retaining fasteners.
Tip-over hazard. Failure to install the correct proximity and/or limit switches in the correct location will result in the machine tipping over, resulting in death or serious injury.
21 Use a slide hammer to remove the trunnion pins from the primary boom extension cylinder. 22 Remove the primary boom extension cylinder hold down brackets at the pivot end of the boom. 23 Attach a lifting strap from an overhead crane to the lifting eye on the primary boom extension cylinder.
Part No. 102916
27 Tag and disconnect the wiring connectors from the proximity and limit switches at the top of the number 2 boom tube at the platform end of the boom. Do not remove the proximity or limit switches.
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 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.
34 Attach a lifting strap from an overhead crane to the number 3 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.
35 Support and slide the number 3 boom tube out of the number 2 boom tube. When the number 3 boom tube is approximately halfway removed, remove the bottom wear pads from the number 2 boom tube at the platform end of the boom.
Tip-over hazard. Failure to install the correct proximity and/or limit switches in the correct location will result in the machine tipping over, resulting in death or serious injury. 30 Tag and disconnect the wiring connectors from the proximity and limit switches at the ground controls side of the number 0 boom tube at the platform end of the boom. Do not remove the proximity or limit switches. 31 Remove the retaining fasteners from each black plastic boom tube cover at the platform end of the machine. Remove the covers. 32 Remove and label the top and side wear pads of the number 3 boom tube at the pivot end of the boom. Do not remove the bottom wear pads. Note: Pay careful attention to the location and amount of shims used with each wear pad. 33 Remove and label the top and side wear pads from the number 2 boom tube at the platform end of the boom. Do not remove the bottom wear pads. Note: Pay careful attention to the location and amount of shims used with each wear pad.
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Crushing hazard. The number 3 boom tube may become unbalanced and fall when it is removed from the number 2 boom tube if it is not properly supported and attached to the overhead crane. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. 36 Remove and label the top and side wear pads from the number 2 boom tube at the pivot end of the boom. Do not remove the bottom wear pads. Note: Pay careful attention to the location and amount of shims used with each wear pad. 37 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. 38 Attach a lifting strap from an overhead crane to the number 2 boom tube at the platform end of the boom.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 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 boom. Crushing hazard. The number 2 boom tube may become unbalanced and fall when it is removed from the number 1 boom tube if it is not properly supported and attached to the overhead crane.
42 Support the secondary boom extension cylinder with an overhead crane or other suitable lifting device. 43 Remove the pin retaining fasteners from both the rod-end and barrel-end pivot pins. Do not remove the pins. 44 Use a soft metal drift to remove both pivot pins and remove the secondary boom extension cylinder from the machine while guiding the barrel end of the cylinder out of the boom. Crushing hazard. The secondary boom extension cylinder may become unbalanced and fall if it is not properly supported when it is removed from the machine.
Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. 40 Remove the secondary boom extend cylinder cover retaining fasteners. Remove the covers. Bodily injury hazard. Do not operate the machine unless the secondary extend cylinder covers are properly installed. Operating the machine with the covers removed could result in death or serious injury. 41 Tag, disconnect and plug the secondary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Part No. 102916
Component damage hazard. The boom lift cylinder rod can become damaged if the barrel end of the secondary boom extension cylinder is allowed to come in contact with it. 45 Remove and label the top and side wear pads from the number 1 boom tube at the pivot end of the boom. Do not remove the bottom wear pads. Note: Pay careful attention to the location and amount of shims used with each wear pad.
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 46 Remove and label the top and side wear pads from 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 approximately halfway removed, remove the bottom wear pads from the number 0 boom tube at the platform end of the boom. Crushing hazard. The number 1 boom tube may become unbalanced and fall when it is removed from the number 0 boom tube if it is not properly supported and attached to the overhead crane.
How to Disassemble the Boom, S-100 and S-105 Models Note: Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced. The primary boom extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Primary Extension Cylinder. 1 Remove the boom. See 4-2, How to Remove the Boom. 2 Remove the retaining fasteners from the access covers on both sides of the boom at the pivot end. Remove the access covers. a
Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. a
side access 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.
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S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 10 Remove the cotter pin and clevis pin from both cables. a
Note: When installing a clevis pin, always replace the cotter pin with a new one. 11 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin.
b
12 Remove the cable break actuator mounting plate retaining fasteners. Remove the lower plate from the machine. 13 Remove the upper plate and actuator pivot pin. Do not remove the cable break limit switch from the mounting plate.
a b
cable break limit switch 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 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. 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.
14 Push the cable break actuator and cables towards the platform end of the boom approximately 18 inches / 46 cm. 15 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 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 slide hammer to remove the trunnion pins from the primary boom extension cylinder.
Note: When installing the pulleys, be sure that the side of the pulley with the taller flange is facing the center of the boom tube. 9 Locate the number 3 boom tube extension cable clevis pins on both sides of the number 2 boom tube at the pivot end of the boom.
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Section 4 • Repair Procedures
BOOM COMPONENTS 23 Remove the retaining fasteners from the limit switch cover on top of the number 2 boom tube at the platform end of the machine. 24 Carefully remove the cover with proximity and limit switches from the top of the number 2 boom tube at the platform end of the boom. Tip-over hazard. Failure to install the correct proximity and/or limit switches in the correct location will result in the machine tipping over, resulting in death or serious injury.
a
a
red cable adjustment locking bracket
20 Remove the primary boom extension cylinder hold down brackets at the pivot end of the boom. 21 Attach a lifting strap from an overhead crane to the lifting eye on the primary boom extension cylinder. 22 Support and slide the primary boom extension cylinder out of the boom assembly while guiding the cables out of the boom and place it on a structure capable of supporting it. Crushing hazard. The primary boom extension cylinder may become unbalanced and fall when it is removed from the boom if it is not properly supported and attached to the overhead crane. Component damage hazard. Cables can be damaged if they are kinked or pinched.
25 Tag and disconnect the wiring connectors from the proximity and limit switches at the top of the number 2 boom tube at the platform end of the boom. 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 location will result in the machine tipping over, resulting in death or serious injury. 28 Tag and disconnect the wiring connectors from the proximity and limit switches at the ground controls side of the number 1 boom tube at the platform end of the boom. Do not remove the proximity or limit switches. 29 Remove the retaining fasteners from each black plastic boom tube cover at the platform end of the machine. Remove the covers.
Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
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Part No. 102916
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Section 4 • Repair Procedures
BOOM COMPONENTS 30 Remove and label the top and side wear pads of the number 3 boom tube at the pivot end of the boom. Do not remove the bottom wear pads.
34 Remove and label the top and side wear pads from the number 2 boom tube at the pivot end of the boom. Do not remove the bottom wear pads.
Note: Pay careful attention to the location and amount of shims used with each wear pad.
Note: Pay careful attention to the location and amount of shims used with each wear pad.
31 Remove and label the top and side wear pads from the number 2 boom tube at the platform end of the boom. Do not remove the bottom wear pads.
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.
Note: Pay careful attention to the location and amount of shims used with each wear pad.
32 Attach a lifting strap from an overhead crane to the number 3 boom tube at the platform end of the boom.
36 Attach a lifting strap from an overhead crane to the number 2 boom tube at the platform end of the boom.
33 Support and slide the number 3 boom tube out of the number 2 boom tube. When the number 3 boom tube is approximately halfway removed, remove the bottom wear pads from the number 2 boom tube at the platform end of the boom.
37 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 boom.
Crushing hazard. The number 3 boom tube may become unbalanced and fall when it is removed from the number 2 boom tube if it is not properly supported and attached to the overhead crane.
Crushing hazard. The number 2 boom tube may become unbalanced and fall when it is removed from the number 1 boom tube if it is not properly supported and attached to the overhead crane.
Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
Part No. 102916
Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
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BOOM COMPONENTS
4-3 Boom Lift Cylinder
5 Place support blocks under the boom lift cylinder.
How to Remove 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 is not properly supported by the overhead crane.
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 serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom until there is approximately 4 feet / 1.2 m between the turntable and boom rest pad. 2 Attach a lifting strap from an overhead crane or other suitable lifting device to the rod end of the the boom lift cylinder.
Crushing hazard. The boom may fall when the rod-end pivot pin is removed if the boom is not properly supported by the overhead crane. 7 Carefully raise the boom with the overhead crane until the rod end of the boom lift cylinder can be removed. 8 Carefully lower the rod end of the boom lift cylinder down onto the support blocks. 9 Carefully raise the boom with the overhead crane until the barrel end of the boom lift cylinder is accessible. 10 Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.
3 Attach an overhead 10 ton / 9071 kg crane to the platform end of the boom for support. Do not lift the boom. 4 Remove the boom storage area cover retaining fasteners. Remove the cover from the machine.
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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.
Part No. 102916
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Section 4 • Repair Procedures
BOOM COMPONENTS 11 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
17 With the boom lift cylinder being supported by the overhead crane, pull the boom lift cylinder toward the platform until it is out. Crushing hazard. The boom lift cylinder may become unbalanced and fall if it is not properly supported when it is removed from the machine.
a
b a b
engine pivot plate anchor hole engine pivot plate retaining fastener
12 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 13 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.
Component damage hazard. Be careful not to damage the proximity and/or limit switches when removing the boom lift cylinder. Component damage hazard. The cables and hydraulic hoses can be damaged if the boom lift cylinder is pulled across them.
Crushing hazard. Failure to install the bolt into the engine pivot plate anchor hole to secure it from moving could result in death or serious injury. 14 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.
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Section 4 • Repair Procedures
BOOM COMPONENTS
4-4 Extension Cylinders
3 Remove the access cover retaining fasteners from both sides of the boom. Remove the access covers.
The primary boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 2 and 3 boom tubes. The secondary boom extension cylinder (S-120 and S-125 models) is located underneath the number 0 boom tube and is responsible for extending the number 1 boom tube. The extension cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.
4 Secure the number 2 and number 3 boom tubes together with a strap or chain to prevent them from moving. 5 Remove the cable clamp from the cable break limit switch wiring.
a
How to Remove the Primary Boom Extension Cylinder 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 serious injury and significant component damage. Dealer service is strongly recommended. 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.
a
6 Disconnect the wiring connector from the cable break limit switch. 7 Tag, disconnect and plug the hydraulic hoses from the primary boom extension cylinder. Cap the fittings on the cylinder.
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.
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cable break limit switch
S-100 • S-105 • S-120 • S-125
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.
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Section 4 • Repair Procedures
BOOM COMPONENTS 8 S-120 and S-125 models: Remove the fasteners from the inner cable track mounting bracket at the primary boom extension cylinder.
17 Push the cable break actuator and cables towards the platform end of the boom approximately 18 inches / 46 cm.
9 S-120 and S-125 models: Lay the inner cable track and hoses down and out of the way.
18 Remove the retaining fasteners from the red cable adjustment locking bracket. Remove the red locking bracket.
10 Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the pivot end of the boom. 11 Remove the pulley pivot pins, cable guards and pulleys. Note: When installing the pulleys, be sure that the side of the pulley with the shorter flange is facing the inside of the boom tube.
Bodily injury hazard. Failure to install the red cable adjustment locking bracket would allow the cable mounting bolts to loosen and fall out which could result in death or serious injury.
12 Locate the number 3 boom tube extension cable clevis pins on both sides of the number 2 boom tube at the pivot end of the boom. 13 Remove the cotter pin and clevis pin from both cables. Note: When installing a clevis pin, always replace the cotter pin with a new one. 14 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin. a
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 cable break limit switch from the mounting plate.
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S-100 • S-105 • S-120 • S-125
a
red cable adjustment locking bracket
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Section 4 • Repair Procedures
BOOM COMPONENTS 19 Remove the two cable adjustment bolts. 20 Remove the cable-end block mounting plate fasteners. Remove the cable-end block mounting plate.
How to Remove the Secondary Boom Extension Cylinder, S-120 and S-125 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 serious injury and significant component damage. Dealer service is strongly recommended.
21 Remove the trunnion pin retaining fasteners. 22 Use a slide hammer to remove the trunnion pins from the primary boom extension cylinder. Note: Use a 1/2 -13 bolt thread on each end of the slide hammer. 23 Attach a lifting strap from an overhead crane to the lifting eye on the primary boom extension cylinder. 24 Support and slide the primary boom extension cylinder out of the boom assembly while guiding the cables out of the boom and place it on a structure capable of supporting it. Crushing hazard. The primary boom extension cylinder may become unbalanced and fall when it is removed from the boom if it is not properly supported and attached to the overhead crane.
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom until the secondary boom extension cylinder barrel-end pivot pin is above the turntable covers. 2 Remove the secondary boom extend cylinder cover retaining fasteners. Remove the covers.
Component damage hazard. Cables can be damaged if they are kinked, pinched or snagged during removal. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
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Bodily injury hazard. Do not operate the machine unless the secondary extend cylinder covers are properly installed. Operating the machine with the covers removed could result in death or serious injury.
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS 3 Tag, disconnect and plug the secondary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Support the secondary boom extension cylinder with an overhead crane or 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 extension cylinder may become unbalanced and fall if it is not properly supported when it is removed from the machine. Component damage hazard. The boom lift cylinder rod can become damaged if the barrel end of the secondary boom extension cylinder is allowed to come in contact with it.
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Section 4 • Repair Procedures
BOOM COMPONENTS
4-5 Boom Extend/Retract Cables
a
How to Adjust the Boom Extend/ Retract Cables
d
Properly adjusted extend/retract cables are essential to safe machine operation. Failure to maintain proper adjustment of the cables could result in unsafe operating conditions and may cause component damage. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise. Note: A flashlight may be necessary to be able to see the extend/retract cables inside of the boom assembly. Note: Perform this procedure with the boom fully retracted.
b
c
a b c d
Illustration 1
1 Start the engine from the ground controls. 2 Raise the boom to a horizontal position. 3 Stop the engine. 4 Remove the boom end cover from the pivot end of the machine. 5 Locate the red locking bracket (c) covering the cable adjustment bolts at the pivot end of the boom (illustration 1). 6 Remove the retaining fastener from the red locking 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.
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limit switch extend cable adjustment bolts red cable adjustment locking bracket boom tube distance
9 At the pivot end of the boom (illustration 1), turn the cable adjustment bolts (b) clockwise to obtain 63/4 inches / 17 cm between the end of the number 3 boom tube and the end of the number 2 boom tube (d). As a guide (Illustration 2), the end of the extension cable coupling (i) should be approximately mid-point (k) between the guide plate (l) and the cable retainer bracket (j). Illustration 2 is visible by removing the boom side covers. Note: Adjust the cable adjustment bolts evenly so the cable break limit switch (a) stays centered in the limit switch actuator (Illustration 1). Note: If the distance is greater than 63/4 inches / 17 cm, loosen the extend cable adjustment bolts and tighten the hex jam nut on the cable tension equalizer bolt until the distance is less than 63/4 inches / 17 cm. Loosen the jam nut and repeat step 9.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
e
f l
k j i
i j k l
extension cable coupling cable retainer bracket equal distance guide plate
Illustration 2 10 At the platform end of the boom, tighten the hex jam nut (h) on the cable tension equalizer bracket located underneath the number 1 boom tube (Illustration 3). Tighten the hex jam nut until it is snug. Do not overtighten. 11 Hold the hex jam nut with a wrench and tighten the nylock nut (g) against the hex jam nut. 12 Re-check that the cable break limit switch is centered in the limit switch actuator. Adjust the extension cable adjustment bolts to center it.
e f g h
boom tube 1 boom tube 2 nylock nut hex jam nut
Part No. 102916
g
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 bracket to secure the bolts. Bodily injury hazard. Failure to reinstall the red cable adjustment locking bracket would allow the cable mounting bolts to loosen and fall out which could result in death or serious injury.
13 At the pivot end of the boom, measure the distance between the end of the number 3 boom tube and the end of the number 2 boom tube. Result: The measurement between the end of the number 3 boom tube and the end of the number 2 boom tube should be 63/4 to 67/8 inches / 17 to 17.5 cm (d).
h
15 Lower the boom to the stowed position. 16 Start the engine from the platform controls.
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Section 4 • Repair Procedures
BOOM COMPONENTS 17 Extend the boom approximately 2 feet / 0.6 m. 18 Retract the boom. While retracting the boom, visually inspect the number 2 and number 3 boom tubes. Result: The number 2 should not move more than 1/2 inch (13 mm) before the number 3 boom tube begins to retract. Note: If the number 2 boom tube moves more than /2 inch (13 mm) before the number 3 boom tube begins to retract, repeat the procedure until the number 2 boom moves less than 1/2 inch before the number 3 boom begins to retract.
1
How to Replace the Boom Extend/ Retract Cables Note: The cable pulleys must also be replaced when replacing the cables. 1 Remove the boom extension cylinder. See 4-4, How to Remove the Primary Boom Extension Cylinder. Boom extend cables: 2 Remove the retaining fasteners that secure the extension cable retainer to the pulley mount. Remove the retainer. 3 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube.
o
Boom Tube One
Boom Tube Two Boom Tube Three
Boom Tube One
n
4 Remove the front and rear fasteners from the anchor bracket that supports the cable anchors. Remove the bracket. 5 Remove the pulley and boom extend cables from the extension cylinder assembly. Discard the old cables and pulleys.
m
m figure 3 platform end n figure 2, boom tube 3 o figure 1, pivot end
Illustration 4
6 Route the new boom extend cables through the boom extend pulley bracket. Note: 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 bracket that mounts to the number 3 boom tube.
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Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS Boom retract cables: 9 Remove the fasteners from the boom retract cables at the platform end of the boom. 10 Attach a rope to one of the boom 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.
20 Secure the number 2 and number 3 booms together at the platform end with a chain or strap to prevent them from moving. 21 Install the boom extension cylinder assembly into the boom. Note: Before lowering the extension cylinder into the saddles of the number 1 boom tube, wrap the boom retract cables around the pulleys. 22 Remove the chain or strap from the platform end of the number 2 and number 3 boom tubes. 23 Adjust the boom extend/retract cables. See, How to Adjust the Boom Extend/Retract Cables.
14 At the pivot end of the boom, carefully pull the rope with the new retract cable attached. 15 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube. Remove the rope. 16 Repeat steps 11 through 16 for the other boom retract cable. 17 At the platform end of the boom, install the retract cables and fasteners to the adjustment plate. 18 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder. 19 Install the new boom retract pulleys to the pivot end of the boom extension cylinder.
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Section 4 • Repair Procedures
Turntable Covers 5-1 Turntable Covers
4 Mark the location of the hinges on the bulkhead to ensure proper cover alignment during installation.
In addition to the standard hinged turntable covers, there are two fixed turntable covers. One fixed cover protects the fuel tank on the engine side of the machine and the other protects the turntable rotator assembly on the ground controls side of the machine.
5 Remove the cover hinge to bulkhead retaining fasteners. 6 Carefully lift and remove the cover from the machine. Crushing hazard. The turntable cover could become unbalanced and fall when it is removed from the machine if it is not properly supported and secured to a appropriate lifting device.
How to Remove a Hinged Turntable Cover 1 Raise the turntable cover. Support and secure the open cover to an overhead crane or forklift. Do not lift it.
Bodily injury hazard. Safety decals are essential to safe machine operation. Failure to replace all safety and instructional decals could result in death or serious injury. If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover.
Crushing hazard. Due to its heavy weight, do not attempt to support the cover by hand. Component damage hazard. Protect the cover from damage by using carpet or padding on the crane or forklift forks. 2 Remove the upper and lower retaining clips from the gas strut.
Note: Alignment adjustments may be necessary when a new cover is installed.
3 Gently pry the strut pivot sockets off of the ball studs and remove the strut. Protect the strut cylinder rod from damage. Crushing hazard. The turntable cover will fall when the gas struts are removed if it is not properly supported.
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Section 4 • Repair Procedures
TURNTABLE COMPONENTS
How to Remove a Fixed Turntable Cover 1 Ground controls side: Remove the top retaining fasteners from the power to platform plug panel and loosen the bottom retaining fasteners. Do not disconnect the wiring. 2 Support the cover with a suitable lifting device. Protect the cover from damage. 3 Remove the cover mounting fasteners. 4 Carefully remove the cover from the machine. Crushing hazard. The turntable cover may become unbalanced and fall when it is removed from the machine if it is not properly supported. Bodily injury hazard. Safety decals are essential to safe machine operation. Failure to replace all safety and instructional decals could result in death or serious injury. If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover. Note: Alignment adjustments may be necessary when a new cover is installed.
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Section 4 • Repair Procedures
Engines 6-1 RPM Adjustment
How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic proportional controller located on the drive pump.
Refer to Maintenance Procedure, Check and Adjust the Engine RPM.
2 Remove the hose clamp from the air cleaner hose at the air cleaner. Carefully disconnect the hose from the air cleaner.
6-2 Flex Plate The flex plate couples the engine to the pump. The flex plate is bolted to the engine flywheel and has a cut-out in the center for the pump coupler. a
b
c
d
e
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 Support the drive pump assembly with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts.
f a pump b pump shaft c coupler d flex plate e flywheel f Deutz models- .245 inch / 6.2 mm gap Cummins or Perkins models .255 inch / 6.5 mm gap
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7 Carefully pull the pump away from the engine and secure it from moving. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 8 Remove the flex plate mounting fasteners, then remove the flex plate from the flywheel.
S-100 • S-105 • S-120 • S-125
Part No. 102916
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Section 4 • Repair Procedures
ENGINES
How to Install the Flex Plate
1 8
1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. 2 Apply Loctite® removable thread sealant to the mounting fasteners. Then torque the flex plate mounting bolts in sequence to: Cummins engines: 23 ft-lbs / 31.2 Nm. Deutz and Perkins engines: 28 ft-lbs / 38 Nm.
5
6
4
3 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine.
7 2
Perkins Engines Cummins Engines Before Serial Number 1029 Deutz 913 Engines
4 Apply Loctite® removable thread sealant to the pump coupler set screw. Perkins and Cummins engines before serial number 1029 and Deutz 913 engines: Torque the set screw to 20 ft-lbs / 27 Nm. Perkins and Cummins engines after serial number 1028 and Deutz 2011 engines: Torque the set screw to 61 ft-lbs / 83 Nm. 5 Install the bell housing/mounting plate assembly. Apply Loctite® removable thread sealant to the mounting fasteners. Then torque the pump retaining fasteners to: Cummins, Perkins and Deutz 913 engines: 28 ft-lbs / 38 Nm. Deutz 2011 engines: 47 ft-lbs / 63 Nm.
3
1 8
3
5
6
7
4 2
Perkins Engines Cummins Engines After Serial Number 1028
Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged.
1
Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur.
6
3
4
5
2
Deutz 2011 Engines
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Section 4 • Repair Procedures
ENGINES
6-3 Oil Pressure and Coolant Temperature Sending Units Cummins and Perkins Models The coolant temperature sending unit is an electrical device. If the coolant temperature reaches 210° F / 99° C, the ECM will shut the engine off to prevent damage and will not start until the coolant temperature drops below 210° F / 99° C. The engine temperature will be shown on the display screen at the ground controls when the key is on and the Emergency Stop Button is pulled out to the on position. Use the scroll buttons and scroll to the Engine Temperature screen. Component damage hazard. Do not crank the engine with a water temperature fault shown on the display at the ground controls. The oil pressure sending unit is an electrical device. If the oil pressure drops below 12 psi / 0.8 bar, the ECM will shut the engine off to prevent damage. The engine oil pressure will be indicated on the display screen at the ground controls while the engine is running. Use the scroll buttons and scroll to the Engine Oil Pressure screen.
6-4 Oil Pressure and Temperature Sending Units - Deutz Models The engine oil temperature sending unit is an electrical device. If the engine oil temperature reaches 275° F / 135° C, the ECM will shut the engine off to prevent damage and will not start until the engine oil temperature drops below 275° F / 135° C. The engine temperature will be shown on the display screen at the ground controls when the key is on and the Emergency Stop Button is pulled out to the on position. Use the scroll buttons and scroll to the Engine Temperature screen. Component damage hazard. Do not crank the engine with a oil temperature fault shown on the display at the ground controls. The oil pressure sending unit is an electrical device. If the oil pressure drops below 12 psi / 0.8 bar, the ECM will shut the engine off to prevent damage. The engine oil pressure will be indicated on the display screen at the ground controls while the engine is running. Use the scroll buttons and scroll to the Engine Oil Pressure screen.
Component damage hazard. Do not crank the engine with a low oil pressure fault shown on the display at the ground controls.
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Component damage hazard. Do not crank the engine with a low oil pressure fault shown on the display at the ground controls.
Part No. 102916
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Section 4 • Repair Procedures
Ground Controls The ground control box (TCON) is the communication and operations center for the machine. The ground control box contains two key switches. The key switch towards the top of the control box is for selection of ground or platform controls. The key switch at the bottom of the control box is the Service Bypass key switch. It is used to allow the boom to be raised above 10° with the axles retracted and to correct an out-of-level platform. If the machine trips an envelope safety switch, the operator at the ground controls can turn and hold the Service Bypass key switch in the recover position and the machine will automatically lower the boom to the stowed position in sequence. The ground control box contains a replaceable membrane decal with touch sensitive buttons for various machine functions. The ground control box also contains two printed circuit boards: The LCD (Liquid Crystal Display) circuit board is mounted to the inside of the control box lid which controls the LCD display screen. The ECM circuit board is the main circuit board for the machine. There are relays on the ECM circuit board that can be replaced. All operating parameters and configuration of options for the machine are stored in the ECM memory.
7-1 Circuit Boards How to Remove the LCD Display Screen Circuit Board 1 Push in the Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box mounting fasteners. Remove the platform control box from the machine. Component damage hazard. Cables can be damaged if they are kinked or pinched. 3 Locate the cables that connect to the bottom of the control box. Number each cable and its location at the control box. 4 Disconnect the cables from the bottom of the platform control box. 5 Remove the control cable plug retaining fasteners from the bottom of the platform control box. 6 Remove the platform control box lid fasteners. Open the control box lid.
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 Industries Service Department. Note: When an ECM circuit board is replaced, the proportional valves will need to be calibrated. See 1-3, How to Calibrate a Joystick.
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Section 4 • Repair Procedures
GROUND CONTROLS 7 Locate the ECM circuit board mounted to the inside of the platform control box. 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 printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 8 Remove the ECM circuit board mounting fasteners. 9 Carefully remove the ECM circuit board from the platform control box.
7-2 Membrane Decal The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside. The membrane contains touch sensitive areas that, when pushed, activates the machine functions. The membrane buttons activate machine functions similar to toggle switches, but do not have any moving parts.
How to Replace the Membrane Decal 1 Turn the key switch at the ground controls to the off position. 2 Push in the Emergency Stop button to the off position at both the ground and platform controls. 3 Remove the ground control box lid fasteners. Open the control box lid. 4 Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit board. 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 printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.
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Section 4 • Repair Procedures
GROUND CONTROLS 5 Carefully remove the membrane decal from the control box lid while guiding the ribbon cables out of the control box lid.
7-3 Control Relays
6 Remove any decal adhesive from the control box lid with a mild solvent.
Relays used for single function switching are single pole double throw (SPDT) relays.
Note: Do not allow any solvent to come in contact with the LCD display screen.
How to Test a Single Pole Double Throw Relay
7 Install the new membrane decal (Genie part number 50811) while guiding the ribbon cables through the control box lid.
Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
8 Connect the ribbon cables to the ECM circuit board. 9 Close the control box lid and install the retaining fasteners.
Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 1 Turn the key switch to the off position. 2 Open the ground control box and remove the relay to be tested from the ECM circuit board.
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GROUND CONTROLS 3 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination. Test
Desired result 85 to 95 Ω
terminal 85 to 86
no continuity terminal 87 to 87a & 30 (infinite Ω) continuity terminal 87a to 30 (zero Ω)
87 86
87a
85
30 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 (infinite Ω) terminal 87 to 30 continuity (zero Ω)
85
86
87
87a
30
Control Relay Schematic
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Limit Switches 120 ft / 36.6 m
110 ft / 33.5 m
LSB9AS 65
LSB14AO 68
100 ft / 30.5 m LSB2RO 102 ft (31.1 m)
90 ft / 27.4 m
LSB4EO 100 ft (30.5 m)
80 ft / 24.4 m LSB8AS 50
LSB13AO 53
LSB13AO 53
70 ft / 21.3 m
60 ft / 18.3 m
LSB3EO 75 ft (22.9 m)
LSB4ES 75.5 ft (23 m)
LSB2RS 101 ft (30.8 m) LSB8AS 50
LSB3EO 75 ft (22.9 m)
LSB4ES 75.5 ft (23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m LSB7DS 11
LSB1DO 10
LSB1DO 10
20 ft / 6.1 m
LSB7DS 11
10 ft / 3 m LSB3RS 3.5 ft (1.1 m)
LSB3RO 3 ft (0.9 m)
LSB3RO 3 ft (0.9 m)
0 ft / 0 m
S-100 and S-105 Models
S-120 and S-125 Models
LSAX1RO
LSAX1EO
LSB3RS 3.5 ft (1.1 m)
LSAX2RO
LST10
LSAX2ES LSAX2EO
LSAX1ES
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LIMIT SWITCHES
8-1 Limit Switches How to Test the Limit Switches There are 2 types of limit switches: Mechanical (roller arm) and proximity. Mechanical limit switches are activated by a part of the machine physically moving the roller arm of the switch. Proximity switches are a magnetic type of switch and are activated by the close presence of a ferrous metal. Mechanical Operational Limit Switch:
3 Activate the limit switch. Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity. terminal 1 to 2 no continuity (infinite Ω) continuity terminal 3 to 4 (zero Ω) terminal 1 to 3 and 4 no continuity (infinite Ω) terminal 2 to 3 and 4 no continuity (infinite Ω)
Mechanical Safety Limit Switch:
1 Manually activate the limit switch. Result: The limit switch arm should move freely and spring return to center. A distinct click should be felt and heard. 2 Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity. terminal 1 to 2 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)
Numbering Legend
1 Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity. terminal 1 to 2 continuity (zero Ω) terminal 3 to 4 continuity (zero Ω) terminal 1 to 3 and 4 no continuity (infinite Ω) terminal 2 to 3 and 4 no continuity (infinite Ω) terminal 5 to 6 no continuity (infinite Ω)
Circuit number
AX Axle B Boom T Turntable LS Limit switch
D A L E R
Down Angle Load moment Extend O Operational Retract S Safety
LS AX 1 R O 4 - 64
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Section 4 • Repair Procedures
LIMIT SWITCHES 2 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.
3 Place a piece of ferrous metal (steel, iron, etc.) in front of the target area so it is no more than 1 /2 inch / 12.7 mm away from the target area of the proximity switch.
terminal 1 to 2 terminal 3 to 4 terminal 1 to 3 and 4 terminal 2 to 3 and 4 terminal 5 to 6
4 Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity.
no continuity (infinite Ω) no continuity (infinite Ω) no continuity (infinite Ω) no continuity (infinite Ω) no continuity (infinite Ω)
Proximity Switch: 1 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
no continuity (infinite Ω)
2 Locate the target area of the proximity switch.
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 from the target area of the proximity switch. 6 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
no continuity (infinite Ω)
How to Adjust the Limit Switches Note: Perform this procedure on a flat and level area and free from obstructions. 1 Fully retract the boom.
a
2 Place a digital protractor or digital level on top of the boom tube.
Part No. 102916
Proximity switch a target area
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LIMIT SWITCHES S-120 and S-125 models:
All models:
3 Raise boom until the protractor reads 67.5 degrees.
14 S-100 and S-105 models: Raise the boom to 52.5 degrees.
4 Loosen the mounting fasteners from the 68 degree proximity switch (LSB14AO).
15 Loosen the mounting fasteners from the 53 degree proximity switch (LSB13AO).
5 Disconnect the deutsch connector from the 68 degree proximity switch (LSB14AO) and connect an ohmmeter or continuity tester to terminals 3 and 4 of the deutsch connector.
16 Disconnect the deutsch connector from the 53 degree proximity switch (LSB13AO) and connect an ohmmeter or continuity tester to terminals 3 and 4 of the deutsch connector.
6 Adjust LSB14AO until the switch contacts just open. While observing the digital protractor, raise the boom until the switch contacts close, then lower the boom until the switch contacts open. Repeat the process until the switch contacts open between 67.5 and 68 degrees.
17 Adjust LSB13AO until the switch contacts just open. While observing the digital protractor, raise the boom until the switch contacts close, then lower the boom until the switch contacts open. Repeat the process until the switch contacts open between 52.5 and 53 degrees.
7 Tighten the 68 degree proximity switch (LSB14AO) mounting fasteners.
18 Tighten the 53 degree limit switch mounting fasteners.
8 Lower the boom to 65.3 degrees.
19 Lower the boom to 50.3 degrees.
9 Loosen the mounting fasteners from the 65 degree safety switch (LSB9AS).
20 Loosen the mounting fasteners from the 50 degree safety switch (LSB8AS).
10 Disconnect the deutsch connector from the 65 degree safety switch (LSB9AS) and connect an ohmmeter or continuity tester to terminals 1 and 2, and to terminals 3 and 4 of the deutsch connector.
21 Disconnect the deutsch connector from the 50 degree safety switch (LSB8AS) and connect an ohmmeter or continuity tester to terminals 1 and 2, and to 3 and 4 of the deutsch connector.
11 Adjust LSB9AS until the switch contacts just open. While observing the digital protractor, raise the boom until the switch contacts close, then lower the boom until the switch contacts open. Repeat the process until the switch contacts open between 65 and 65.5 degrees.
22 Adjust LSB8AS until the switch contacts just open. While observing the digital protractor, raise the boom until the switch contacts close, then lower the boom until the switch contacts open. Repeat the process until the switch contacts open between 50 and 50.5 degrees.
12 Tighten the 65 degree safety switch mounting fasteners. 13 Lower the boom to 52.5 degrees.
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LIMIT SWITCHES
8-2 Limit Switch and Level Sensor Locations LSB3RO LSB3EO LSB4EO LSB3RS
LSB9AS
LSB4ES
LSB8AS
LSB1DO
LSB7DS
LSB13AO
LSB14AO
LSB19LO
LSB6S
LSB2RO
LSB19LO LSAX1ES
TURNTABLE LEVEL LSAX1RO SENSOR
LSAX1EO
LSAX2ES
LSB2RS
LSAX2RO
PLATFORM LEVEL SENSOR
LSAX2EO LST1O
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LIMIT SWITCHES Located under the drive chassis end cover at the center of the square end (blue): LSAX1RO, LSAX1EO, LSAX1ES Located under the drive chassis end cover at the center of the round end (yellow): LSAX2RO, LSAX2EO, LSAX2ES Located in the center of the swing chassis: LST1O Located on the hydraulic tank tray: Turntable Level Sensor Located on the inside of the swing chassis bulkhead at the counterweight end: LSB9AS, LSB8AS Located at the base of the swing chassis near the counterweight: LSB1LO Located at the counterweight end of Boom tube 0: LSB6S Located on the counterweight side of the lift cylinder support assembly: LSB1DO, LSB7DS, LSB13AO, LSB14AO Located on the outside of the platform end of Boom tube 0: LSB2RO, LSB2RS Located on the top of the platform end of Boom tube 2: LSB3EO, LSB3RS, LSB3RO, LSB2RO, LSB4ES Located on the platform rotator: Platform Level Sensor
8-3 Limit Switch Functions LSAX1RO: Operational Limit Switch, Front Axle, Retract. This switch activates when the axle is fully retracted, activating axle retracted LED and shutting off power to axle retract coils after two seconds. LSAX2RO: Operational Limit Switch, Rear Axle, Retract. This switch activates when the axle is fully retracted, activating axle retracted LED and shutting off power to axle retract coils after two seconds. LSAX1EO: Operational Limit Switch, Front Axle, Extend. This switch is activated when the axle is fully extended. If this switch is not activated, boom functions are restricted to the stowed range. If unit is out of stowed, all boom functions are disabled. Axle can be extended while driving to recover. LSAX2EO: Operational Limit Switch, Rear Axle, Extend. This switch is activated when the axle is fully extended. If this switch is not activated, boom functions are restricted to the stowed range. If unit is out of stowed, all boom functions are disabled. Axle can be extended while driving to recover. LSAX1ES: Safety Limit Switch, Front Axle, Extend. 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, Extend. 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.
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LIMIT SWITCHES LSB6S: Safety Limit Switch, Cable Tension. Cuts power to the extend directional valve if extend cables are out of adjustment or one breaks. LSB1DO: Operational Limit Switch, 10O Angle. This switch activates anytime the boom is raised above 10O. If axles are not extended, boom up is disabled and the extend axle LED and icon will flash as long as boom up is operated. At this point, if axles are extended, the motors are shifted to low and drive speed is limited to 0.7 mph. LSB7DS: Safety Limit Switch, 11O Angle. If axles are not extended, this switch is activated when boom is raised to 11O, cutting power to boom up and axle retract. O
LSB13AO: Operational Limit Switch, 53 Angle. This switch activates at 53O boom angle, allowing the boom to be extended beyond 75 feet. If the boom is lowered past this switch when the boom is beyond 75 feet, boom extend and boom down are disabled. The retract boom LED and icon and alarm will flash as long as boom down is operated. LSB8AS: Safety Limit Switch, 50O Angle. This switch cuts power to boom extend, boom down and the engine fuel solenoid when it is mechanically activated at 50O if the boom length is more than 75.5 feet. LSB14AO: Operational Limit Switch, 68O Angle. This switch is activated at 68O boom angle and allows the boom to be extended beyond 100 feet. If the boom is lowered past this switch when extended beyond 100 feet, boom extend and boom down are disabled. The boom retract LED and icon and alarm will flash as long as boom down is operated. LSB9AS: Safety Limit Switch, 65O Angle. This switch cuts power to boom extend, boom down and the engine fuel solenoid when it is mechanically activated at 65O if the boom length is more than 101 feet.
Part No. 102916
LSB3RO: Operational Limit Switch, 3’ Extend. This switch activates anytime the boom is extended beyond 3 feet. If axles are not extended, boom extend is disabled and the extend axle LED and icon will flash as long as boom extend is operated. If axles are extended at this point, the motors are shifted to low and drive speed is limited to 0.7 mph. The boom up/down speed and turntable rotate speed are limited to 60% of maximum. LSB3RS: Safety Limit Switch, 3.5’ Extend. If axles are not extended, this switch is activated when the boom is extended beyond 3.5 feet, cutting power to boom extend and axle retract. LSB3EO: Operational Limit Switch, 75’ Extend. This switch activates anytime the boom is extended to 75 feet or beyond. At this point drive speed is reduced to 0.4 mph, boom up/down is reduced to 29% of maximum and turntable rotate is reduced to 40% of maximum. If boom angle is less than 53O, then boom extend is disabled and the raise boom LED and icon and alarm will flash as long as boom extend is operated. LSB4ES: Safety Limit Switch, 75.5’ Extend. This switch cuts power to boom extend, boom down and engine fuel solenoid when it is mechanically activated at 75.5 feet, if boom angle is less than 50O. LSB4EO: Operational Limit Switch, 100’ Extend. This switch activates anytime the boom is extended to 100 feet or beyond. The boom up/down is reduced to 20% of maximum. If boom angle is less than 68O, then boom extend is disabled and the raise boom LED and icon and alarm will flash as long as boom extend is operated. If boom angle is greater than 65O, the BO lockout valve will activate allowing hydraulic flow to the external cylinder to continue to extend to 120 feet.
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LIMIT SWITCHES LSB2RS: Safety Limit Switch, 101’ Extend. This switch cuts power to boom extend, boom down and engine fuel solenoid when it is mechanically activated at 101 feet, if boom angle is less than 65O. LSB2RO: Operational Limit Switch, 100’ Retract. This switch is activated anytime boom length is 100’ or less. Anytime the boom is being retracted while this switch is activated, the BN lockout valve is activated allowing hydraulic flow out of the inner cylinder. LSB19LO: Operational Limit Switch, Down Overload. This switch disables all functions except boom retract and boom up and activates a medium frequency alarm and the boom down overload diagnostic code. LST1O: Operational Limit Switch, Drive Enable. This switch is activated when the turntable is rotated 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 platform. The range of measurement is +/- 20O. The safety cutout is set at +/- 10O from gravity and will disable the primary and secondary boom up/ down functions and the platform level up/down functions.
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Hydraulic Pumps 9-1 Function Pumps
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 allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
There are three hydraulic pumps connected to the engine. There is one variable displacement pump that is used for drive functions and two fixed displacement pumps attached to the drive pump that are used for all other machine functions.
How to Remove the Function Pumps 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.
3 Support the function pumps with an overhead crane or other suitable lifing device. 4 Remove the pump mounting bolts. Carefully remove the pumps.
1 Close the two hydraulic tank valves located at the hydraulic tank.
Crushing hazard. The function pumps may become unbalanced and fall when the mounting bolts are removed if they are not properly supported. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pumps after installing the pumps. See 9-2, How to Prime the Pumps.
open
closed
Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.
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HYDRAULIC PUMPS
9-2 Drive Pump
3 Close the two hydraulic tank valves located at the hydraulic tank.
The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Sundstrand-Sauer service center. Call the Genie Industries Service Department to locate your local authorized service center.
open
Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.
How to Remove the Drive Pump Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended.
4 Tag, disconnect and plug the hydraulic hoses from the drive pump. Cap the fittings on the pump. 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.
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 function pumps. See How to Remove the Function Pumps. 2 Disconnect the electrical connection at the electronic displacement controller (EDC) located on the drive pump.
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closed
5 Support the drive pump with a suitable lifting device and remove the two drive pump mounting fasteners. 6 Carefully pull the drive pump out until the pump coupler separates from the flex plate.
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Section 4 • Repair Procedures
HYDRAULIC PUMPS 7 Remove the drive pump from the machine. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.
Cummins and Perkins models: 2 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine to access the fuel injection pump.
Note: Before installing the pump, verify proper pump coupler spacing. Refer to the appropriate flex plate installation instructions for your engine.
How to Prime the Pumps Component damage hazard. Be sure that the hydraulic tank shutoff valves are in the open position before priming the pump. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur.
a
b a b
engine pivot plate anchor hole engine pivot plate retaining fastener
3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.
open
closed
1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to one of the test ports located under the drive pump.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Crushing hazard. Failure to install the bolt into the engine pivot plate anchor hole to secure it from moving could result in death or serious injury.
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HYDRAULIC PUMPS 5 Deutz models: Disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump.
a a
Perkins models a fuel shutoff solenoid
6 Have another person crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 250 psi / 17.2 bar.
Deutz models a fuel shutoff solenoid
Cummins and Perkins models: Disconnect the wire from the fuel shutoff solenoid at the injector pump.
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 the injector pump.
a
Cummins and Perkins models: Connect the wire to the fuel shutoff solenoid at the injector pump.
8 Start the engine and check for hydraulic leaks.
Cummins models a fuel shutoff solenoid
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HYDRAULIC PUMPS
9-3 Auxiliary Pump
4 Activate any function using auxiliary power. Result: If the pressure gauge reads 2500 psi / 172 bar, immediately stop. The pump is good.
How to Test the Auxiliary Pump The auxiliary pump is a 2-section, gear-type pump. Pump number 1 is the pump section closest to the pump motor and pump number 2 is the pump section that is farther from the pump motor. Each section of the pump has its own relief valve located within the pump body. 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 Disconnect and plug the high pressure hydraulic hose from pump number 1. 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. 2 Connect a 0 to 5000 psi / 0 to 345 bar pressure gauge to the high pressure port on pump number 1. 3 Turn the key switch to ground control and pull out the Emergency Stop button to the on position.
Part No. 102916
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 hydraulic hose. 7 Disconnect the hydraulic hose from the high pressure port from pump number 2. 8 Connect a 0 to 5000 psi / 0 to 345 bar pressure gauge to the high pressure port on pump number 2. 9 Turn the key switch to ground control and pull out the Emergency Stop button to the on position. 10 Activate any function using auxiliary power. Result: If the pressure gauge reads 3000 psi / 207 bar, immediately stop. The pump is good. Result: If pressure fails to reach 3000 psi / 207 bar, the internal relief valve setting is incorrect or the pump is bad and will need to be serviced or replaced. 11 Remove the pressure gauge and reconnect the hydraulic hose.
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HYDRAULIC PUMPS
How to Remove the Auxiliary Pump 1 Open the ground controls side turntable cover. 2 Tag, disconnect and plug the hydraulic hoses from the pumps. 3 Remove the pump mounting fasteners and remove the pump from the pump motor.
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Manifolds 10-1 Function Manifold Components, S-100 and S-105 Models (to serial number 136)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
1
Relief valve, 1800 psi / 124.1 bar........ FA...........Boom extend pressure limit.......................18-20 ft-lbs / 24-27 Nm
Item
Function
Torque
2 Proportional solenoid valve................. FB...........Boom extend/retract proportional speed control.............33-37 ft-lbs / 44.9-50.3 Nm 3
Solenoid valve, 3 position 4 way......... FC...........Turntable rotate left/right..................25-27 ft-lbs / 34-36.7 Nm
4
DO3 valve, 3 position 4 way................FD...........Boom up/down........................................30-35 in-lbs / 3-4 Nm
5 Priority flow regulator valve, 0.1 gpm / 0.38 L/min........................... FE...........Bleeds off differential sensing valves to tank........................18-20 ft-lbs / 24-27 Nm 6 Proportional solenoid valve................. FF...........Boom up/down proportional speed control.................................33-37 ft-lbs / 44.9-50.3 Nm Proportional solenoid valve................. FG...........Turntable rotate proportional 7 speed control......................................18-20 ft-lbs / 24-27 Nm 8
Counterbalance valve, 3200 psi / 220.6 bar
FH
Boom down circuit...............................30-35 ft-lbs / 38-41 Nm
9 Relief valve, 2600 psi / 179.3 bar........ FI.............Turntable rotate, boom lift and boom retract pressure limit...............25-27 ft-lbs / 34-36.7 Nm 10 Check valve........................................ FJ............Load sensing circuit, boom up/down.....................................12-14 ft-lbs / 16-19 Nm
This list continues. Please turn the page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 77
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 FA
2 FB
4
3 FD
FC
FE
FR
5
17
16
FQ FF 6
FG 15
FP
7
FH 8 FI FJ FK FL
FM 14
9 10 11 12
TP 13
4 - 78
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-100 and S-105 Models, continued (to serial number 136)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
11
Orifice - plug, 0.040 inch / 1.02 mm...........................FK...........Differential sensing dampening
Item
Function
Torque
12 Check valve........................................ FL............Load sensing circuit, turntable rotate....................................12-14 ft-lbs / 16-19 Nm 13
Diagnostic Nipple................................................Testing
14
Check valve........................................ FM...........Load sensing circuit, boom extend/retract.............................12-14 ft-lbs / 16-19 Nm
15
Differential sensing valve.................... FP...........Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
16
Solenoid valve, 2 position 3 way......... FQ...........Boom retract control..................................25-27 ft-lbs / 34-37 Nm
17
Solenoid valve, 2 position 3 way......... FR...........Boom extend control..................................52-60 ft-lbs / 71-82 Nm
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 79
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 FA
2 FB
4
3 FD
FC
FE
FR
5
17
16
FQ FF 6
FG 15
FP
7
FH 8 FI FJ FK FL
FM 14
9 10 11 12
TP 13
4 - 80
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-2 Function Manifold Components, S-100 and S-105 Models (from serial number 137)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
1
Solenoid Valve Assembly, 3 position 4 way, DO3, 12V DC.......... FD...........Boom up/down..............................................30-35 in-lbs / 3-4 Nm
2
Solenoid Valve, 3 position 4 way........ FC...........Turntable rotate control, left/right...............25-27 ft-lbs / 34-37 Nm
Item
Function
Torque
3 Proportional Solenoid Valve................ FG...........Turntable rotate, proportional speed control.................. 18-20 ft-lbs / 25-27 Nm 4
Solenoid Valve, 2 position 3 way........ AA...........Auxiliary drive/steer selector......................25-27 ft-lbs / 34-37 Nm
5
Relief Valve, 3000 psi / 206.8 bar....... AC...........Platform manifold pressure limit................18-20 ft-lbs / 24-27 Nm
6
Flow Regulator Valve, 3 gpm / 11.36 L/min............................ AD...........Priority flow to platform..............................25-27 ft-lbs / 34-37 Nm
7
Check Valve, 5 psi / 0.34 bar.............. AE...........Blocks flow from pump 2 to auxiliary pump............................. 12-14 ft-lbs / 16.3-19 Nm
8 Proportional Solenoid Valve, N.C....... FF...........Primary lift, proportional valve speed control..............................33-37 ft-lbs / 45-50 Nm 9
Check Valve, 10 psi / 0.69 bar............ AB...........Blocks flow from pump 1 and 2 to auxiliary pump.......................... 18-20 ft-lbs / 24.5-27.2 Nm
10 Check Valve........................................ AG...........Blocks flow from auxiliary pump, port 2A to pump 1............................... 33-37 ft-lbs / 45-50 Nm 11 Check Valve, 5 psi / 0.34 bar.............. AF...........Blocks flow from auxiliary pump, ports 2A and 3A to pump 2................. 25-27 ft-lbs / 34-37 Nm This list continues on the next page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 81
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 FD
FC
24
2
FA
FG
3
FR 23
AA
AC
AD
FQ 22
AE
4
5
6 7
FF 8
21 20 19 18 17
FE FL FP
AB 9
FJ FM
AG AF 16
FB FI FH FK
10 11 12 13 14
TP 15
4 - 82
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-100 and S-105 Models, continued (from serial number 137)
The function manifold is mounted to the turntable next to the ground controls. Index No.
Description
Schematic Item
Function
Torque
12 Relief Valve, 2600 psi / 179.3 bar....... FI.............Turntable, primary lift and boom retract pressure limit................. 25-27 ft-lbs / 34-37 Nm 13
Counterbalance Valve, 3200 psi / 220.6 bar............................ FH...........Primary lift, load holding............................30-35 ft-lbs / 38-41 Nm
14
Orifice Plug, 0.040 inch / 1.016 mm.... FK...........Differential sensing damping
15
Diagnostic Nipple................................ TP...........Testing
Proportional Valve............................... FB...........Boom extend/retract solenoid 16 valve proportional speed control.........33-37 ft-lbs / 45-50 Nm 17 Check Valve, 5 psi / 0.34 bar.............. FM...........Extension cylinder load sense check............................. 12-14 ft-lbs / 16.3-19 Nm 18
Check Valve, 5 psi / 0.34 bar.............. FJ............Primary lift load sense check...........12-14 ft-lbs / 16.3-19 Nm
19
Differential Sensing Valve, 110 psi / 7.58 bar................................ FP...........Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
20 Check Valve, 5 psi / 0.34 bar.............. FL............Extension cylinder load sense check............................. 12-14 ft-lbs / 16.3-19 Nm 21 Flow Regulator Valve, 0.1 gpm / 0.38 L/min........................... FE...........Bleeds off differential sensing valve to tank.................... 18-20 ft-lbs / 24.5-27.2 Nm 22
Solenoid Valve, 2 position 3 way........ FQ...........Boom retract control..................................52-60 ft-lbs / 71-82 Nm
23
Solenoid Valve, 2 position 3 way........ FR...........Boom extend control..................................52-60 ft-lbs / 71-82 Nm
24 Relief Valve, 1800 psi / 124.1 bar....... FA...........Boom extend pressure limit............................................18-20ft-lbs/ 24.5-27.2 Nm.....................................................
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 FD
FC
24
2
FA
FG
3
FR 23
AA
AC
AD
FQ 22
AE
4
5
6 7
FF 8
21 20 19 18 17
FE FL FP
AB 9
FJ FM
AG AF 16
FB FI FH FK
10 11 12 13 14
TP 15
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Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models How to Adjust the Function Manifold Relief Valve Note: Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 345 bar pressure gauge to the test port on the function manifold. 2 Start the engine from the ground controls. 3 Simultaneously push and hold the function enable/high speed button and the boom retract button with the boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Oil Specifications. 4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item FI). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified.
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. 3 Fully raise and extend the boom. 4 Simultaneously push and hold the function enable/high speed button and the boom extend button with the boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item FA). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 6 to confirm the relief valve pressure.
6 Repeat steps 2 through 5 to confirm the relief valve pressure.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-4 Proportional Valves Function Manifold Note: When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity, the proportional valve cartridge or coil will need to be calibrated. See Repair Procedure, How to Calibrate a Joystick.
4 - 86
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Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-5 Function Manifold Components, S-120 and S-125 Models (to serial number 430)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
1
Relief valve, 1800 psi / 124.1 bar.........BA...........Boom extend pressure limit................ 18-20 ft-lbs / 24-27 Nm
Item
Function
Torque
2 Proportional solenoid valve................. BB...........Boom extend/retract proportional speed control..................33-37 ft-lbs / 45-50 Nm 3
Solenoid valve, 3 position 4 way......... BC...........Turntable rotate left/right....................25-27 ft-lbs / 34-37 Nm
4
DO3 valve, 3 position 4 way............... BD...........Boom up/down........................................30-35 in-lbs / 3-4 Nm
5 Priority flow regulator valve, 0.1 gpm / 0.38 L/min........................... BE...........Bleeds off differential sensing valves to tank........................18-20 ft-lbs / 24-27 Nm 6 Proportional solenoid valve................. BF...........Boom up/down proportional speed control......................................33-37 ft-lbs / 45-50 Nm Proportional solenoid valve................. BG...........Turntable rotate proportional 7 speed control......................................18-20 ft-lbs / 24-27 Nm 8
Counterbalance valve, 3200 psi / 220.6 bar............................ BH...........Boom down circuit..............................30-35 ft-lbs / 38-41 Nm
9 Relief valve, 2600 psi / 179.3 bar........ BI............Turntable rotate, boom lift and boom retract pressure limit.................25-27 ft-lbs / 34-37 Nm 10 Check valve........................................ BJ............Load sensing circuit, boom up/down....................................12-14 ft-lbs / 16-19 Nm 11
Orifice - plug, 0.040 inch / 1.02 mm...........................BK...........Differential sensing dampening
This list continues. Please turn the page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 BA
2 BB
3
4
BC
BD
BE
5
BR 19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
BI BJ BK
BN 15
4 - 88
BM 14
BL 13
8
9 10 11
TP 12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-120 and S-125 Models, continued (to serial number 430)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
12
Diagnostic nipple.................................................Testing
Item
Function
Torque
13 Check valve........................................ BL...........Load sensing circuit, turntable rotate...................................12-14 ft-lbs / 16-19 Nm 14
Check valve........................................ BM..........Load sensing circuit, boom extend/retract............................12-14 ft-lbs / 16-19 Nm
15
Solenoid valve, N.C. Poppet............... BN...........Boom retract sequence control..................33-37 ft-lbs / 45-50 Nm
16
Solenoid valve, N.C. Poppet............... BO...........Boom extend sequence control.................33-37 ft-lbs / 45-50 Nm
17
Differential sensing valve.................... BP...........Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
18
Solenoid valve, 2 position 3 way......... BQ...........Boom retract control..................................52-60 ft-lbs / 71-82 Nm
19
Solenoid valve, 2 position 3 way......... BR...........Boom extend control..................................52-60 ft-lbs / 71-82 Nm
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 89
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 BA
2 BB
3
4
BC
BD
BE
5
BR 19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
BI BJ BK
BN 15
4 - 90
BM 14
BL 13
8
9 10 11
TP 12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-6 Function Manifold Components, S-120 and S-125 Models (from serial number 431 to 574)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
1
DO3 Valve, 3 position 4 way,.............. BD...........Boom up/down........................................ 30-35 in-lbs / 3-4 Nm
2
Solenoid Valve, 3 position 4 way........ BC...........Turntable rotate left/right.....................25-27 ft-lbs / 34-37 Nm
Item
Function
Torque
3 Proportional Solenoid Valve................ BG...........Turntable rotate, proportional speed control...................................... 18-20 ft-lbs / 25-27 Nm 4
Solenoid Valve, 2 position 3 way........ AA...........Auxiliary drive/steer selector................25-27 ft-lbs / 34-37 Nm
5
Relief Valve, 3000 psi / 206.8 bar....... AC...........Platform manifold pressure limit..........18-20 ft-lbs / 25-27 Nm
6
Flow Regulator Valve, 3 gpm / 11.36 L/min............................ AD...........Priority flow to platform........................25-27 ft-lbs / 34-37 Nm
7
Check Valve, 5 psi / 0.34 bar.............. AE...........Blocks flow from pump 2 to auxiliary pump......................... 12-14 ft-lbs / 16.2-18.9 Nm
8 Proportional Solenoid Valve, N.C....... BF...........Primary lift, proportional speed control.................. 33-37 ft-lbs / 45-50 Nm 9
Check Valve........................................ AB...........Blocks flow from pump 1 and 2 to auxiliary pump................................ 18-20 ft-lbs / 25-27 Nm
10 Check Valve........................................ AG...........Blocks flow from auxiliary pump, port 2A to pump 1............................... 33-37 ft-lbs / 45-50 Nm 11 Check Valve........................................ AF...........Blocks flow from auxiliary pump, ports 2A and 3A to pump 2................. 25-27 ft-lbs / 34-37 Nm 12 Relief Valve, 2600 psi / 179.3 bar....... BI............Turntable, primary lift and boom retract pressure limit........................... 25-27 ft-lbs / 34-37 Nm This list continues on the next page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 91
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 BD BC
26
2
BA
BG 3 25
BR AA
AC
24
AD
BQ
AE BF 23 22 21
20 19 18
17
4
5
6 7 8
BO BE BL
BP AB
BJ
9
BM
BN AG 10 AF BI BH BK
BB 16
4 - 92
11 12 13 14
TP 15
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-120 and S-125 Models, continued (from serial number 431 to 574)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
13
Counterbalance Valve, 3200 psi / 220.6 bar............................ BH...........Primary lift, load holding..................... 30-35 ft-lbs / 41-47 Nm
14
Orifice Plug, 0.040 inch / 1.016 mm.... BK...........Differential sensing damping
15
Diagnostic Nipple................................ TP...........Testing
Item
Function
Torque
16 Proportional Solenoid Valve, N.C....... BB...........Boom extend/retract proportional speed control...................................... 33-37 ft-lbs / 45-50 Nm 17
Solenoid Valve, 2 position 2 way, N.C.......................... BN...........Boom retract sequence control.......... 33-37 ft-lbs / 45-50 Nm
18 Check Valve, 5 psi / 0.34 bar.............. BM..........Extension cylinder load sense check............................. 12-14 ft-lbs / 16.3-19 Nm 19
Check Valve, 5 psi / 0.34 bar.............. BJ............Primary lift load sense check........... 12-14 ft-lbs / 16.3-19 Nm
20
Differential Sensing Valve, 110 psi / 7.58 bar................................ BP...........Directs flow to functions...................... 25-27 ft-lbs / 34-37 Nm
21 Check Valve, 5 psi / 0.34 bar.............. BL...........Turntable rotate load sense check............................. 12-14 ft-lbs / 16.3-19 Nm 22 Flow Regulator Valve, 0.1 gpm / 0.38 L/min........................... BE...........Bleeds off differential sensing valve to tank.......................... 18-20 ft-lbs / 25-27 Nm 23
Solenoid Valve, 2 position 2 way, N.C.......................... BO...........Boom extend sequence control......... 33-37 ft-lbs / 45-50 Nm
24
Solenoid Valve, 2 position 3 way........ BQ...........Boom retract control.......................... 52-60 ft-lbs / 71-82 Nm
25
Solenoid Valve, 2 position 3 way........ BR...........Boom extend control.......................... 52-60 ft-lbs / 71-82 Nm
26
Relief Valve, 1800 psi / 124.1 bar....... BA...........Boom extend pressure limit................ 18-20 ft-lbs / 25-27 Nm
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 93
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 BD BC
26
2
BA
BG 3 25
BR AA
AC
24
AD
BQ
AE BF 23 22 21
20 19 18
17
4
5
6 7 8
BO BE BL
BP AB
BJ
9
BM
BN AG 10 AF BI BH BK
BB 16
4 - 94
11 12 13 14
TP 15
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-7 Function Manifold Components, S-120 and S-125 Models (from serial number 575)
The function manifold is mounted to the turntable next to the ground controls. Index
Schematic
No.
Description
1
Solenoid Valve Assembly, 3 position 4 way, DO3, 12V DC.......... BD...........Boom up/down........................................ 30-35 in-lbs / 3-4 Nm
Item
Function
Torque
2
Solenoid Valve, 2 position 3 way........ AA...........Auxiliary drive/steer selector................25-27 ft-lbs / 34-37 Nm
3
Check Valve, 5 psi / 0.34 bar.............. AE...........Blocks flow from pump 2 to auxiliary pump............................. 12-14 ft-lbs / 16.3-19 Nm
4
Flow Regulator Valve, 3 gpm / 11.36 L/min............................ AD...........Priority flow to platform..................23-25 ft-lbs / 31.2-33.9 Nm
5
Check Valve, 10 psi / 0.69 bar............ AB...........Blocks flow from pump 1 and 2 to auxiliary pump................................ 18-20 ft-lbs / 25-27 Nm
6 Solenoid Valve, 3 position 4 way ....... BC...........Turntable rotate control, left/right............................................... 25-27 ft-lbs / 34-37 Nm Proportional Solenoid Valve................ BG...........Turntable rotate, 7 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...........Turntable rotate load sense check............................. 12-14 ft-lbs / 16.3-19 Nm 10 Proportional Solenoid Valve................ BB...........Boom extend/retract proportional speed control.................. 33-37 ft-lbs / 45-50 Nm 11 Check Valve, 5 psi / 0.34 bar.............. AF...........Blocks flow from auxiliary pump, ports 2A and 3A to pump 2................. 25-27 ft-lbs / 34-37 Nm 12
Diagnostic Nipple................................ TP...........Testing
13 Relief Valve, 3000 psi / 206.8 bar....... AC...........Platform manifold pressure limit..................................... 18-20 ft-lbs / 25-27 Nm This list continues on the next page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 95
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 BD
2
3
4
5
AA AE AD AB
BC
27
BR
BG
BP 26
25 24 23 22 21 20 19 18
6
7
8
BQ
BL
BN
9
BO BF BS BB 10 BK AF BJ
11
BM TP BE AC BI AG BH BA
4 - 96
S-100 • S-105 • S-120 • S-125
12 13 14 15 16 17
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-120 and S-125 Models, continued (from serial number 575)
The function manifold is mounted to the turntable next to the ground controls. Index No.
Description
Schematic Item
Function
Torque
14 Relief Valve, 2600 psi / 179.3 bar....... BI............Turntable, primary lift and boom retract pressure limit.............. 12-14 ft-lbs / 16.3-19 Nm 15 Check Valve........................................ AG...........Blocks flow from auxiliary pump, port 2A to pump 1............................... 33-37 ft-lbs / 45-50 Nm 16
Counterbalance Valve, 3200 psi / 220.6 bar............................ BH...........Primary lift, load holding......................30-35 ft-lbs / 41-47 Nm
17
Relief Valve, 1800 psi / 124.1 bar....... BA...........Boom extend pressure limit.................18-20 ft-lbs / 25-27 Nm
18 Flow Regulator Valve, 0.1 gpm / 0.38 L/min........................... BE...........Leads off differential sensing valve to tank.......................... 18-20 ft-lbs / 25-27 Nm 19 Check Valve, 5 psi / 0.34 bar.............. BM..........Extension cylinder load sense check............................. 12-14 ft-lbs / 16.3-19 Nm 20
Check Valve, 5 psi / 0.34 bar.............. BJ............Primary lift load sense check............12-14 ft-lbs / 16.3-19 Nm
21
Orifice Plug, 0.040 inch / 1.016 mm.... BK...........Differential sensing damping
22
Check Valve, 30 psi / 2.06 bar............ BS...........Back pressure check, boom extend....................................... 33-37 ft-lbs / 45-50 Nm
23 Proportional Solenoid Valve................ BF...........Primary lift, proportional speed control.................. 33-37 ft-lbs / 45-50 Nm 24
Solenoid Valve, 2 position 2 way, N.C.......................... BO...........Boom extend sequence control...........33-37 ft-lbs / 45-50 Nm
25
Solenoid Valve, 2 position 2 way, N.C.......................... BN...........Boom retract sequence control............33-37 ft-lbs / 45-50 Nm
26
Solenoid Valve, 2 position 3 way........ BQ...........Boom retract control............................52-60 ft-lbs / 71-82 Nm
27
Solenoid Valve, 2 position 3 way........ BR...........Boom extend control............................52-60 ft-lbs / 71-82 Nm
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 97
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1 BD
2
3
4
5
AA AE AD AB
BC
27
BR
BG
BP 26
25 24 23 22 21 20 19 18
6
7
8
BQ
BL
BN
9
BO BF BS BB 10 BK AF BJ
11
BM TP BE AC BI AG BH BA
4 - 98
S-100 • S-105 • S-120 • S-125
12 13 14 15 16 17
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models How to Adjust the Function Manifold Relief Valve Note: Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 345 bar pressure gauge to the test port on the function manifold. 2 Start the engine from the ground controls. 3 Simultaneously push and hold the function enable/high speed button and the boom retract button with the boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item BI). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified.
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 Fully raise and extend the boom. 4 Simultaneously push and hold the function enable/high speed button and the boom extend button with the boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item BA). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 6 to confirm the relief
6 Repeat steps 2 through 5 to confirm the relief valve pressure.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 99
October 2015
Section 4 • Repair Procedures
MANIFOLDS valve pressure.
10-9 Proportional Valves Function Manifold Note: When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity, the proportional valve cartridge or coil will need to be calibrated. See 1-3, How to Calibrate a Joystick Controller.
4 - 100
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-10 Platform Manifold Components, S-100 and S-120 Models The platform manifold is mounted to the platform mounting weldment. Index
Schematic
No.
Description
Item
Function
Torque
1
Proportional solenoid valve, 3 position 4 way.................................. GH..........Platform level up/down..............................18-20 ft-lbs / 24-27 Nm
2
Check valve........................................ GF...........Platform rotate circuit
3
Check valve........................................ GJ...........Platform level circuit
4
Accumulator, 500 psi / 34.5 bar.......... GM..........Hydraulic dampening........................................... 23 ft-lbs / 31 Nm
5 Differential sensing valve, N.O............ GI............Platform level differential sensing circuit......................................23-25 ft-lbs / 31-34 Nm 6 Differential sensing valve, N.O............ GE...........Platform rotate differential sensing circuit......................................23-25 ft-lbs / 31-34 Nm 7
Orifice - plug, 0.030 inch / 0.762 mm.. GB...........Platform rotate left circuit
8
Orifice - plug, 0.030 inch / 0.762 mm.. GC..........Platform rotate right circuit
9
Shuttle valve....................................... GG..........Platform level load sense circuit..........7.4-9 ft-lbs / 10-12 Nm
10
Shuttle valve....................................... GA...........Platform rotate load sense circuit.........7.4-9 ft-lbs / 10-12 Nm
11
Differential sensing valve, N.C............ GC..........Directs flow to functions.............................23-25 ft-lbs / 31-34 Nm
12
Proportional solenoid valve, 3 position 4 way.................................. GD..........Platform rotate left/right.............................18-20 ft-lbs / 24-27 Nm
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Section 4 • Repair Procedures
MANIFOLDS
1 GH
12
3
2 GF
4
GJ
GQ
GD
GO 11
GI
GE
GA 10
4 - 102
GG
GC 9
S-100 • S-105 • S-120 • S-125
8
5
6
GB 7
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-11 Platform Manifold Components, S-105 and S-125 Models The platform manifold is mounted to the platform mounting weldment. Index
Schematic
No.
Description
Item
Function
Torque
1
Proportional solenoid valve, 3 position 4 way.................................. CH...........Platform level up/down..............................18-20 ft-lbs / 24-27 Nm
2
Check valve........................................ CF...........Platform rotate circuit
3
Check valve........................................ CJ...........Platform level circuit
4
Proportional solenoid valve, 3 position 4 way.................................. CL...........Jib boom up/down.....................................18-20 ft-lbs / 24-27 Nm
5
Check valve........................................ CN...........Jib boom circuit
6
Accumulator, 500 psi / 34.5 bar.......... CQ..........Hydraulic dampening........................................... 23 ft-lbs / 31 Nm
7 Differential sensing valve, N.O............ CM..........Jib boom differential sensing circuit......................................23-25 ft-lbs / 31-34 Nm 8 Differential sensing valve, N.O............ CI............Platform level differential sensing circuit......................................23-25 ft-lbs / 31-34 Nm 9 Flow control valve, 0.1 gpm / 0.38 L/min........................... CP...........Bleeds off differential sensing valve to tank 10 Differential sensing valve, N.O............ CE...........Platform rotate differential sensing circuit......................................23-25 ft-lbs / 31-34 Nm 11
Shuttle valve....................................... CK...........Jib boom load sense circuit
12
Orifice - plug, 0.030 inch / 0.762 mm.. CB...........Platform rotate left circuit
13
Orifice - plug, 0.030 inch / 0.762 mm.. CC...........Platform rotate right circuit
14
Shuttle valve....................................... CG..........Platform level load sense circuit..........7.4-9 ft-lbs / 10-12 Nm
15
Shuttle valve....................................... CA...........Platform rotate load sense circuit.........7.4-9 ft-lbs / 10-12 Nm
16
Differential sensing valve, N.C............ CO..........Directs flow to functions.............................23-25 ft-lbs / 31-34 Nm
17
Proportional solenoid valve, 3 position 4 way.................................. CD...........Platform rotate left/right.............................18-20 ft-lbs / 24-27 Nm
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Section 4 • Repair Procedures
MANIFOLDS
2
1 CH
17
16
CF
3 CJ
4
5
CL
CN
6 CQ
CD
CO
CM 7
CI
CP
CE
CA 15
4 - 104
CG 14
CC 13
CB 12
S-100 • S-105 • S-120 • S-125
8
9
10
CK 11
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-12 Proportional Valves Platform Manifold Note: When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity, the proportional valve cartridge or coil will need to be calibrated. See 1-3, How to Calibrate a Joystick.
10-13 Platform Rotate Counterbalance Valve Manifold Components Index
Schematic
No.
Description
Item
Function
Torque
1
Counterbalance valve......................... A.............Platform rotate left.....................................37-44 ft-lbs / 50-60 Nm
2
Counterbalance valve......................... B.............Platform rotate right...................................37-44 ft-lbs / 50-60 Nm
A
1
2
Part No. 102916
A
B
B
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Section 4 • Repair Procedures
MANIFOLDS
10-14 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor. Index
Schematic
No.
Description
Item
Function
Torque
1
Counterbalance valve......................... A.............Turntable rotate left...................................37-44 ft-lbs / 50-60 Nm
2
Counterbalance valve......................... B.............Turntable rotate right.................................37-44 ft-lbs / 50-60 Nm
3
Shuttle valve, 2 position 3 way............ C.............Turntable rotation brake release...............10-12 ft-lbs / 14-16 Nm
A
A
C 3
B
C
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1
B 2
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-15 Steer and Axle Extend/Retract Manifold Components - View 1
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end of the machine. Index No. Description
Schematic Item Function
Torque
1 Solenoid Valve, 3 position 4 way........ EA...........Steering cylinder control, square end, right side..........................18-20 ft-lbs / 24-27 Nm 2 Solenoid Valve, 3 position 4 way........ EB...........Steering cylinder control, square end, left side............................18-20 ft-lbs / 24-27 Nm 3 Solenoid Valve, 3 position 4 way........ EC...........Steering cylinder control, round end, right side............................18-20 ft-lbs / 24-27 Nm 4 Solenoid Valve, 3 position 4 way........ ED...........Steering cylinder control, round end, left side..............................18-20 ft-lbs / 24-27 Nm Flow Regulator Valve, 5 1.4 gpm / 5.3 L/min............................. ET...........Steering cylinder speed, round end, right side, retract................18-20 ft-lbs / 24-27 Nm 6
Flow Regulator Valve, 2 gpm / 7.6 L/min................................ EU...........Steering cylinder speed, round end, left side, extend.................18-20 ft-lbs / 24-27 Nm
7
Flow Regulator Valve, 2 gpm / 7.6 L/min................................ EV...........Steering cylinder speed, square end, right side, extend.............18-20 ft-lbs / 24-27 Nm
8 9
Flow Regulator Valve, 0.1 gpm / 0.38 L/min........................... EO...........Bleeds off differential valve to tank............18-20 ft-lbs / 24-27 Nm Differential Sensing Valve, 110 psi..... EP...........Meters flow to functions sensing ..............25-27 ft-lbs / 34-37 Nm
10 Flow Regulator Valve, 1.4 gpm / 5.3 L/min............................. EW..........Steering cylinder speed, square end, left side, retract................18-20 ft-lbs / 24-27 Nm 11
Solenoid Valve, 3 position 4 way.................................. ES...........Axle extend contrrol...................................25-27 ft-lbs / 34-37 Nm
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MANIFOLDS
1 EA
3
2 EB
EC
ES 11 ED
4
EW 10
EP 9 EO 8
EV
EU 7
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ET 6
5
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-16 Steer and Axle Extend/Retract Manifold Components - View 2
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end of the machine. Index No. Description 1
Schematic Item Function
Torque
Flow Regulator Valve, 2 gpm / 7.6 L/min................................ EE...........Steering cylinder speed.............................18-20 ft-lbs / 25-27 Nm
2 Flow Regulator Valve, 1.4 gpm / 5.3 L/min............................. EJ............Steering cylinder speed, circle end, left side, retract....................................18-20 ft-lbs / 25-27 Nm 3 Flow Regulator Valve, 1.4 gpm / 5.3 L/min............................. EQ...........Steering cylinder speed, square end, right side, retract..............18-20 ft-lbs / 25-27 Nm 4
Flow Regulator Valve, 2 gpm / 7.6 L/min................................ ER...........Steering cylinder speed, square end, left side, extend...............18-20 ft-lbs / 25-27 Nm
5 Check Valve, 5 psi / 0.34 bar.............. EX...........Axle extend load sense, both ends..........................................12-14 ft-lbs / 16.3-19 Nm 6
Relief Valve, 1800 psi / 124 bar.......... EQQ........Axle extend................................................18-20 ft-lbs / 25-27 Nm
7
Relief Valve, 3000 psi / 207 bar.......... EZ...........Steering pressure limit...............................18-20 ft-lbs / 25-27 Nm (Removed from S-120/125 at serial number 522, S-100/105 at serial number 148)
8 Check Valve, 5 psi / 0.34 bar.............. EY...........Axle retract load sense, both ends..........................................12-14 ft-lbs / 16.3-19 Nm 9
Check Valve, 5 psi / 0.34 bar.............. EKK.........Steering load sense, square end, right side, extend..............................12-14 ft-lbs / 16.3-19 Nm
10 Check Valve, 5 psi / 0.34 bar.............. EII...........Steering load sense, square end, right side, retract...............................12-14 ft-lbs / 16.3-19 Nm 11
Check Valve........................................ EM..........Steering cylinder lock, square end, right side, extend/retract......................18-20 ft-lbs / 25-27 Nm
12 Check Valve, 5 psi / 0.34 bar.............. ENN........Steering load sense, square end, left side, retract.................................12-14 ft-lbs / 16.3-19 Nm 13
Check Valve, 5 psi / 0.34 bar.............. EJJ..........Steering load sense, square end, left side, extend................................12-14 ft-lbs / 16.3-19 Nm
This list continues. Please turn the page.
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Section 4 • Repair Procedures
MANIFOLDS
1 EE
3
2 EJ
EQ
4
5 ER
EX
TP 21
EQQ EZ
EY
EKK
EOO 20
4 - 110
EPP EMM 19
18
EG 17
ELL EH EK EJJ ENN 16
15
14
13
12
EM 11
6 7
8
9
EII 10
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Steer and Axle Extend/Retract Manifold Components - View 2, continued The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end of the machine. Index No. Description
Schematic Item Function
Torque
14
Check Valve........................................ EK...........Steering cylinder lock, square end, left side, extend/retract........................18-20 ft-lbs / 25-27 Nm
15
Check Valve........................................ EH...........Steering cylinder lock, circle end, right side, extend/retract......................18-20 ft-lbs / 25-27 Nm
16 Check Valve, 5 psi / 0.34 bar.............. ELL.........Steering load sense, circle end, right side, retract...............................12-14 ft-lbs / 16.3-19 Nm 17
Check Valve........................................ EG...........Steering cylinder lock, circle end, left side, extend/retract.....................12-14 ft-lbs / 16.3-19 Nm
18
Check Valve, 5 psi / 0.34 bar.............. EMM.......Steering load sense, circle end, right side, extend..............................12-14 ft-lbs / 16.3-19 Nm
19
Check Valve, 5 psi / 0.34 bar.............. EPP.........Steering load sense, circle end, left side, extend................................12-14 ft-lbs / 16.3-19 Nm
20 Check Valve, 5 psi / 0.34 bar.............. EOO........Steering cylinder lock, circle end, left side, retract.................................12-14 ft-lbs / 16.3-19 Nm 21
Diagnostic Nipple Cap........................ TP...........Testing
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Section 4 • Repair Procedures
MANIFOLDS
1 EE
3
2 EJ
EQ
4
5 ER
EX
TP 21
EQQ EZ
EY
EKK
EOO 20
4 - 112
EPP EMM 19
18
EG 17
ELL EH EK EJJ ENN 16
15
14
13
12
EM 11
6 7
8
9
EII 10
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-17 Valve Adjustments - Steer and Axle Extend/Retract Manifold How to Adjust the Steer and Axle Retract Relief Valve Note: Perform this procedure with the axles retracted and the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 345 bar pressure gauge to the test port on the steer and axle extend/retract manifold. 2 Start the engine from the platform controls. 3 Position the machine so that the left front wheel is against an immoveable object such as a curb. 4 Press down the foot switch and activate the steer function. Steer the wheel into the curb and hold. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specifications.
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 Connect a 0 to 5000 psi / 0 to 345 bar pressure gauge to the test port on the steer and axle extend/retract manifold. 2 Start the engine from the platform controls. 3 Press down the foot switch and push the axle extend button. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item EQQ). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified.
5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item EZ). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap.
6 Repeat steps 2 through 5 to confirm relief valve pressure.
Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 6 to confirm relief valve pressure.
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MANIFOLDS
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Section 4 • Repair Procedures
MANIFOLDS
10-18 Traction Manifold Components (S-100/105- to serial number 290) (S-120/125- to serial number 1194)
The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index No. Description
Schematic Item
Function
Torque
1
Solenoid valve, 2 position 3 way......... DA...........2 speed control..........................................25-30 ft-lbs / 38-41 Nm
2
Flow regulator valve, 2 gpm / 7.57 L/min.............................. DB...........Drive slip limit, rear....................................35-40 ft-lbs / 47-54 Nm
3 Flow divider/combiner valve................ DC...........Controls flow to rear drive motors in forward and reverse.....130-140 ft-lbs / 176-190 Nm 4
Flow regulator valve, 2 gpm / 7.57 L/min.............................. DD...........Drive slip limit, front...................................35-40 ft-lbs / 47-54 Nm
5 Flow divider/combiner valve................ DE...........Controls flow to front drive motors in forward and reverse.....130-140 ft-lbs / 176-190 Nm 6
Flow divider/combiner valve................ DF...........Controls flow to front and rear flow divider combiner valves (items DC and DE)......................130-140 ft-lbs / 176-190 Nm
7
Check valve........................................ DG..........Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
8
Check valve........................................ DH...........Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
9
Flow regulator valve, 2.7 gpm / 10.22 L/min......................... DI............Drive slip limit, front and rear.....................35-40 ft-lbs / 47-54 Nm
10
Check valve........................................ DJ...........Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
11
Check valve........................................ DK...........Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
This list continues. Please turn the page.
Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS
1 DA
2 DB
3 DC
DO 17 DD 4
DN 16 15
14
DM DE
5
DP
DF 6
13
12
DL
TP DG
DH
DK 11
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S-100 • S-105 • S-120 • S-125
DJ 10
7
8
DI 9
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Traction Manifold Components, continued
(S-100/105- to serial number 290), (S-120/125- to serial number 1194)
The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index No. Description 12
Schematic Item
Function
Torque
Diagnostic fitting.................................. TP...........Testing
13 Shuttle valve, 3 position 3 way.................................. DL...........Charge pressure circuit that gets hot oil out of low presure side of the drive pump.........................35-40 ft-lbs / 47-54 Nm 14 Check valve, 50 psi / 3.45 bar............. DP...........2 speed/brake charge pressure circuit....................................25-30 ft-lbs / 38-41 Nm 15
Relief valve, 250 psi / 17.2 bar............ DM..........Charge pressure circuit.............................35-40 ft-lbs / 47-54 Nm
16 Orifice - plug, 0.030 inch / 0.762 mm........................ DN...........Brake release and 2 speed shift control 17 Solenoid valve, 2 position 3 way......... DO..........Brake control.............................................25-30 ft-lbs / 38-41 Nm
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Section 4 • Repair Procedures
MANIFOLDS
1 DA
2 DB
3 DC
DO 17 DD 4
DN 16 15
14
DM DE
5
DP
DF 6
13
12
DL
TP DG
DH
DK 11
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S-100 • S-105 • S-120 • S-125
DJ 10
7
8
DI 9
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-19 Traction Manifold Components
(S-100/105- from serial number 291) (S-120/125- from serial number 1195) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index No. Description
Schematic Item
Function
Torque
1
Check Valve........................................ HA...........Anti-cavitation...............................30-35 ft-lbs / 40.7-47.5 Nm
2
Solenoid Valve, 2 position 3 way........ HB...........Two-speed drive motor shift..........26-30 ft-lbs / 35.3-40.7 Nm
3
Solenoid Valve, 2 position 3 way........ HC...........Brake release................................26-30 ft-lbs / 35.3-40.7 Nm
4 Check Valve........................................ HD...........Keeps brakes released if temporary loss of charge pressure.................20-25 ft-lbs / 27.1-33.9 Nm 5 Shuttle Valve, 3 position 3 way........... HE...........Charge pressure circuit that directs hot oil out of low pressure side of drive pump.................................50-55 ft-lbs / 67.8-74.6 Nm 6
Relief Valve, 250 psi / 17.23 bar......... HF...........Charge pressure circuit.................20-25 ft-lbs / 27.1-33.9 Nm
7
Orifice Plug, 0.030 inch / 0.762 mm.... HG..........Brake and two-speed circuit..........20-25 ft-lbs / 27.1-33.9 Nm
8
Check Valve........................................ HH...........Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
9
Check Valve........................................ HI............Anti-cavitation................................30-35 ft-lbs / 40.7-47.5 Nm
10 Flow Divider/Combiner Valve.............. HJ...........Controls flow to square end drive motors in forward and reverse................90-100 ft-lbs / 122-135.6 Nm 11
Check Valve........................................ HK...........Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
12 Bi-directional/Flow Control Valve, 2 gpm / 7.6 L/min................................ HL...........Equalizes pressure on both sides of divider/combiner valve FJ .............30-35 ft-lbs / 40.7-47.5 Nm
This list continues. Please turn the page.
Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS
1 HA
2 HB
3 HC
4 HD
5 HE
HR 18
HQ 17 HF 6
HP 16 HO 15 HG
7
HN 14 HM HH
13
HI
8
9
HJ 10
HL 12
4 - 120
HK 11
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Traction Manifold Components, continued
(S-100/105- from serial number 291), (S-120/125- from serial number 1195) The drive manifold is mounted inside the drive chassis at the circle end of the machine. Index No. Description
Schematic Item
Function
Torque
13 Bi-directional/Flow Control Valve, 2 gpm / 7.6 L/min................................ HM..........Equalizes pressure on both sides of divider/combiner valve FQ.........30-35 ft-lbs / 40.7-47.5 Nm 14 Bi-directional/Flow Control Valve, 2 gpm / 7.6 L/min................................ HN...........Equalizes pressure on both sides of divider/combiner valve FQ.........30-35 ft-lbs / 40.7-47.5 Nm 15
Check Valve........................................ HO..........Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
16 Flow Divider/Combiner Valve.............. HP...........Controls flow to circle end drive motors in forward and reverse................90-100 ft-lbs / 122-135.6 Nm 17 Flow Divider/Combiner Valve.............. HQ..........Controls flow to divider/combiner valves FJ and FP........................90-100 ft-lbs / 122-135.6 Nm 18
Check Valve........................................ HR...........Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS
1 HA
2 HB
3 HC
4 HD
5 HE
HR 18
HQ 17 HF 6
HP 16 HO 15 HG
7
HN 14 HM HH
13
HI
8
9
HJ 10
HL 12
4 - 122
HK 11
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-20 Valve Adjustments Traction Manifold
10-21 Valve Coils
How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the test port located on the drive manifold. 2 Start the engine from the platform controls. 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 4 Turn the engine off. Use a wrench to hold the charge pressure relief valve and remove the cap (item DM or FF). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap.
How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid 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 operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
6 Repeat steps 2 through 5 to confirm the relief valve pressure.
Note: If the machine has been in operation, allow the coil to cool at least 3 hours before performing this test. 1 Tag and disconnect the wiring from the coil to be tested. 2 Test the coil resistance using a multimeter set to resistance (Ω). Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil.
Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS
Valve Coil Resistance Specification
How to Test a Coil Diode
Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 20°C that your air temperature increases or decreases from 68°F / 20°C. Description
Specification
Solenoid valve, 2 position 3 way, 12V DC (schematic item DA, DO, FB, FC)
9Ω
Solenoid valve, 3 position 4 way, 12V DC (schematic item EA, EB, EC, ED) (before serial number 292)
9.8 Ω
Solenoid valve, 3 position 4 way, 12V DC (schematic item EA, EB, EC, ED) (after serial number 291)
8.8 Ω
Proportional solenoid valve, 12V DC (schematic item FG, BG, GD, GH)
5.4 Ω
Proportional solenoid valve, 12V DC (schematic item FB, FF, BB, BF)
5Ω
3 position 4 way D03 valve, 12V DC (schematic item FD, BD)
4.6 Ω
Solenoid Valve, 2 position 3 way, 12V DC (schematic item FQ, FR, BQ, BR)
4.6 Ω
Solenoid Valve, 2 position 2 way, 12V DC (schematic item BN, BO)
7.2 Ω
Solenoid valve, 3 position 4 way 12V (schematic items ES, FC, BC) (before serial number 292)
7.2 Ω
Solenoid valve, 3 position 4 way 12V (schematic items ES) (after serial number 291)
7.1 Ω
Solenoid valve, 2 position 3 way 12V (schematic items AA)
7.2 Ω
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 following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Test the coil for resistance. Refer to, How to Test a Coil. 2 Connect a 10Ω resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. Note: The battery should read 9V DC or more when measured across the terminals.
a AMMETER
COIL
d
-
b
+
c
10 RESISTOR
+
c
9V BATTERY
b
a multimeter b 9V DC battery c 10Ω resistor d coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6
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Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS 3 Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. 4 Connect the negative lead to the other terminal on the coil. Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced.
Part No. 102916
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Section 4 • Repair Procedures
Fuel and Hydraulic Tanks 11-1 Fuel Tank
5 Remove the fuel tank hold down strap retaining fasteners. Remove the straps from the fuel tank.
How to Remove the Fuel Tank
6 Support and secure the fuel tank to an appropriate lifting device.
Explosion and fire hazard. Engine fuels are combustible. Remove the fuel tank in an open, well-ventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Explosion and fire hazard. Never drain or store fuel in an open container due to the possibility of fire.
7 Remove the fuel tank from the machine. Crushing hazard. The fuel tank may become unbalanced and fall if it is not properly supported and secured to the lifting device. Component damage hazard. The fuel tank is plastic and may become damaged if it is allowed to fall. Note: Clean the fuel tank and inspect for cracks and other damage before installing.
1 Remove the fixed engine side turntable cover. See 5-1, How to Remove a Fixed Turntable Cover. 2 Tag, disconnect and 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. See capacity specifications. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. Note: Be sure to only use a hand operated pump suitable for use with diesel fuel.
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Section 4 • Repair Procedures
FUEL AND HYDRAULIC TANKS
11-2 Hydraulic Tank
2 Close the two hydraulic shutoff valves located at the hydraulic tank.
The primary functions of the hydraulic tank are to cool, clean and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a filter condition indicator.
How to Remove the Hydraulic Tank
open
Component damage hazard. Be sure that the hydraulic tank shutoff valves are in the open position before priming the pump. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. If the hydraulic tank shutoff valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.
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. 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 ground controls side turntable cover. See 5-1, How to Remove a Hinged Turntable Cover.
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closed
3 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container. See capacity specifications.
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FUEL AND HYDRAULIC TANKS 4 Remove the ground controls support bracket retaining fasteners. Remove the ground controls assembly from the machine.
12 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall if it is not properly supported and secured to the overhead crane.
Component damage hazard. Be sure to properly support the ground control box. Do not allow the ground controls to hang by the wiring. Component damage hazard. The ground control box wiring can be damaged if it is kinked or pinched.
Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank. See 9-2, How to Prime the Pumps.
5 Tag and disconnect the wiring from the horn.
Note: Always use pipe thread sealant when installing the drain plug and strainers.
6 Remove the horn retaining fasteners. Remove the horn from the machine.
Note: Refer to Specifications, Machine Specifications for hydraulic oil requirements.
7 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves. 8 Tag, disconnect and plug the supply hose for the auxiliary 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.
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Section 4 • Repair Procedures
Turntable Rotation Components 12-1 Turntable Rotation Hydraulic Motor and Drive Hub
3 Tag, disconnect and plug the hydraulic hoses from the manifold that is mounted to the motor. 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.
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 Specifications.
4 Remove the motor/brake mounting fasteners. Remove the motor from the brake. a
1 Secure the turntable from rotating with the turntable rotation lock pin.
b c
unlocked
locked
2 Remove the ground controls side fixed turntable cover. See 5-1, How to Remove a Fixed Turntable Cover.
e
d
a motor b motor/brake mounting bolts c brake d drive hub mounting bolts e drive hub
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Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable Rotation Drive Hub
4 Attach a lifting strap from an overhead crane or other suitable lifting device to the drive hub. 5 Remove the drive hub mounting bolts and remove the drive hub from the machine.
1 Secure the turntable from rotating with the turntable rotation lock pin.
unlocked
Tip-over hazard. If the turntable rotation lock pin is not properly installed, machine stability is compromised and the machine could tip over when the drive hub is removed from the machine, which could result in death or serious injury.
locked
Crushing hazard. The drive hub may become unbalanced and fall if it is not properly supported by the overhead crane or lifting device.
2 Remove the turntable rotation motor. See How to Remove the Turntable Rotation Hydraulic Motor. 3 Remove the brake from the drive hub and set it off to the side.
6 Remove the plug from the side of the drive hub. Drain the oil from the hub.
a
Installing the Drive Hub:
b
7 Install the drive hub. Use blue thread locking seal on all bolts. Torque the drive hub mounting bolts to 280 ft-lbs / 380 Nm.
c
8 Install the brake onto the drive hub and torque the mounting fasteners to 20 ft-lbs / 27 Nm. 9 Install the motor onto the brake and torque the mounting fasteners to 93 ft-lbs / 126 Nm.
e
9 Fill the drive hub with oil from the side hole until the oil level is even with the bottom of the hole. Apply pipe thread sealant to the plugs and install the plugs. Refer to Specifications, Specifications.
d
a motor b motor/brake mounting bolts c brake d drive hub mounting bolts e drive hub
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10 Adjust turntable rotation gear backlash.
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Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is adjustable to control the gap between the rotation motor gear and the turntable bearing. Note: Be sure to check the backlash with the machine on a flat level surface. 1 Secure the turntable from rotating with the turntable rotation lock pin.
a a b unlocked
locked
b
adjustment bolt with lock nut pivot plate mounting bolts
4 Loosen the lock nut on the turntable drive hub adjustment bolt.
2 Remove the ground controls side fixed turntable cover. See 5-1, How to Remove a Fixed Turntable Cover.
5 Tighten the turntable drive hub adjustment bolt until the turntable drive hub gear is fully engaged and tight into the turntable rotate gear.
3 Loosen the turntable rotate drive hub mounting bolts. Do not remove them.
6 Turn the adjustment bolt 3/4 turn counterclockwise. Tighten the lock nut on the adjustment bolt.
Note: It may be necessary to raise the boom slightly to access all the turntable rotate drive hub mounting bolts.
7 Rotate the drive hub away from the turntable rotate gear until it contacts the adjustment bolt. Torque the turntable rotate drive hub mounting bolts. Refer to Specifications, Machine Torque Specifications. 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding.
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Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
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Section 4 • Repair Procedures
Axle Components 13-1 Steer Sensors
Measure the circle-end tires: 3 Press the square-end steer mode button.
The steer sensor measures steer angle and communicates that information to the ground controls ECM. The steer sensor on the ground controls side of the machine at the square end acts as the lead sensor. The other three sensors follow the position, or steer angle, of the lead sensor. There is a steer sensor mounted to the top of each upper yoke pivot pin. Note: If the square-end steering function becomes inoperative, switch to circle-end steer mode and the ground controls side circle-end steer sensor will become the lead sensor.
4 Measure the distance between the inside of one circle-end tire and the chassis side plate on both sides of the axle. Measure here
Square-end
Circle-end
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.
Part No. 102916
Result: Both measurements should be the same to indicate that the tires are parallel with the chassis. Note: If the measurements are different or if a tire is not parallel with the chassis, the steer sensor of that tire will need to be adjusted. See How to Adjust a Steer Sensor. 5 Repeat step 4 for the other circle-end tire.
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Section 4 • Repair Procedures
AXLE COMPONENTS Measure the square-end tires:
How to Adjust a Steer Sensor
6 Press the circle-end steer mode button.
Square-end steer sensors:
7 Measure the distance between the inside of one square-end tire and the chassis side plate on both sides of the axle.
1 At the platform controls, press the circle-end steer mode button.
Measure here
2 Locate the steer sensor on top of the yoke pivot pin. 3 Loosen the steer sensor cover retaining fasteners. Do not remove them.
Square-end
Circle-end
4 Rotate the steer sensor cover either clockwise or counterclockwise. Measure the distance between the inside of tire and the chassis side plate on both sides of the axle. Measure here
Result: Both measurements should be the same to indicate that the tires are parallel with the chassis.
Square-end
Circle-end
Note: If the measurements are different or if a tire is not parallel with the chassis, the steer sensor of that tire will need to be adjusted. See How to Adjust a Steer Sensor. 8 Repeat step 4 for the other square-end tire.
5 Repeat step 4 until the tire is parallel with the chassis. 6 Tighten the steer sensor cover fasteners. 7 Repeat steps 2 through 6 for the other squareend steer sensor.
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AXLE COMPONENTS Circle-end steer sensors: 8 At the platform controls, press the square-end steer mode button. 9 Locate the steer sensor on top of the yoke pivot pin. 10 Loosen the steer sensor cover retaining fasteners. Do not remove them. 11 Rotate the steer sensor cover either clockwise or counterclockwise. Measure the distance between the inside of tire and the chassis side plate on both sides of the axle. Measure here
Square-end
Circle-end
13-2 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that may require periodic replacement. There is a steer sensor mounted to the upper yoke pivot pin. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the hose hanger bracket retaining fasteners mounted to the top of the yoke. Remove the hose hanger bracket from the machine. 2 Tag, disconnect and plug the hydraulic hoses from the drive motor and brake assembly. Cap the fittings on the drive motor and brake.
12 Repeat step 4 until the tire is parallel with the chassis. 13 Tighten the steer sensor cover fasteners. 14 Repeat steps 9 through 13 for the other circleend steer sensor.
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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.
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Section 4 • Repair Procedures
AXLE COMPONENTS 3 Mark the mounting position of the steer sensor cover on the yoke. Note: It is very important that the steer sensor is installed in the exact position it was in prior to removal. If the steer sensor is not installed correctly, the steer function may operate improperly. If any steer functions operate improperly after removing and installing a steer sensor, see 13-1, How to Adjust a Steer Sensor. 4 Remove the steer sensor cover retaining fasteners. Carefully remove the steer sensor cover and lay it out of the way. Component damage hazard. The steer sensor is a very sensitive instrument. It can be damaged internally if it is dropped or sustains any physical shock, even if the damage is not visible. 5 Lay the hoses and steer sensor cable out of the way. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 6 Mark the mounting position of the steer sensor activator 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 steer functions operate improperly after removing and installing a steer sensor activator pin, see 13-1, How to Adjust a Steer Sensor. 8 Loosen the wheel lug nuts. Do not remove them. 9 Center a lifting jack of ample capacity under the axle of the yoke and drive hub to be removed. Do not raise the machine. 10 Block the wheels at the opposite end of the machine. 11 Raise the machine approximately 6 inches (15 cm) and place blocks under the chassis for support. 12 Remove the lug nuts and remove the tire and wheel assembly. 13 Remove the drive motor mounting fasteners. 14 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine. 15 Remove the pin retaining fasteners from the steering cylinder rod-end pivot pins. Remove the pins. 16 Remove the pin retaining fasteners from the upper and lower yoke pivot pins.
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Section 4 • Repair Procedures
AXLE COMPONENTS 17 Support the yoke/drive hub assembly with a lifting jack. Secure the yoke/drive hub assembly to the lifting jack.
13-3 Drive Motor
18 Use a soft metal drift to remove both yoke pivot pins.
How to Remove a Drive Motor Component damage hazard. Repairs to the motor should only be performed by an authorized dealer.
19 Remove the yoke/drive hub assembly from the machine. Crushing hazard. The yoke/ hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack.
Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended.
20 Place the yoke/drive hub assembly on a flat surface with the drive hub facing down. 21 Remove the drive hub mounting fasteners that attach the yoke to the drive hub. Remove the yoke weldment from the drive hub. Note: Replace the thrust washer with a new one when installing the yoke/drive hub assembly onto the axle. Refer to Specifications, Machine Torque Specifications.
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 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the drive motor. 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. 2 Remove the drive motor mounting fasteners. 3 Slide the drive motor shaft out of the brake and drive hub. Remove the drive motor from the machine.
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Section 4 • Repair Procedures
AXLE COMPONENTS
13-4 Drive Hub
8 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack.
How to Remove a Drive Hub
9 Remove the drive hub mounting bolts that attach the drive hub to the yoke. Remove the drive hub from the machine.
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 drive motor. See 13-3, How to Remove a Drive Motor.
Crushing hazard. The drive hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack. Refer to Specifications, Machine Torque Specifications.
2 Tag, disconnect and plug the hydraulic hose from the brake. Cap the fittting on the brake. 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. 3 Loosen the wheel lug nuts. Do not remove them. 4 Center a lifting jack of ample capacity under the axle of the drive hub to be removed. Do not raise the machine. 5 Block the wheels at the opposite end of the machine. 6 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. 7 Remove the wheel lug nuts. Remove the tire and wheel assembly.
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Section 4 • Repair Procedures
AXLE COMPONENTS
13-5 Steer Cylinders
7 Place a rod through each steer cylinder pivot pin and twist to remove the pins.
How to Remove a Steering Cylinder 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 Locate the hose bracket mounted to the steer cylinder.
8 Remove the steering cylinder from the machine.
2 Remove the hose bracket cover retaining fasteners. Remove the hose bracket cover.
Crushing hazard. The steer cylinder may become unbalanced and fall if it is not properly supported by the lifting device.
3 Remove the hose bracket retaining fasteners from the steering cylinder. 4 Tag, disconnect and plug the hydraulic hoses from the steering cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Remove the pin retaining fasteners from the steer cylinder pivot pins. 6 Support the steer cylinder with a suitable lifting device.
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Section 4 • Repair Procedures
AXLE COMPONENTS
13-6 Extendable Axles
Top and bottom wear pads:
The extendable axles are used to widen the foot print of the drive chassis for stability.
How to Shim an Extendable Axle Note: Measure each wear pad. Replace the wear pad if it is less than 7/16 inch / 11 mm thick. If the wear pad is 7/16 inch / 11 mm thick or more, perform the following procedure. 1 Fully extend the axle. 2 Remove the wear pad retaining fasteners. Side wear pads: 3 Install the new shims under the wear pad to obtain zero clearance and zero drag. 4 Use a round punch through the wear pad mounting holes to align the shims with the wear pad. Install the wear pad retaining fasteners.
3 Center a lifting jack of ample capacity under the axle that needs to be shimmed. Do not raise the machine. 4 Block the wheels at the opposite end of the machine. 5 Raise the machine just until the weight of the machine is relieved off of the axle. Do not raise the wheels off of the ground. 6 Install the new shims under the wear pad to obtain zero clearance and zero drag. 7 Use a round punch through the wear pad mounting holes to align the shims with the wear pad. Install the wear pad retaining fasteners. 8 Extend and 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.
5 Extend and 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.
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Section 4 • Repair Procedures
AXLE COMPONENTS
How to Remove an Inner Axle 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. Note: Perform this procedure with the tires parallel to the chassis and the axles fully extended.
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.
1 Remove the top drive chassis cover.
11 Remove the cotter pin from the axle extension cylinder clevis pin.
2 Remove the yoke and hub assembly. See 13-2, How to Remove the Yoke and Hub.
Note: Alwayse use a new cotter pin when installing a clevis pin.
3 Remove the steering cylinder. See 13-5, How to Remove a Steering Cylinder. 4 Remove the axle cover retaining fasteners located above the axle. Remove the chassis cover from the machine.
12 Use a soft metal drift to remove the axle extension cylinder clevis pin. 13 Carefully support and slide the inner axle out of the chassis. Remove the axle from the machine.
5 Remove the upper wear pad retainer plate retaining fasteners. Remove the plate from the machine.
Crushing hazard. The inner axle may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.
6 Attach a lifting strap from an overhead crane of ample capacity to the inner axle for support. Do not lift it.
Component damage hazard. The aluminum limit switch track and the axle extension cylinder may become damaged if the axle is allowed to fall when it is removed from the machine.
7 Remove the retaining fasteners from the upper and lower wear pads at the outer axle. Do not remove the side wear pads. Note: Pay careful attention to the location and amount of shims used with each wear pad.
Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. Note: When installing an inner axle, there needs to be a minimum of 1/8 inch / 3.1 mm gap between the proximity switches and the aluminum limit switch track. Measure the gap with the axles in both the retracted and extended positions. Adjust the proximity switches as necesary to obtain a 1 /8 inch / 3.1 mm gap.
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Section 4 • Repair Procedures
AXLE COMPONENTS
How to Remove the Axle Extension Cylinder
7 Attach a lifting strap from an overhead crane to the end of the axle extension cylinder.
1 Remove a yoke and hub assembly. See 13-2, How to Remove the Yoke and Hub. 2 Remove the axle. See How to Remove an Inner Axle. 3 Remove the access covers from the end of the remaining axle. 4 Tag, disconnect and plug the axle extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Tag and disconnect the wiring connectors from the proximity switches and limit switch. Do not remove the switches. Note: The wiring connectors for the switches can be accessed through the access holes on either side of the chassis end plate.
Note: Attach the lifting strap to the end of the cylinder that has the inner axle removed. 8 Remove the cotter pin from the axle extension cylinder clevis pin on the remaining inner axle. Note: Alwayse use a new cotter pin when installing a clevis pin. 9 Use a soft metal drift to remove the pin. Crushing hazard. The axle extension cylinder may fall if it is not properly supported. Component damage hazard. The axle extension cylinder and limit switches can become damaged if the axle extension cylinder is allowed to fall. 10 Carefully support and slide the axle extension cylinder out of the axle. Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.
6 Place blocks under the axle extension cylinder for support.
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Section 5 • Diagnostic Codes
Diagnostic Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-100, S-105, S-120, S-125 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use.
Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.
Read each appropiate fault code thoroughly. Attempting shortcuts may produce hazardous conditions.
Immediately tag and remove from service a damaged or malfunctioning machine.
Be aware of the following hazards and follow generally accepted safe workshop practices.
Repair any machine damage or malfunction before operating the machine.
Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement.
Unless otherwise specified, perform each repair procedure with the machine in the following configuration:
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between the non-steer wheels
• Turntable secured with the turntable rotation lock
• Key switch in the off position with the key removed
• Wheels chocked
• All external AC power disconnected from the machine
Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 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. Note: Perform all troubleshooting on a firm, level surface. Note: Two persons will be required to safely perform some troubleshooting procedures.
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Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Fault Diagnostics Control System How to Read Control System Fault Codes Note: Initial fault testing occurs at power-up.
Faults are abnormal conditions that exist due to component failure or System misuse. CPU, memory, LCD, LED, limited joystick and limited operator switch testing is done on power-up. If an operator switch is depressed on power-up, the display should show and error and not allow any machine functions.
Releasing the switch will clear the error and allow all machine functions. The joystick operates similarly.
All other fault testing is done continuously.
1 When a fault is diagnosed, the PCON fault indicator will flash and a fault message will be displayed on the TCON LCD. The message will contain the fault source and type. 2 Additional information, including the occurrence counter and a time-stamp is available with a PC, connected to one of the RS232 ports. Up to 16 unique fault messages can be saved. Each fault is saved with the device identity, fault type, engine hour time-stamp and an 8-bit occurrence counter. 3 The fault code table on the following pages lists the functions or components monitored by the system.
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Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Not calibrated
Normal function except threshold for one or the other direction is zero, Display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Not calibrated
Normal function except threshold for one or the other direction is zero, Display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Primary Boom Ext/Ret Flow Valve Value at 5.0 V Value Too High Value Too Low Value at 0 V
Primary Boom Up/Down Flow Valve
Value at 5.0 V Value Too High Value Too Low Value at 0 V
Primary Boom Extend Valve Fault Check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Range Check (underspeed) Range Check (low oil pressure) Range Check (high temperature)
Display message on LCD
Power up controller with problem corrected
Fault Check
Display message on LCD
Power up controller with problem corrected
Axle Extend/Retract Buttons
Fault Check (both buttons pressed)
Axle Extend/Retract disabled, display message on LCD
Power up controller with problem corrected
Axle Valves
Fault Check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Primary Boom Retract Valve Primary Boom Up Valve Primary Boom Down Valve Engine Speed Oil Pressure Water/Oil Temp Water/Oil Temp Sensor Oil Pressure Sensor
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Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Value at 5.0 V Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Not calibrated
Joystick Speed and Direction frozen at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Not calibrated
Joystick Speed and Direction frozen at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Joystick Speed and Direction frozen at zero and neutral
Calibrate Joystick
Value Too High Value Too Low Primary Ext/Ret Joystick
Value at 0 V
Value at 5.0 V Value Too High Value Too Low Primary Up/Down Joystick
Value at 0 V
Value at 5.0 V Value Too High Value Too Low Value at 0 V Steer Joystick
Not calibrated
Just calibrated
Initiate one second beep of audible warning device
Primary Boom Up/Down switches on TCON
Fault Check (both buttons pressed)
Primary Boom Up/Down disabled, display message on LCD
Primary Boom Ext/Ret switches on TCON
Fault Check (both buttons pressed)
Primary Boom Ext/Retract disabled, display message on LCD
Primary Boom Length
Fault Check (unknown length)
Primary Boom Angle
Fault Check (unknown angle)
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Self-clearing (transient) Power up controller with problem corrected Power up controller with problem corrected Power up controller with problem corrected
Stop all boom functions, allow only boom retract, once fully retracted allow boom down. Display message on LCD Stop all boom functions, allow only Power up controller with boom retract. Display message on LCD problem corrected
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Primary Up/Down Speed
Not calibrated
Display message on LCD and allow operation at default speed
Perform auto calibrate precedure
Display message on LCD and allow operation at default speed
Perform auto calibrate precedure
Primary Extend/Retract Speed
Not calibrated
SAFETY SWITCH P3
Display message on LCD P3 SAFETY SWITCH FAULT
SAFETY SWITCH P6R1
Display message on LCD P6R1 SAFETY SWITCH FAULT
SAFETY SWITCH P6R2
Display message on LCD P6R2 SAFETY SWITCH FAULT
SAFETY SWITCH P7
Display message on LCD P7 SAFETY SWITCH FAULT
SAFETY SWITCH P7R
Display message on LCD P7R SAFETY SWITCH FAULT
SAFETY SWITCH P9A
Display message on LCD P9A SAFETY SWITCH FAULT
SAFETY SWITCH P9B
Fault Check
Display message on LCD P9B SAFETY SWITCH FAULT
SAFETY SWITCH P10
Display message on LCD P10 SAFETY SWITCH FAULT
SAFETY SWITCH P11
Display message on LCD P11 SAFETY SWITCH FAULT
SAFETY SWITCH P12
Display message on LCD P12 SAFETY SWITCH FAULT
SAFETY SWITCH P14
Display message on LCD P14 SAFETY SWITCH FAULT
SAFETY SWITCH P18
Display message on LCD P18 SAFETY SWITCH FAULT
SAFETY SWITCH P22
Display message on LCD P22 SAFETY SWITCH FAULT
SAFETY SWITCH P22R
Display message on LCD P22R SAFETY SWITCH FAULT
CAN Bus
Part No. 102916
Fault Check
Display message on LCD
S-100 • S-105 • S-120 • S-125
Power up controller with problem corrected
Power up controller with problem corrected
5-5
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source Primary Boom Lock-Out Valve #1 Primary Boom Lock-Out Valve #2 Platform Overload Shut Down Mode
Error Type
Effects
Recovery Actions
Fault Check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Fault Check (if active)
Display message on LCD
Power up controller with problem corrected
Value at 5.0 V Value Too High Value Too Low Turntable Rotate Joystick
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Value at 0 V Not calibrated
Just calibrated
Joystick Speed and Direction frozen at zero and neutral
Calibrate Joystick
Initiate one second beep of audible warning device
Self-clearing (transient)
TT rotate disabled, display message on Power up controller with problem corrected LCD
Turntable Rotate Buttons
Fault Check (both buttons pressed)
Turntable Rotate Speed
Not calibrated
Display message on LCD and allow operation at default speed
Perform auto calibrate procedure
Not calibrated
Normal function except threshold for one or the other directions is zero,display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Turntable Rotate Flow Valve
Value at 5.0 V Value Too High Value Too Low Value at 0 V Turntable Rotate CW Valves Turntable Rotate CCW Valves
Fault Check
Limited Speed and Direction frozen at Power up controller with zero and neutral, Alarm sounds problem corrected
Fault Check
Display message on LCD and sound audible alarm
Turntable Level Sensor X-Direction Turntable Level Sensor Y-Direction
Correct problem
Platform Level Sensor Y-Direction
5 - 6
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Not calibrated
Joystick Speed and Direction frozen at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
Value at 5.0 V Value Too High Value Too Low Propel Joystick
Value at 0 V
Not calibrated Just calibrated Propel Valves (High Current)
Calibrate Thresholds Self-clearing (transient)
Value at 5.0 V Value Too High Value Too Low Value at 0 V
Motor Speed Valve
Normal function except threshold for one or the other direction is zero, Display 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
Power up controller with problem corrected
Shut down engine, Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Fault Check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Fault Check (both buttons pressed)
Affected functions disabled, display message on LCD
Power up controller with problem corrected
Display message on LCD
Recycle power
Disable Generator, Display message on LCD Display
Power up controller with problem corrected
Fault Check
Brake Valve Platform Level Up Valve Platform Level Down Valve Platform Rotate CW Valve Platform Rotate CCW Valve Jib Up Valve Jib Down Valve Jib Switches Platform Rotate Switches Platform Level Switches Footswitch Timeout Hydraulic Generator/Welder - Bypass Valve
Part No. 102916
Fault Check
S-100 • S-105 • S-120 • S-125
5-7
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Not calibrated
Joystick Speed and Direction frozen at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible warning device
Self-clearing (transient)
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 SteeringJoystick
Value at 0 V
Value at 5.0 V Value Too High LF Steer Angle Sensor
Value Too Low Value at 0 V Value at 5.0 V Value Too High
RF Steer Angle Sensor
Value Too Low
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Value at 0 V Value at 5.0 V Value Too High LR Steer Angle Sensor
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Fault Check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Power up controller with problem corrected
Fault Check
Display message on LCD
Power up controller with problem corrected
Value Too Low Value at 0 V Value at 5.0 V
RR Steer Angle Sensor
Value Too High Value Too Low Value at 0 V
LF Steer Valves RF Steer Valves LR Steer Valves RR Steer Valves Hydraulic Generator/Welder - Bypass Valve
5 - 8
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES P_38-Propel (P13-17 TCON) P_22-Jib Jib Lvl Pwr
P_39-Turntable Rotate (P13-19 TCON) P_22R - Primary Up/Down FC
P_10-Primary Boom Extend (P12-08 TCON) P_12 - Axle Retract (P121-08 SCON)
P_38
P_39
Turntable tilt axis (+5°, secondary boom not stowed) Primary Boom Angle (crosscheck)
OFF
OFF
OFF
OFF
OFF
OFF
OFF*
Primary Boom Length (crosscheck)
OFF
OFF
OFF
OFF
OFF*
Primary 2 Cylinder (crosscheck)
OFF
OFF
OFF*
Boom Envelope Safety Interlock
OFF
Axle Safety Not Stowed
OFF
Axles crosscheck Angle sensor vs. safety switch(es) Axle (not fully extended) and TT Rotate (stowed and in drive disable zone) Turntable Tilt Angle (crosscheck SCON internal sensor 3 in a delta configuration) Loss of CAN
OFF
P_10
P_11-Primary Up (P12-09 TCON)
P_11
P_9A
P_9A-Primary Down (P12-06 TCON)
P_9B
P_22R
P_12
OFF
OFF
OFF
OFF OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF*
Platform Overload (SCON pin #1)
OFF OFF
Platform Out of Level (>10°)
OFF
Jib Bellcrank Out of Level (>10°)
OFF
Boom Safety (max angle)
OFF
OFF
Boom Safety (max length)
OFF
OFF
OFF OFF
OFF
OFF OFF
Axle Retract Safety Cable Tension (#1 or #2)
P_22
P_9BIgnition/Fuel (P12-07 TCON)
OFF OFF
OFF
* P-9A and P-10 energized if boom is fully retracted as indicated by LSB3RS
Part No. 102916
S-100 • S-105 • S-120 • S-125
5-9
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES Fault Source and Type will display as: Source " ID XXX_xx FAULT "
Type
Where XXX is the one to three digit Fault Source and xx is the two digit Fault Type. TCON - Turntable Controller PCON - Platform Controller SCON - Safety Controller DCON - Drive Controller Fault Type ID Description 11 Value at 5V 12 Value too High 13 No Response 15 Value too Low 16 Value at 0V 17 Not Calibrated 21 Fault 26 Timeout 31 Invalid Setup 32 Min Cal Too Low 33 Min Cal Too High
5 - 10
Fault Source ID Description 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 40 Turntable Rotate Joystick 43 Footswitch Timeout 44 Jib Up/Down Joystick 48 PBMAS Safety Envelope (SCON) 49 Jib Up/Down Buttons 50 Jib Up/Down Flow Valve 52 Steer Joystick 53 Left Front Steer Sensor 54 Right Front Steer Sensor 55 Left Rear Steer Sensor 56 Right Rear Steer Sensor 59 Rocker Steer Joystick 61 PBMLS Safety Envelope (SCON) 63 Front Axle Sensor 64 Rear Axle Sensor
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES
Fault Source ID Description 65 Turntable Level Sensor X-Direction 66 Turntable Level Sensor Y-Direction 67 Boom Length Sensor Cross-Check (SCON) 68 Boom Safety Envelope (SCON) 70 Turntable Controller - Platform Controller Software Version 73 Engine Pressure Sensor 74 Engine Temperature Sensor 75 LSB2RO/LSB4EO Cross-Check 80 TCON/SCON Calibration Inconsistent 81 Boom Up/Down Flow Valve (Fine) 82 Boom Extend/Retract Flow Valve 83 Boom Extend/Retract Speed 85 Boom Up/Down Speed 86 Boom Angle Sensor 90 Jib Rotate Flow Valve 91 Turntable Rotate Buttons 92 Turntable Rotate Flow Valve 93 Turntable Rotate Speed 94 Boom Length Sensor 95 Jib Rotate Joystick 98 Platform Level Sensor 99 Platform Level Buttons 110 Platform Rotate Buttons 113 Jib Rotate Buttons 117 Propel Power P38 118 Turntable Rotate Power P39 121 Valve Power P6R1 122 Engine Power P6R2 123 Enable Input Power P7
Part No. 102916
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 Power P22R 134 DCON Valve Power P7R 142 Turntable Rotate CW Valve 143 Turntable Rotate CCW Valve 144 Axle Safety Not Stowed (SCON) 145 Boom Up Valve 146 Boom Down Valve 147 Platform Overload Switches Inconsistent (SCON) 148 Boom Extend Valve 149 Boom Retract Valve 152 Boom Up/Down Flow Valve (Gross) 153 Primary Lockout P1 Valve 154 Primary Lockout P2 Valve 157 Axles Fully Extended Cross-Check (SCON) 158 Drive Disable Zone and Axles Not Fully Extended (SCON) 160 Left Front Steer Valve 161 Right Front Steer Valve 162 Left Rear Steer Valve 163 Right Rear Steer Valve 164 Axle Valve 165 Boom Not Retracted and Chassis Tilted (SCON)
S-100 • S-105 • S-120 • S-125
5 - 11
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES
Fault Source ID Description 166 Brake Valve 167 Motor Shift Valve 168 Chassis Tilt Sensors Cross-Check (SCON) 170 Jib Bellcrank Level Sensor 171 Jib Bellcrank Level Flow Valve 172 AUX Relay 173 Platform Level Toggle Switch 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/Generator Valve 245 Check Machine Software Type at TCON 246 Check Machine Software Type at SCON 247 TCON/SCON Software Inconsistent
5 - 12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP
Description
51
3
1019
EGR-Valve, short circuit to battery
51
3
1024
Position sensor error of actuator EGR-Valve; signal range check high
51
3
1226
EGR-Valve; short circuit to battery (A02)
51
3
1227
EGR-Valve; short circuit to battery (A67)
51
4
1020
EGR-Valve; short circuit to ground
51
4
1025
Position sensor error of actuator EGR-Valve; signal range check low
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
Actuator error EGR-Valve; Power stage over temp due to high current
51
12
1018
Actuator EGR-Valve; powerstage over temperature
51
12
1021
Mechanical actuator defect EGR-Valve
51
12
1225
Actuator EGR-Valve; over temperature
51
4
1228
EGR-Valve; short circuit to ground (A02)
94
1
474
51
4
1229
EGR-Valve; short circuit to ground (A67)
Low fuel pressure; warning threshold exceeded
94
1
475
51
4
1232
Actuator error EGR-Valve; Voltage below threshold
Low fuel pressure; shut off threshold exceeded
94
3
472
51
5
1015
Actuator error EGR-Valve; signal range check low
Sensor error low fuel pressure; signal range check high
94
4
473
51
5
1017
Actuator EGR-Valve; open load
Sensor error low fuel pressure; signal range check low
51
5
1023
Actuator error EGR-Valve; signal range check low
97
3
464
Sensor error water fuel; signal range check high
51
5
1223
Actuator EGR-Valve; open load
97
4
465
Sensor error water fuel; signal range check low
51
6
1014
Actuator error EGR-Valve; signal range check high
97
12
1157
Water in fuel level prefilter; maximum value exceeded
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 13
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP
Description
100
0
734
High oil pressure; warning threshold exceeded
100
0
735
High oil pressure; shut off threshold exceeded
100
1
736
Low oil pressure; warning threshold exceeded
100
1
737
Low oil pressure; shut off threshold exceeded
100
3
732
Sensor error oil pressure; signal range check high
100
4
733
Sensor error oil pressure; signal range check low
102
2
88
Charged air pressure above warning threshold
102
2
89
Charged air pressure above shut off threshold
102
4
777
Sensor error charged air press; signal range check low
105
0
996
High charged air cooler temperature; warning threshold exceeded
105
0
997
High charged air cooler temperature; shut off threshold 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
5 - 14
SPN FMI KWP
Description
108
3
412
Sensor error ambient air press; signal range check high
108
4
413
Sensor error ambient air press; signal range check low
110
0
98
High coolant temperature; warning threshold exceeded
110
0
99
High coolant temperature; shut off threshold exceeded
110
3
96
Sensor error coolant temp; signal range check high
110
4
97
Sensor error coolant temp; signal range check low
111
1
101
Coolant level too low
132
11
1
Air flow sensor load correction factor exceeding the maximum drift limit; plausibility error
132
11
2
Air flow sensor load correction factor exceeding drift limit; plausibility error
132
11
3
Air flow sensor low idle correction factor exceeding the maximum drift limit
132
11
4
Air flow sensor load correction factor exceeding the maximum drift limit
157
3
877
Sensor error rail pressure; signal range check high
157
4
878
Sensor error rail pressure; signal range check low
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP
Description
168
0
1180
Physical range check high for battery voltage
168
1
1181
Physical range check low for battery voltage
168
2
47
High battery voltage; warning threshold exceeded
168
2
48
Low battery voltage; warning threshold exceeded
168
3
45
Sensor error battery voltage; signal range check high
168
4
46
Sensor error battery voltage; signal range check low
171
3
417
Sensor error environment temperature; signal range check high
171
4
418
Sensor error environment temperature; 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 check high for oil temperature
175
0
745
High oil temperature; warning threshold exceeded
175
0
746
High oil temperature; shut off threshold exceeded
175
1
741
Physical range check low for oil temperature
175
2
738
Sensor oil temperature; plausibility error
175
2
739
Sensor oil temperature; plausibility error oil temperature too high
175
3
743
Sensor error oil temperature; signal range check high
175
4
744
Sensor error oil temperature; signal range check low
172
0
1182
Physical range check high for intake air temperature
190
0
389
172
1
1183
Physical range check low for intake air temperature
Engine speed above warning threshold (FOC-Lewel 1)
190
2
421
172
2
9
Sensor ambient air temperature; plausibility error
Offset angle between crank and camshaft sensor is too large
190
8
419
172
2
983
Intake air sensor; plausibility error
Sensor camshaft speed; disturbed signal
172
3
981
Sensor error intake air; signal range check high
172
4
982
Sensor error intake air; signal range check low
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 15
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP
Description
190
8
422
Sensor crankshaft speed; disturbed signal
190
11
390
Engine speed above warning threshold (FOC-Lewel 2)
190
12
420
Sensor camshaft speed; no signal
190
12
423
Sensor crankshaft speed; no signal
190
14
391
Engine speed above warning threshold (Overrun Mode)
190
14
1222
Camshaft and Crankshaft speed sensor signal not available on CAN
411
0
791
Physical range check high for differential pressure Venturiunit (EGR)
411
1
792
Physical range check low for differential pressure Venturiunit (EGR)
411
3
795
Sensor error differential pressure Venturiunit (EGR); signal range check high
411
4
381
Physical range check low for (EGR) differential pressure
411
4
796
Sensor error differential pressure Venturiunit (EGR); signal range check low
5 - 16
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-Receive-Frame TSC1TR; Setpoint
597
2
49
Break lever mainswitch and break lever redundancy switch status not plausible
624
3
971
SVS lamp; short circuit to batt
624
4
972
SVS lamp; short circuit to grd
624
5
969
SVS lamp; open load
624
12
970
SVS lamp; powerstage over temperature
630
12
376
Access error EEPROM memory (delete)
630
12
377
Access error EEPROM memory (read)
630
12
378
Access error EEPROM memory (write)
639
14
84
CAN-Bus 0 "BusOff-Status"
651
3
580
Injector 1 (in firing order); short circuit
651
4
586
High side to low side short circuit in the injector 1 (in firing order)
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol
SPN FMI KWP
Description
677
3
956
SPN FMI KWP
Description
Starter relay high side; short circuit to battery
651
5
568
Injector 1 (in firing order); interruption of electric connection
677
3
960
Starter relay low side; short circuit to battery
652
3
581
Injector 2 (in firing order); short circuit
677
4
957
Starter relay high side; short circuit to ground
652
4
587
High side to low side short circuit in the injector 2 (in firing order)
677
4
961
Starter relay low side; short circuit to ground
652
5
569
Injector 2 (in firing order); interruption of electric connection
677
5
958
Starter relay; no load error
677
12
959
653
3
582
Injector 3 (in firing order); short circuit
Starter relay; powerstage over temperature
703
3
426
653
4
588
High side to low side short circuit in the injector 3 (in firing order)
Engine running lamp; short circuit to battery
703
4
427
653
5
570
Injector 3 (in firing order); interruption of electric connection
Engine running lamp; short circuit to ground
703
5
424
Engine running lamp; open load
703
12
425
Engine running lamp; powerstage over temperature
729
5
545
Cold start aid relay open load
729
12
547
Cold start aid relay; over temperature error
898
9
305
Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
1079 13
946
Sensor supply voltage monitor 1 error (ECU)
1080 13
947
Sensor supply voltage monitor 2 error (ECU)
654
3
583
Injector 4 (in firing order); short circuit
654
4
589
High side to low side short circuit in the injector 4 (in firing order)
654
5
571
Injector 4 (in firing order); interruption of electric connection
676
11
543
Cold start aid relay error
676
11
544
Cold start aid relay open load
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 17
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES 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; signal range check high
1180 11
1066
Sensor exhaust gas temperature upstream turbine; plausibility error
1188 2
1414
Wastegate; status message from ECU missing
1188 7
1415
Wastegate actuator; blocked
1188 11
1411
Wastegate actuator; internal error
1188 11
1412
Wastegate actuator; ELO calibration not performed correctly
1188 11
1416
Wastegate actuator; over temperature (> 145°C )
1188 11
1417
Wastegate actuator; over temperature (> 135°C )
1188 11
1418
Wastegate actuator; operating voltage error
1188 11
1413
Wastegate actuator calibration deviation too large, recalibration required
1231 14
85
CAN-Bus 1 "BusOff-Status"
1231 14
86
CAN-Bus 2 "BusOff-Status"
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP
Description
1109 2
121
Engine shut off demand ignored
1136 0
1398
Physikal range check high for ECU temperature
1136 1
1399
Physikal range check low for ECU temperature
1136 3
1400
Sensor error ECU temperature; signal range check high
1136 4
1401
Sensor error ECU temperature; signal range check low
1176 3
849
Sensor error pressure sensor upstream turbine; signal range check high
1176 4
850
Sensor error pressure sensor downstream turbine; signal range check high
1180 0
1193
Physical range check high for exhaust gas temperature upstream turbine
1180 0
1460
Turbocharger Wastegate CAN feedback; warning threshold exceeded
1180 0
1462
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
5 - 18
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP
Description
1237 2
747
Override switch; plausibility error
1322 12
610
Too many recognized misfires in more than one cylinder
1323 12
604
Too many recognized misfires in cylinder 1 (in firing order)
1324 12
605
Too many recognized misfires in cylinder 2 (in firing order)
1325 12
606
Too many recognized misfires in cylinder 3 (in firing order)
1326 12
607
Too many recognized misfires in cylinder 4 (in firing order)
2659 0
1524
Physical range check high for EGR exhaust gas mass flow
Physical range check low for EGR exhaust gas mass flow
2659 1
1525
2659 2
1523
Exhaust gas recirculation AGS sensor; plausibility error
2659 2
1527
AGS sensor temperature exhaust gas mass flow; plausibility error
2659 12
1526
Exhaust gas recirculation; AGS sensor has "burn off" not performed
2797 4
1337
Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 0
Part No. 102916
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 ground monitoring Test in Cyl. Bank 1
3224 2
127
DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream cat; DPF-system downstream cat); length of frame incorrect
3224 9
128
Timeout Error of CAN-Receive-Frame AT1IG1; NOX Sensor upstream
3248 4
1047
Sensor error particle filter downstream temperature; signal range check low
3699 2
1616
DPF differential pressure sensor and a further sensor or actuator CRT system defective
3699 2
1617
Temperature sensor us. and ds. DOC simultaneously defect
3699 14
1615
Maximum stand-still-duration reached; oil exchange required
4765 0
1039
Physical range check high for exhaust gas temperature upstream (DOC)
4765 1
1042
Physical range check low for exhaust gas temperature upstream (DOC)
S-100 • S-105 • S-120 • S-125
5 - 19
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol
FMI KWP Description
523008 2
649
Timeout error in Manipulation control
523009 9
825
Pressure Relief Valve (PRV) reached maximum allowed opening count
523009 10
833
Pressure Relief Valve (PRV) reached maximum allowed open time
523212 9
171
Timeout Error of CAN-Receive-Frame ComEngPrt; Engine Protection
523216 9
198
Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat command, engine command
SPN
FMI KWP Description
4766
0
1029 Physical range check high for exhaust gas temperature downstream (DOC)
4766
1
1032 Physical range check low for exhaust gas temperature downstream (DOC)
4768
2
1036 Sensor exhaust gas temperature upstream (DOC); plausibility error
4768
3
1044 Sensor error exhaust gas temperature upstream (DOC); signal range check high
4768
4
1045 Sensor error exhaust gas temperature upstream (DOC); signal range check low
523240 9
179
Timeout CAN-message FunModCtl; Function Mode Control
4769
2
1026 Sensor exhaust gas temperature downstream (DOC); plausibility error
523350 4
565
Injector cylinder-bank 1; short circuit
4769
3
1034 Sensor error exhaust gas temperature downstream (DOC); signal range check high
523352 4
566
Injector cylinder-bank 2; short circuit
523354 12
567
Injector powerstage output defect
523470 2
826
Pressure Relief Valve (PRV) forced to open; performed by pressure increase
523470 2
827
Pressure Relief Valve (PRV) forced to open; performed by pressure shock
4769
4
1035 Sensor error 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
5 - 20
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
FMI KWP Description
523470 7
876
Maximum rail pressure in limp home mode exceeded (PRV)
523470 11
831
The PRV can not be opened at this operating point with a pressure shock
FMI KWP Description
523612 12
613
Internal ECU monitoring detection reported error
523612 12
614
Internal ECU monitoring detection reported error
523612 12
615
Internal ECU monitoring detection reported error
523612 12
616
Internal ECU monitoring detection reported error
523470 11
832
Rail pressure out of tolerance range
523612 12
617
523470 12
828
Open Pressure Relief Valve (PRV); shut off condition
Internal ECU monitoring detection reported error
523612 12
618
523470 12
829
Open Pressure Relief Valve (PRV); warning condition
Internal ECU monitoring detection reported error
523612 12
619
523470 14
830
Pressure Relief Valve (PRV) is open
Internal ECU monitoring detection reported error
523612 12
620
523550 12
980
T50 start switch active for too long
Internal ECU monitoring detection reported error
523612 12
621
523601 13
948
Sensor supply voltage monitor 3 error (ECU)
Internal ECU monitoring detection reported error
523612 12
623
523603 9
126
Timeout Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor
Internal ECU monitoring detection reported error
523612 12
624
Internal ECU monitoring detection reported error
523605 9
300
Timeout Error of CAN-Receive-Frame TSC1AR; Traction Control
523612 12
625
Internal ECU monitoring detection reported error
523612 12
627
Internal ECU monitoring detection reported error
523612 12
628
Internal ECU monitoring detection reported error
523606 9
301
Timeout 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
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 21
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
FMI KWP Description
523615 3
596
Metering unit (Fuel-System); short circuit to battery low side
523615 4
595
Metering unit (Fuel-System); short circuit to ground high side
523615 4
597
Metering unit (Fuel-System); short circuit to ground low side
523615 5
592
Metering unit (Fuel-System); open load
523615 12
593
Metering unit (Fuel-System); powerstage over temperature
523619 2
488
Physical range check high for exhaust gas temperature upstream (SCR-CAT)
523698 11
122
Shut off request from supervisory monitoring function
523717 12
125
Timeout Error of CAN-Transmit-Frame AmbCon; Weather environments
523718 3
1488 SCR mainrelay; short circuit to battery (only CV56B)
523718 4
1489 SCR mainrelay; short circuit to ground (only CV56B)
523612 12
637
523612 12
1170 Internal software error ECU
523612 14
973
Softwarereset CPU SWReset_0
523612 14
974
Softwarereset CPU SWReset_1
523612 14
975
Softwarereset CPU SWReset_2
523613 0
856
Maximum positive deviation of rail pressure exceeded (RailMeUn0)
523613 0
857
Maximum positive deviation of rail pressure in meeting unit exceeded (RailMeUn1)
523613 0
858
Railsystem leakage detected (RailMeUn10)
523613 0
859
Maximum positive deviation of rail pressure in meeting unit exceeded (RailMeUn2)
523613 0
860
Negative deviation of rail pressure second stage (RailMeUn22)
523718 5
523613 0
862
Maximum rail pressure exceeded (RailMeUn4)
1486 SCR mainrelay; open load (only CV56B)
523718 12
523613 1
861
Maximum rail pressure exceeded (RailMeUn3)
1487 SCR mainrelay; powerstage over temperature (only CV56B)
523766 9
281
523613 2
864
Setpoint of metering unit in overrun mode not plausible
Timeout Error of CAN-Receive-Frame Active TSC1AE
523613 3
594
Metering unit (Fuel-System); short circuit to battery high side
523767 9
282
Timeout Error of CAN-Receive-Frame Passive TSC1AE
5 - 22
Internal ECU monitoring detection reported error
FMI KWP Description
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
FMI KWP Description
523897 13
561
Check of missing injector adjustment value programming (IMA) injector 3 (in firing order)
Check of missing injector adjustment value programming (IMA) injector 4 (in firing order)
FMI KWP Description
523768 9
283
Timeout Error of CAN-Receive-Frame Active TSC1AR
523898 13
562
523769 9
284
Timeout Error of CAN-Receive-Frame Passive TSC1AR
523910 6
1261 Air Pump; over current
523913 3
74
Timeout Error of CAN-Receive-Frame Passive TSC1DE
Sensor error glow plug control diagnostic line voltage; signal range check high
523913 4
75
Sensor error glow plug control diagnostic line voltage; signal range check low
523914 3
78
Glow plug control; short circuit to battery
523914 4
79
Glow plug control; short circuit to ground
523914 5
76
Glow plug control; open load
523914 5
1216 Glow plug control release line; short circuit error
523914 11
1217 Glow plug control; internal error
523914 12
77
523919 2
1378 Sensor air pump airpressure; plausibility error
523920 2
1379 Sensor exhaust gas back pressure burner; plausibility error
523770 9
523776 9
285
291
Timeout Error of CAN-Receive-Frame TSC1TE active
523777 9
292
Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
523778 9
293
Active Timeout Error of CAN-Receive-Frame TSC1TR
523779 9
294
Passive Timeout Error of CAN-Receive-Frame TSC1TR
523788 12
299
Timeout Error of CAN-Transmit-Frame TrbCH; Status Wastegate
523793 9
202
Timeout Error of CAN-Receive-Frame UAA10; AGS sensor service message
523794 9
203
Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data
523895 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)
Part No. 102916
Glow plug control; powerstage over temperature
S-100 • S-105 • S-120 • S-125
5 - 23
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
523936 12
169
523946 0
1158 Zerofuel calibration injector 1 (in firing order); maximum value exceeded
523946 1
1164 Zerofuel calibration injector 1 (in firing order); minimum value exceeded
523947 0
1159 Zerofuel calibration injector 2 (in firing order); maximum value exceeded
523947 1
1165 Zerofuel calibration injector 2 (in firing order); minimum value exceeded
523948 0
1160 Zerofuel calibration injector 3 (in firing order); maximum value exceeded
523948 1
1166 Zerofuel calibration injector 3 (in firing order); minimum value exceeded
523949 0
1160 Zerofuel calibration injector 4 (in firing order); maximum value exceeded
523949 1
1166 Zerofuel calibration injector 4 (in firing order); minimum value exceeded
523960 0
1011 Physical range check high for EGR cooler downstream temp.
FMI KWP Description
523922 7
1262 Burner Shut Off Valve; blocked closed
523922 7
1264 Burner Shut Off Valve; blocked closed
523929 0
109
Fuel Balance Control integrator injector 1 (in firing order); maximum value exceeded
523929 1
115
Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded
523930 0
110
Fuel Balance Control integrator injector 2 (in firing order); maximum value exceeded
523930 1
116
Fuel Balance Control integrator injector 2 (in firing order); minimum value exceeded
523931 0
111
Fuel Balance Control integrator injector 3 (in firing order); maximum value exceeded
523931 1
117
Fuel Balance Control integrator injector 3 (in firing order); minimum value exceeded
523932 0
112
Fuel 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
5 - 24
FMI KWP Description Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
FMI KWP Description
523960 0
1458 High exhaust gas temperature EGR cooler downstream; warning threshold exceeded
523960 1
1012 Physical range check low for EGR cooler downstream temp.
523960 1
1459 High exhaust gas temperature EGR cooler downstream; shut off threshold exceeded
523980 14
1187 Bad quality of reduction agent detected
523981 11
918
Urea-tank without heating function (heating phase)
523982 0
360
Powerstage diagnosis disabled; high battery voltage
523982 1
361
Powerstage diagnosis disabled; low battery voltage
523988 3
1245 Charging lamp; short circuit to battery
523988 4
1246 Charging lamp; short circuit to ground
523988 5
1243 Charging lamp; open load
523988 12
1244 Charging lamp; open temp.
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
Part No. 102916
FMI KWP Description
524016 2
1259 Amount of air is not plausible to pumb speed
524016 2
1260 Calculated amount of air is not plausible to HFM reading
524016 11
1258 HFM sensor; electrical fault
524021 11
1263 Burner fuel line pipe leak behind Shut Off Valve
524024 11
1302 Deviation of the exhaust gas temp. setpoint to actual value downstream (DOC) too high
524028 2
1431 CAN message PROEGRActr; plausible error
524029 2
1432 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation positioner
524030 7
1440 EGR actuator; internal error
524031 13
1441 EGR actuator; calibration error
524032 2
1442 EGR actuator; status message EGRCust is missing
524033 7
1443 EGR actuator; due to overload in Save Mode
524034 3
1438 Disc separator; short circuit to battery
524034 4
1439 Disc separator; short circuit to ground
524034 5
1436 Disc separator; open load
524034 12
1437 Disc separator; powerstage over temperature
S-100 • S-105 • S-120 • S-125
5 - 25
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN
SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
FMI KWP Description
524108 9
1669 Timeout Error of CAN-Transmit-Frame ComEGRTVActr
FMI KWP Description
524035 12
1341 Injector diagnostics; time out error in the SPI communication
524109 9
524057 2
1505 Electric fuel pump; fuel pressure build up error
1679 Timeout Error of CAN-Receive-Frame ComRxEGRTVActr
524110 9
524097 9
1663 Timeout Error of CAN-Transmit-Frame DPFBrnAirPmpCtl
1670 Timeout Error of CAN-Transmit-Frame ComETVActr
524111 9
524098 9
1664 Timeout Error of CAN-Transmit-Frame ComDPFBrnPT
1680 Timeout Error of CAN-Receive-Frame ComRxETVActr
524112 9
1671 Timeout ComlTVActr
524099 9
1665 Timeout Error of CAN-Transmit-Frame ComDPFC1
524113 9
1681 Timeout Error of CAN-Receive-Frame ComRxlTVActr
524100 9
1666 Timeout Error of CAN-Transmit-Frame ComDPFHisDat
524114 9
1659 Timeout Error of CAN-Transmit-Frame A1DOC
524101 9
1667 Timeout Error of CAN-Transmit-Frame ComDPFTstMon
524115 9
1660 Timeout Error of CAN-Transmit-Frame AT1S
524116 9
524102 9
1674 Timeout Error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
1661 Timeout Error of CAN-Transmit-Frame SCR2
524117 9
1662 Timeout Error of CAN-Transmit-Frame SCR3
524103 9
1675 Timeout Error of CAN-Receive-Frame ComRxDPFBrnAirPmp
524118 9
1672 Timeout Error of CAN-Receive-Frame ComRxCM1
524104 9
1676 Timeout Error of CAN-Receive-Frame ComRxDPFCtl
524119 9
1673 Timeout Error of CAN-Receive-Frame ComRxCustSCR3
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
5 - 26
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN
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
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 27
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
27
3
Engine Exhaust Gas Recirculation Valve Position: Voltage Above Normal
Value Position Sensor- Test
27
4
Engine Exhaust Gas Recirculation Valve Position: Voltage Be- low Normal
Value Position Sensor- Test
29
3
Accelerator Pedal Position 2: Voltage Above Normal
Analog Throttle Position Sensor Circuit Test
29
4
Accelerator Pedal Position 2: Voltage Above Normal
Analog Throttle Position Sensor Circuit Test
51
3
Engine Throttle Valve 1 Position: Voltage Above Normal
Value Position Sensor- Test
51
4
Engine Throttle Valve 1 Position: Voltage Below Normal
Value Position Sensor- Test
91
3
Accelerator Pedal Position 1: Voltage Above Normal
Analog Throttle Position Sensor Circuit Test
91
4
Accelerator Pedal Position 1: Voltage Below Normal
Analog Throttle Position Sensor Circuit 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 Pressure Sensor Open or Short Circuit - Test
102
20
Engine Intake Manifold #1 Pressure: Data Drifted High
Engine Pressure Sensor Open or Short Circuit - Test
102
21
Engine Intake Manifold #1 Pressure: Data Drifted Low
Engine Pressure Sensor Open or Short Circuit - Test
105
3
Engine Intake Manifold #1 Temperature: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
105
4
Engine Intake Manifold #1 Temperature: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
107
2
Engine Air Filter 1 Differential Pressure: Erratic, Intermittent, or Incorrect
Switch Circuits - Test
107
15
Engine Air Filter 1 Differential Pressure: High - least severe Inlet Air Is Restricted (1)
107
16
Engine Air Filter 1 Differential Pressure: High - moderate severity (2)
5 - 28
Inlet Air Is Restricted
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
108
3
Barometric Pressure: Voltage Above Normal
Engine Pressure Sensor Open or Short Circuit - Test
108
4
Barometric Pressure: Voltage Below Normal
Engine Pressure Sensor Open or Short Circuit - Test
110
3
Engine Coolant Temperature: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
110
4
Engine Coolant Temperature: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
110
15
Engine Coolant Temperature: High - least severe (1)
Coolant Temperature Is High
110
16
Engine Coolant Temperature: High - moderate severity (2)
Coolant Temperature Is High
152
2
Number Of ECU Resets: Erratic, Intermittent, or Incorrect
ECM Memory - Test
157
0
Engine Injector Metering Rail#1 Pressure: High - most severe (3)
Fuel Rail Pressure Problem
157
2
Engine Injector Metering Rail#1 Pressure: Erratic, Intermittent, or Incorrect
Fuel Rail Pressure Problem
157
3
Engine Injector Metering Rail#1 Pressure: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
157
4
Engine Injector Metering Rail#1 Pressure: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
157
10
Engine Injector Metering Rail#1 Pressure: Abnormal Rate of Change
Engine Temperature Sensor Open or Short Circuit - Test
157
16
Engine Injector Metering Rail#1 Pressure: High - moderate severity (2)
Fuel Rail Pressure Problem
157
17
Engine Injector Metering Rail#1 Pressure: Low - least severe (1) Fuel Rail Pressure Problem
157
18
Engine Injector Metering Rail#1 Pressure: Low - moderate severity (2)
Fuel Rail Pressure Problem
168
3
Battery Potential/ Power Input 1: Voltage Above Normal
Ignition Keyswitch Circuit and Battery Supply Circuit - Test
166
2
Engine Rated Power: Erratic, Intermittent, or Incorrect
ECM Memory - Test
166
14
Engine Rated Power: Special Instruction
ECM Memory - Test
168
4
Battery Potential/ Power Input 1: Voltage Below Normal
Ignition Keyswitch Circuit and Battery Supply Circuit - Test
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 29
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
172
3
Engine Air Inlet Temperature Sensor: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
172
3
Engine Air Inlet Temperature Sensor: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
173
3
Engine Exhaust Gas Temperature: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
173
4
Engine Exhaust Gas Temperature: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
174
3
Engine Fuel Temperature 1: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
174
4
Engine Fuel Temperature 1: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
190
8
Engine Speed: Abnormal Frequency, Pulse Width, or Period
Engine Speed/Timing Sensor Circuit - Test
190
15
Engine Speed: High - least severe (1)
Engine Over speeds
558
2
Accelerator Pedal1Low Idle Switch: Erratic, Intermittent, or Incorrect
Idle Validation Switch Circuits - Test
593
31
Engine Idle Shutdown has Shutdown Engine
This code indicates that an engine idle shutdown is about to occur. This code does not represent a fault. If equipped, the warning lamp will come on.
594
31
Engine Idle Shutdown Driver Alert Mode
This code indicates that an engine idle shut down has occurred. This code does not represent a fault. If equipped, the warning lamp will flash and the shutdown lamp will come on.
623
6
Red Stop Lamp: Current Above Normal
Indicator Lamp Circuit- Test
624
6
Amber Warning Lamp: Current Above Normal
Indicator Lamp Circuit- Test
630
2
Calibration Memory: Erratic, Intermittent, or Incorrect
Injector Data Incorrect- Test
637
11
Engine Timing Sensor: Other Failure Mode
Engine Speed/Timing Sensor Circuit - Test
639
9
J1939 Network #1: Abnormal Update Rate
CAN Data Link Circuit - Test
639
14
J1939 Network #1: Special Instruction
CAN Data Link Circuit - Test
651
5
Engine Injector Cylinder #01: Current Below Normal
Injector Solenoid Circuit - Test
651
6
Engine Injector Cylinder #01: Current Above Normal
Injector Solenoid Circuit - Test
651
20
Engine Injector Cylinder #01: Data Drifted High
Injector Data Incorrect- Test
651
21
Engine Injector Cylinder #01: Data Drifted Low
Injector Data Incorrect- Test
5 - 30
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
652
5
Engine Injector Cylinder #02: Current Below Normal
Injector Solenoid Circuit - Test
652
6
Engine Injector Cylinder #02: Current Above Normal
Injector Solenoid Circuit - Test
652
20
Engine Injector Cylinder #02: Data Drifted High
Injector Data Incorrect- Test
652
21
Engine Injector Cylinder #02: Data Drifted Low
Injector Data Incorrect- Test
653
5
Engine Injector Cylinder #03: Current Below Normal
Injector Solenoid Circuit - Test
653
6
Engine Injector Cylinder #03: Current Above Normal
Injector Solenoid Circuit - Test
653
20
Engine Injector Cylinder #03: Data Drifted High
Injector Data Incorrect- Test
653
21
Engine Injector Cylinder #03: Data Drifted Low
Injector Data Incorrect- Test
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 Starting Aid - Test
676
6
Engine Glow Plug Relay: Current Above Normal
Glow Plug Starting Aid - Test
676
19
Engine Glow Plug Relay: Data Error
Glow Plug Starting Aid - Test
677
3
Engine Starter Motor Relay: Voltage Above Normal
Start Relay Circuit - Test
677
5
Engine Starter Motor Relay: Current Below Normal
Start Relay Circuit - Test
677
6
Engine Starter Motor Relay: Current Above Normal
Start Relay Circuit - Test
723
8
Engine Speed Sensor #2: Abnormal Frequency, Pulse Engine Speed/Timing Sensor Circuit - Test Width, or Period
976
2
PTO Governor State: Erratic, Intermittent, or Incorrect PTO Switch Circuit - Test
1041
2
Start Signal Indicator: Erratic, Intermittent, or Incorrect Start Relay Circuit - Test
Part No. 102916
S-100 • S-105 • S-120 • S-125
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Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
1076
2
Engine Fuel Injection Pump Fuel Control Value: Erratic, Intermittent, or Incorrect
Solenoid Value - Test
1076
5
Engine Fuel Injection Pump Fuel Control Value: Current Below Normal
Solenoid Value - Test
1076
6
Engine Fuel Injection Pump Fuel Control Value: Current Above Normal
Solenoid Value - Test
1081
5
Engine Wait to Start Lamp: Current Below Normal
Indicator Lamp Circuit - Test
1081
6
Engine Wait to Start Lamp: Current Above Normal
Indicator Lamp Circuit - Test
1127
16
Engine Turbocharger 1 Boost Pressure: High - moderate Intake Manifold Air Pressure Is High severity (2)
1127
18
Engine Turbocharger 1 Boost Pressure: Low - moderate Intake Manifold Air Pressure Is Low severity (2)
1188
5
Engine Turbocharger Wastegate Actuator 1 Position: Current Below Normal
Solenoid Value - Test
1188
6
Engine Turbocharger Wastegate Actuator 1 Position: Current Above Normal
Solenoid Value - Test
1209
3
Engine Exhaust Gas Pressure: Voltage Above Normal
Engine Pressure Sensor Open or Short Circuit - Test
1209
4
Engine Exhaust Gas Pressure: Voltage Below Normal
Engine Pressure Sensor Open or Short Circuit - Test
1221
2
Continuously Monitored Systems Support/Status: Erratic, Intermittent, or Incorrect
ECM Memory - Test
1221
14
Continuously Monitored Systems Support/Status: Special Instruction
Another diagnostic code has requested engine speed limitation. The warning lamp will flash. The engine speed is limited to 1200rpm. Troubleshoot all other diagnostic codes. No troubleshooting is required for this diagnostic code.
1239
0
Engine Fuel Leakage 1: High- most severe (3)
Fuel Rail Pressure Problem
1485
7
ECM Main Relay: Not Responding Properly
Electrical Power Supply - Test
1485
14
ECM Main Relay: Special Instruction
Electrical Power Supply - Test
5 - 32
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
2791
5
Engine Exhuast Gas Recirculation (EGR) Value Control: Current Below Normal
Motorized Value - Test
2791
6
Engine Exhuast Gas Recirculation (EGR) Value Control: Current Above Normal
Motorized Value - Test
2791
7
Engine Exhuast Gas Recirculation (EGR) Value Control: Motorized Value - Test Not Responding Properly
2797
6
Engine Injector Group 1: Current Above Normal
Injector Solenoid Circuit - Test
2797
7
Engine Injector Group 1: Not Responding Property
Injector Solenoid Circuit - Test
2798
6
Engine Injector Group 2: Current Above Normal
Injector Solenoid Circuit - Test
2840
12
ECU Instance: Failure
ECM Memory - Test
2840
14
ECU Instance: Special Instruction
Electrical Power Supply - Test
2880
2
Engine Operator Primary Intermediate Speed Select: Erratic, Intermittent, or Incorrect
Throttle Switch Circuit - Test
2880
3
Engine Operator Primary Intermediate Speed Select: Voltage Above Normal
Throttle Switch Circuit - Test
2880
4
Engine Operator Primary Intermediate Speed Select: Voltage Below Normal
Throttle Switch Circuit - Test
2970
2
Accelerator Pedal 2 Low Idle Switch: Erratic, Intermittent, Idle Validation Switch Circuit - Test or Incorrect
3217
3
After treatment #1 Intake 02: Voltage Above Normal
Oxygen Level - Test
3217
4
After treatment #1 Intake 02: Voltage Below Normal
Oxygen Level - Test
3217
5
After treatment #1 Intake 02: Current Below Normal
Oxygen Level - Test
3217
6
After treatment #1 Intake 02: Current Above Normal
Oxygen Level - Test
3217
12
After treatment #1 Intake 02: Failure
Oxygen Level - Test
3217
13
After treatment #1 Intake 02: Out of Calibration
Oxygen Level - Test
3217
15
After treatment #1 Intake 02: High - least severe (1)
Oxygen Level - Test
Part No. 102916
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October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
3219
15
After treatment #1 Intake Gas Sensor at Temperature: High - least severe (1)
Oxygen Level - Test
3219
17
After treatment #1 Intake Gas Sensor at Temperature: Low - least severe (1)
Oxygen Level - Test
3222
3
After treatment #1 Intake Gas Sensor Heater: Voltage Above Normal
Oxygen Level - Test
3222
4
After treatment #1 Intake Gas Sensor Heater: Voltage Below Normal
Oxygen Level - Test
3222
5
After treatment #1 Intake Gas Sensor Heater: Current Below Normal
Oxygen Level - Test
3242
3
Particulate Trap Intake Gas Temperature: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
3242
4
Particulate Trap Intake Gas Temperature: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
3251
0
Particulate Trap Differential Pressure: High- most severe (3)
Diesel Particulate Filter Collects Excessive Soot
3251
3
Particulate Trap Differential Pressure: Voltage Above Normal
Engine Pressure Sensor Open or Short Circuit - Test
3251
4
Particulate Trap Differential Pressure: Voltage Below Normal
Engine Pressure Sensor Open or Short Circuit - Test
3251
7
Particulate Trap Differential Pressure: Not Responding Properly
Diesel Particulate Filter Has Differential Pressure Problem
3251
10
Particulate Trap Differential Pressure: Abnormal Rate of Change
Diesel Particulate Filter Has Differential Pressure Problem
3251
16
Particulate Trap Differential Pressure: High-moderate severity (2)
Diesel Particulate Filter Collects Excessive Soot
3251
17
Particulate Trap Differential Pressure: Low - least severe (1)
Diesel Particulate Filter Has Differential Pressure Problem
3509
2
Sensor Supply Voltage 1: Erratic, Intermittent, or Incorrect
5 Volt Sensor Supply Circuit - Test
3510
2
Sensor Supply Voltage 2: Erratic, Intermittent, or Incorrect
5 Volt Sensor Supply Circuit - Test
3511
2
Sensor Supply Voltage 3: Erratic, Intermittent, or Incorrect
5 Volt Sensor Supply Circuit - Test
3697
6
Particulate Trap Lamp Command: Current Above Normal
Indicator Lamp Circuit - Test
3698
6
Exhaust System High Temperature Lamp Command: Current Below Normal
Indicator Lamp Circuit - Test
5 - 34
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN
FMI
Description
Refer to Engine Manual
3702
6
Diesel Particulate Filter Active Regeneration Inhibited Status: Current Above Normal
Indicator Lamp Circuit - Test
4765
3
After treatment #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
4765
4
After treatment #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
5055
17
Engine Oil Viscosity: Low - least severe (1)
Oil Contains Fuel
5055
18
Engine Oil Viscosity: Low - moderate severity (2)
Oil Contains Fuel
5099
6
Engine Oil Pressure Low Lamp Data: Current Above Normal Indicator Lamp Circuit - Test
5319
31
After treatment Diesel Particulate Filter Incomplete Regeneration
Diesel Particulate Filter Active Regeneration Was Interrupted
5324
7
Engine Glow 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 Actuator #1: Current Above Normal
Motorized Valve - Test
5419
7
Engine Throttle Actuator #1: Not Responding Properly
Motorized Valve - Test
5571
2
High Pressure Common Rail Fuel Pressure Relief Valve: Erratic, Intermittent, or Incorrect
Fuel Rail Pressure Problem
5571
7
High Pressure Common Rail Fuel Pressure Relief Valve: Not Responding Properly
Fuel Rail Pressure Problem
5571
10
High Pressure Common Rail Fuel Pressure Relief Valve: Abnormal Rate of Change
Fuel Rail Pressure Problem
5571
14
High Pressure Common Rail Fuel Pressure Relief Valve: Special Instruction
Fuel Rail Pressure Problem
5571
16
High Pressure Common Rail Fuel Pressure Relief Valve: High-moderate severity (2)
Fuel Rail Pressure Problem
5826
16
Emission Control System Operator Inducement Severity High-moderate severity (2)
Refer to "Operator Inducement Codes"
Part No. 102916
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October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Control System Fault Codes How to Clear Boom Safety Switch Faults Note: Beginning with software release 3.0, the boom envelope switches will latch and faults must be reset in software or through the use of the TCON LCD. They will not clear by repowering the machine. Note: There are two methods to reset the faults, by using Web GPI or through the menu available on the TCON LCD. Using Web GPI 1 Connect the device containing the WEB GPI software to the TCON with an RS-232 cable. 2 Select the Safety folder, then the Fault Status screen.
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. Release the button after five seconds and press the buttons. 2 Press the switch faults
button until clear all safety appears.
3 Select yes, then press the 4 Press the
button.
button until exit appears.
5 Select yes, then press the
button.
Note: This clears all latching faults, not standard faults.
3 Change any safety switch drop down menus displaying fault to ok. Press send. 4 Exit Web GPI.
5 - 36
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
Software 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 Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.
The software system used on the machine is called Web GPI. It is a software application that is typically used with a laptop computer. The laptop can be connected to the ground controls via a tee harness connector (Genie part number 75094). The Web GPI software can access all adjustable parameters for the machine. It can also be used to aid in troubleshooting and viewing fault code history.
Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the Genie S-100 & Genie S-105 Operator’s Manual and the Genie S-120 & Genie S-125 Operator’s Manual. Be sure that all necessary tools and parts are available and ready for use.
Part No. 102916
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October 2015
Section 5 • Diagnostic Codes
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5 - 38
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics
Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine.
Hydraulic Schematics
Repair any machine damage or malfunction before operating the machine.
Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Operator's Manual on your machine.
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.
Be sure that all necessary tools and test equipment are available and ready for use.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 6 • Schematics
Wire Circuit Legend
Circuit numbering
Circuit suffix
1 Circuit numbers consist of three parts: the circuit prefix, circuit number and circuit suffix. The circuit prefix indicates the type of circuit. The circuit number describes the function of the circuit. The circuit suffix provides an abbreviation for the number or may be used to further define the function of this portion of the circuit. It also may be used to indicate the final end of the circuit, i.e., LS or limit sw.
Definition Suffix AC Generator GEN Alternator Field AF Angle ANG Auxiliary Boom Valve ABV Auxiliary Forward Valve AFV Auxiliary Hydraulic Pump AH Auxiliary Platform Valve APV Auxiliary Reverse Valve ARV Auxiliary Steer/Drive Valve ASV Axle Extend Valve AXE Axle Oscillate AXO Axle Retract Valve AXR Axle Front Position FAP Axle Rear Position RAP Battery BAT Boom Extended BEX Boom Stowed BST Brake BRK Bypass Valves BV Calibrate CAL CAN Signal CAN CAN Shield SHD CATS Module CAT Chain Break CNK Data High DTH Data Low DTL Drive Chassis Controller DCN Drive Enable DE Drive Enable Left DEL Drive Enable Right DER Electrical Displacement Control EDC Envelope Light ENV Engine Speed Select ESP Engine Status Lamp ESL Envelope Lockout ENL Extend/retract Lockout ERL Filter Restricted FLR Filter Switch FLT Flashing Beacon FB Float Switch FS Footswitch Signal FTS Forward FWD Fuel Pump FP Fuel Select (gas/LP) FL Fuel Solenoid FSL
2 The circuit number may be used more than once in a circuit. For Example: C 74 PL – This is the circuit for the lockout valve #1. C stands for control, 74 is the number of the circuit for the primary #1 lock out valve. PL stands for Primary Lockout. S 62 BST – This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed. S stands for safety, 62 is the number of the circuit for boom stowed and BST stands for Boom Stowed. P 48 LP – P stands for power. 48 is the circuit number for work lamps and LP stands for Lamp. R 48 LP – R stands for relay. In this case it is the wire that feeds the relay coil for the work lamp. All other numbers remain the same.
Circuit prefix C........Control D........Data E........Engine G........Gauges N........Neutral P........Power R........Relay Output S........Safety V........Valve
6 - 2
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND Definition Suffix Function Enable FE Ground Control TCN Ground GND Horn HRN High RPM HS Hydraulic Generator HG Ignition IGN Jib Bellcrank Down JBD Jib Bellcrank Up JBU Jib Sensor JBS Jib U/D Control JUD Jib Down JD Jib Up/Down Flow Control JFC Jib Select Valve JSV Jib Up JU Jib E/R Control JER Jib Ext JBE Jib Ret JBR Jib Rotate Left (CCW) JRL Jib Rotate Right (CW) JRR Joystick 5 VDC Power JPW Lamps LPS Left Front LF Left Front Steer Sensor LFS Left Rear LR Left Rear Steer Sensor LRS Limit Switch LS Lift Speed Reduction LSR Load Sensor LDS Lockout LO Low RPM LS Low fuel LOF Motor Shift (Speed) MS Multi Function Valve MFV Platform Control PCN Primary Ext/Ret Lockout PEL Platform Level Down PLD Platform Level Flow Control PLF Platform Level Up PLU Platform Rotate Flow Control PRF Platform Rotate Control PRC Platform Rotate Left (CCW) PRL Platform Rotate Right (CW) PRR Power PWR Power to Length Sensor PSL Platform Tilt Alarm PTA Platform Tilt Sensor PTS Part No. 102916
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 PBL Primary Boom Extend PBE Primary Boom Extend/Retract Flow Control PER Primary Boom Retract PBR Primary Boom Up PBU Primary Boom Up/Dwn Flow Control PUD Primary Boom Extend/Retract Signal PLS Primary Boom Up/Down Signal PES Primary Lockout PL Primary Length Sensor PSL Propel Signal JPL Program Setup Enable PSE Propel Lockout PLL Proportional Valve PRV Proximity Sensor PXS Receptacle REC Recovery RCV Retract Lockout RL Return RET Reverse REV Right Front RF Right Front Steer Sensor RFS Right Rear RR Right Rear Steer Sensor RRS RPM RPM Secondary Boom Angle Sensor SBS Secondary Boom Elevated SBL Sec Boom Down SBD Sec Boom Extend SBE Sec Boom Extend/Retract Flow Control SER Sec Boom Retract SBR Sec Boom Up SBU Sec Boom Up/Dwn Flow Control SUD Secondary Boom SB This list continues on the next page.
S-100 • S-105 • S-120 • S-125
6-3
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND Definition Suffix Secondary Boom Lockout Valve (Extend) SLE Secondary Boom Lockout Valve (Riser Down) SLD Sensor SEN Spare SP Speed Sensor SS Start Aid (Glow Plug or choke) SA Starter STR Steer Control Signal STC Steering Valve Clockwise SCW Steering Valve Counter Clockwise SCC Temp Sender TSR Temp Switches TS Tether TET Tilt Alarm X axis TAX Tilt Alarm Y axis TAY Turntable or Ground Control Panel TCN Turntable Rotate Flow Control TRF Turntable Rotate Right (CW) TRR Turntable Rotate Signal TRS Turntable Tilt Alarm TTA Turntable Tilt Sensor TTS Test Switch TSW
6 - 4
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 valve wiring is striped.
Wire Color Legend BL Blue BL/BK Blue/Black BL/RD Blue/Red BL/WH Blue/White BK Black BK/RD Black/Red BK/WH Black/White BR Brown GN Green GN/BK Green/Black GN/WH Green/White RD Red RD/BK Red/Black RD/WH Red/White OR Orange OR/BL Orange/Blue OR/BK Orange/Black OR/RD Orange/Red WH White White/Black WH/BK WH/RD White/Red YL Yellow
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND Color, Circuit #, and Primary function RD 1 Primary boom up drive RD/BK 2 Primary boom down drive RD/WH 3 Primary boom up/dwn FC proportional valve drive WH 4 Turntable rotate left valve drive WH/BK 5 Turntable rotate right valve drive WH/RD 6 Turntable rotate FC proportional valve drive BK 7 Primary boom extend BK/WH 8 Primary boom retract BK/RD 9 Primary boom Extend/Retract proportional valve drive BL 10 Secondary boom up valve drive BL/BK 11 Secondary boom down valve drive BL/WH 12 Secondary boom up/dwn FC proportional valve drive BL/RD 13 Drive enable OR 14 Platform level up valve OR/BK 15 Platform level down valve OR/RD 16 Platform up/dwn FC proportional valve drive GN 17 Platform rotate left valve driver GN/BK 18 Platform rotate right valve driver GN/WH 19 Jib select valve driver circuit RD 20 12V battery supply WH 21 12V ignition supply BK 22 Keyswitch power to platform 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
Part No. 102916
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 36 Steer clockwise BL/BK 37 Steer counterclockwise BL/WH 38 Gas BL/RD 39 LP OR 40 Limit switch signal stowed OR/BK 41 RPM signal OR/RD 42 Boom retracted signal GN 43 Jib up GN/BK 44 Jib down GN/WH 45 AC Generator WH 46 Drive horn WH/BK 47 Output power enable WH/RD 48 Work lamp WH/BK 49 Motion lamp BL 50 Auxiliary boom BL/WH 51 Auxiliary steer BL/RD 52 Auxiliary platform WH/BK 53 Boom envelope safety valve cutoff BK/WH 54 Power to safety interlock switches (engine) GN/BK 55 Axle oscillation RD 56 Foot switch/TCON estop power RD/WH 57 Boom down safety interlock RD/BK 58 Safety interlock to engine GN/WH 59 Chain break circuit GN/WH 60 Axle extend GN 61 Axle retract OR 62 Boom stowed (safety) OR/RD 63 Power to boom envelope safety switch This list continues on the next page.
S-100 • S-105 • S-120 • S-125
6-5
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND Color, Circuit #, and Primary function OR/BK 64 Power for operational switches BL/WH 65 Low fuel indication BL 66 Drive enable BL 67 Secondary boom not stowed RD 68 Primary boom lowered (operational) BL 69 Primary boom #1 extended BL/WH 70 Primary boom #2 retracted BL/BK 71 Primary boom #2 extended GN 72 Secondary boom extend GN/BK 73 Secondary boom retract RD 74 Primary #1 Lockout RD/WH 75 Primary #2 Lockout BL 76 Pri boom #3 extended WH 77 Lower angle #1 operational WH/BK 78 Upper angle #2 operational BK 79 power from TCON ESTOP N/A 80 Can 2.0/J1939 Shield GN 81 Can 2.0/J1939 Low YL 82 Can 2.0/J1939 High GN/WH 83 Tilt signal x axis GN/BK 84 Tilt signal y axis GN 85 Tilt sensor power OR 86 Hydraulic filter restricted RD 87 Platform level safety power RD/BK 88 Platform level safety output BR 89 Platform level safety ground RD/BK 90 Proximity kill RD/WH 91 Gate Interlock 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)
6 - 6
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 buss + (i.e. ITT or AP) GN 106 Spare RD 107 Alternator field BL/WH 108 Engine status GN/WH 109 Sensor pwr BK 110 Sensor return OR 111 Steer signal RD 112 Steer signal to solenoid valve OR/RD 113 Multi function valve BK/RD 114 Load moment overweight RD/BK 115 Load moment underweight OR 116 Hydraulic oil cooler RD 117 Flashing beacon OR 118 Lift speed reduction BL 119 Hydraulic pressure sensor output OR 120 Oil cooler fan GR 121 Axle oscillate LEFT GN/BK 122 Axle oscillate RIGHT RD/BK 123 Primary boom angle signal operational RD/WH 124 Secondary boom angle signal operational WH/RD 125 Secondary boomlockout (Ext Enable) WH/BK 126 Secondary boom lockout (Riser Down Enable) GN 127 ECU test switch OR/RD 128 Low engine speed
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND Color, Circuit #, and Primary function RD/BK 129 Descent alarm WH/RD 130 Travel alarm BL 131 Motion alarm GN 132 Platform load input GN/WH 133 Platform load alarm GN/BK 134 Key switch power BL/WH 135 Fuel pump RD 136 Power to safety module RD/WH 137 Propel power (P_38) RD/BK 138 Pri boom up/sec boom dwn-Ext (P_11/30) WH/RD 139 Turntable rot FC safety (P_39) OR/RD 140 Boom envelope safety RD 141 Primary boom angle signal safety OR 142 Secondary boom angle signal safety BL/RD 143 Drive enable left BL/WH 144 Drive enable right RD/WH 145 Calibrate BL 146 Jib bellcrank up FC BL/BK 147 Jib bellcrank down FC BL/WH 148 Jib bellcrank sensor GN/WH 149 Jib Up/Down FC GN/BK 150 Hydraulic generator bypass GN 151 Hydraulic EDCoutput BK 152 Injector retard BK 153 Jib extend BK/WH 154 Jib retract OR/RD 155 Pressure comp enable GN/WH 156 Jib Up/Down BK/RD 157 Jib Ext/Ret BL/RD 158 Spare BL/WH 159 Steer joystick signal WH/RD 160 Propel joystick signal WH/BK 161 Sec boom joystick signal OR 162 Joystick 5 VDC power
Part No. 102916
Color, Circuit #, and Primary function BL/WH 163 Pri extend/retract signal RD/WH 164 Pri up/down signal WH/RD 165 TT Rotate signal OR 166 Boom length signal safety OR/BK 167 Boom length signal operational BL/RD 168 Primary boom hydraulic valve lockout GN 169 Envelope active LED WH/RD 170 Load sense relay source WH/BK 171 Load sense relay sink BL 172 UP/DN flow control ground BK 173 Ext/Ret flow control ground WH 174 Key switch power, ground position WH/BK 175 Load sensor signal operational GN/WH 176 Secondary extend/retract FC BL/RD 177 Extend/retract lockout BK 178 Control module status light GN 179 Drive power relay BK 180 Lift power relay OR 181 48 Volt alternator field (or battery) RD 182 24 Volt battery BL 183 Envelope or load sense recovery WH 184 Program setup enable WH 185 Encode A BL 186 Encode B BL 187 Bootstrap or program enable GN 188 Safety cross check BK 189 Data receive BK/WH 190 Data transmit WH/RD 191 Multi-Function pressure relief WH/BK 192 Jib rotate left WH/RD 193 Jib rotate right WH/RD 194 Speed select input OR/RD 195 Electric brake source YL 196 2.5V Sensor power BR N/A Ground or return
S-100 • S-105 • S-120 • S-125
6-7
October 2015
Section 6 • Schematics
Limit Switches
Types of Limit Switches
Limit Switch Numbering
There are two types of limit switches, which are found in various locations throughout the machine: mechanical-type operational or safety switches and magnetic proximity switches. As in aircraft, which features redundant safety systems, each mechanical safety switch is backed up with an independently functioning proximity switch.
LSAX1RO LSAX2RO LSAX1EO LSAX2EO LSAX1ES LSAX2ES LSB6S LSB7DS LSB3RS LSB2RS •• LSB9AS •• LSB8AS LSB4ES LST1O LSB1DO LSB2RO •• LSB3RO LSB3EO LSB4EO •• LSB13AO LSB14AO •• LSB19LO
The mechanical-type operational or safety switches are used to sense a positive displacement or movement of the limit switch actuator, or arm, as the machine moves through its range of operational functions. Included in this group are envelope limit switches, which sense the extended length and angle of the boom, position of the axles and rotational position of the turntable. For example, when the 53° operational switch is activated by achieving a 53° boom angle, the boom may then be extended beyond 75 feet (22.9 m). Another example is the drive enable limit switch, which disables the drive function anytime the boom is rotated 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 the front and rear axle, the turntable and several locations on the boom.
Numbering Legend Circuit number AX Axle B Boom T Turntable LS Limit switch
D A L E R
Down Angle Load moment Extend O Operational Retract S Safety
Front axle retract proximity Rear axle retract proximity Front axle extend proximity Rear axle extend proximity Front axle extend safety Rear axle extend safety Cable tension safety Boom 11° angle safety Boom 3 foot (0.9 m) extend safety Boom 101 feet (30.8 m) extend safety Boom 65° angle safety Boom 50° angle safety Boom 76 feet (23.2 m) extend safety Drive enable mechanical Boom 10° mechanical Boom >100 feet (30.5 m) retract proximity (changed to mechanicalS-100/105- sn 160 S-120/125- sn 628) Boom >3 feet (0.9 m) stowed mechanical Boom 75 feet (22.9 m) extend proximity (changed to mechanicalS-100/105- sn 160 S-120/125- sn 628) Boom 100 feet (30.5 m) extend proximity (changed to mechanicalS-100/105- sn 160 S-120/125- sn 628) Boom 53° angle proximity Boom 68° angle proximity Load moment mechanical
(•• S-120 and S-125 models only)
LS AX 1 R O 6 - 8
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
LIMIT SWITCHES
120 ft / 36.6 m
110 ft / 33.5 m
LSB9AS 65
LSB14AO 68
100 ft / 30.5 m LSB2RO 102 ft (31.1 m)
90 ft / 27.4 m
LSB4EO 100 ft (30.5 m)
80 ft / 24.4 m LSB8AS 50
LSB13AO 53
LSB13AO 53
70 ft / 21.3 m
60 ft / 18.3 m
LSB3EO 75 ft (22.9 m)
LSB4ES 75.5 ft (23 m)
LSB2RS 101 ft (30.8 m) LSB8AS 50
LSB3EO 75 ft (22.9 m)
LSB4ES 75.5 ft (23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m LSB7DS 11
LSB1DO 10
LSB1DO 10
20 ft / 6.1 m
LSB7DS 11
10 ft / 3 m LSB3RS 3.5 ft (1.1 m)
LSB3RO 3 ft (0.9 m)
LSB3RO 3 ft (0.9 m)
0 ft / 0 m
S-100 & S-105 Models (S-100 shown)
S-120 & S-125 Models (S-120 shown)
LSAX1RO
LSAX1EO
LSB3RS 3.5 ft (1.1 m)
LSAX2RO
LST10
LSAX2ES LSAX2EO
LSAX1ES
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-9
October 2015
Section 6 • Schematics
Relay Layout
a
b
c
e
d
f
a b c d e f g h i j k l m n
Fuel solenoid relay (Deutz F4L913 models only). Oil cooler relay. Engine cold start relay. Starter relay. Horn relay. Flashing beacon relay. CR17 relay (K7) - powers C35RPM circuit (Hi/low solenoid). CR16 relay (K8) - powers C34SA circuit (Engine cold start). CR12 relay (K4) - powers primary valves 1 and 2, ignition, glow plug, starter relay, generator, and the boom retract, multifunction and platform rotate valve coils. CR14 relay (K2) - powers P7R or S56PRV circuit including the auxiliary valve, boom extend/retract and turntable rotate valve coils. CR10 relay (K6) - powers C21IGN and C107AF circuits (Fuel on/off solenoid and alternator field). CR15 relay (K1) - powers P22R or C03PBF circuit (Boom up/down valve coil). CR13 relay (K5) - powers P_7 and throttle relay. CR11 relay (K3) - powers P-6R2 or P54ENG circuits.
g
h i j
k l
n
6 - 10
m
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Drive Chassis Controller Pin Legend
DCON
DRIVE CHASSIS CONTROLLER
J2
1 = VLVRET - BR 2 = V61AXRT - GR 3 = V60AXEX - GN/WH 4 = V29MS - RD/WH 5 = (UNUSED) 6 = (UNUSED) 7 = (UNUSED) 8 = V36RRS - BL 9 = V37RRS - BL/BK 10 = C111RRS - OR 11 = C111LRS - OR 12 = C111RFS - OR 13 = C111LFS - OR 14 = VLVRET2 - BR 15 = V32BRK - WH/RD 16 = V36LRS - BL 17 = V37LRS - BL/BK 18 = V36RFS - BL 19 = P110RT - BK 20 = P109ANG - GN/ WH 21 = V37RFS - BL/BK 22 = V36LFS - BL 23 = V37LFS - BL/BK
Part No. 102916
DCON
DRIVE CHASSIS CONTROLLER
J1
1 = GND-DCON - BR 2 = P21DCON - WH 3 = P53LS - GR 4 = (UNUSED) 5 = S56PRV - RD 6 = C61AXRT - GR 7 = (UNUSED) 8 = P61LS - GR 9 = C61LS - GR 10 = (UNUSED) 11 = (UNUSED) 12 = (UNUSED) 13 = (UNUSED) 14 = (UNUSED) 15 = C61LS(A) - GR 16 = (UNUSED) 17 = D81CAN(-) - GR 18 = D82CAN(+) - YL 19 = (UNUSED) 20 = (UNUSED) 21 = (UNUSED) 22 = (UNUSED) 23 = P61LS(A) - GN
J1 BLACK 23 PIN CONNECTOR
J2 1
8
16
23
WHITE 23 PIN CONNECTOR
PIN NUMBERING FOR 23 PIN CONNECTORS
S-100 • S-105 • S-120 • S-125
6 - 11
October 2015
Section 6 • Schematics
Platform Controller Pin Legend
J1
PCON
PCON
PLATFORM
PLATFORM
CONTROLLER
CONTROLLER
J2
1 = VLVRET - BR 2 = (UNUSED) 3 = C17PRL - GR 4 = C18PRR - GR/BK 5 = C43JU - GR 6 = C44JD - GR/BK 7 = C14PLU - OR 8 = C15PLD - OR/BK 9 = (UNUSED) 10 = R90PXS - RD/BK 11 = C90PXS - RD/BK 12 = RET94LDS - GR 13 = C94LDS - WH 14 = R94LDS - BK 15 = C88PTS - RD/BK 16 = R56PTS - RD 17 = C56PTS - RD 18 = (UNUSED) 19 = PLATRET - BR 20 = C84TAY - GR/BK 21 = P85PTS - GR 22 = PTSRET - BR 23 = P87PTS - RD
6 - 12
BLACK 23 PIN CONNECTOR
J1
1 = GNDPCON - BR 2 = P52PCON - BL/RD 3 = (UNUSED) 4 = S56PRV - RD/WH 5 = (UNUSED) 6 = (UNUSED) 7 = P56PRV - RD 8 = (UNUSED) 9 = (UNUSED) 10 = (UNUSED) 11 = (UNUSED) 12 = (UNUSED) 13 = (UNUSED) 14 = (UNUSED) 15 = C47OUT - WH/BK 16 = C46HN - WH 17 = D81CAN(+) - YL 18 = D82CAN(-) - GR 19 = (UNUSED) 20 = (UNUSED) 21 = (UNUSED) 22 = (UNUSED) 23 = P23PCON - BK
J2 WHITE 23 PIN CONNECTOR
1
8
16
23
PIN NUMBERING FOR 23 PIN CONNECTORS
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Turntable Controller Pin Legend
1
24
J4 1
WHITE 35 PIN CONNECTOR
8
RETRACT BOOM 35
23
MACHINE NOT LEVEL PLATFORM NOT LEVEL
12
16
EMERGENCY STOP RAISE BOOM
EXTEND AXLE
61227
A
8
23
WHITE 23 PIN CONNECTOR
PIN NUMBERING FOR 23 PIN CONNECTORS
1
16
J3
AUXILIARY POWER
J5 WIRE LOOM
HIGH SPEED FUNCTION ENABLE
24
1
24
1
LOW SPEED FUNCTION ENABLE
12
J2
35
BLACK 35 PIN CONNECTOR ALARM
SERVICE BYPASS
RECOVERY
8
23
Part No. 102916
1
J1
1 = GNDPCON - BR 2 = P52PCON - WH 3 = C46HN - WH 4 = C47OUT - WH/BK 5 = P23PCON - BK 6 = S56PRV - RD/WH 7 = P56PRV - RD 8 = R48LP - WH/RD 9 = R117FB - RD 10 = (UNUSED) 11 = (UNUSED) 12 = (UNUSED) 13 = (UNUSED) 14 = (UNUSED) 15 = P97TET - BK 16 = (UNUSED) 17 = D81CAN(-) - GR 18 = D82CAN(+) - YL 19 = (UNUSED) 20 = (UNUSED) 21 = (UNUSED) 22 = (UNUSED) 23 = P95TET - OR
16
CONTROLLER
35
TCON
TURNTABLE
RUN
BLACK 23 PIN CONNECTOR
TCON
12
J1
PIN NUMBERING FOR 35 PIN CONNECTORS
TCON
TCON
TCON
TURNTABLE
TURNTABLE
TURNTABLE
TURNTABLE
CONTROLLER
CONTROLLER
CONTROLLER
CONTROLLER
J2
J2
J3
(S-120 & S-125 MODELS) 1 = GNDDCON - BR 2 = P21DCON - RD 3 = P53LS - WH/BK 4 = P54ENG - BK/WH 5 = P56PRV - RD 6 = P57PBD - 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/BL 14 = C65LOFL - BL/WH 15 = C66DREN - BL 16 = (UNUSED) 17 = C68PBD - RD 18 = C89PBE - BK 19 = C70PBE - BL/WH 20 = C71PBE - BL/BK 21 = (UNUSED) 22 = (UNUSED) 23 = V74PRLO - RD 24 = V75PRLO - RD/WH 25 = SNSR GND - BR 26 = (UNUSED) 27 = G119SR - BL 28 = C76PBE - BL 29 = C77AS - WH 30 = C78PS - WH/BK 31 = (UNUSED) 32 = (UNUSED) 33 = (UNUSED) 34 = (UNUSED) 35 = VLVRET1 - BR
(S-100 & S-105 MODELS) 1 = GNDDCON - BR 2 = P21DCON - RD 3 = P53LS - WH/BK 4 = P54ENG - BK/WH 5 = P56PRV - RD 6 = P57PBD - 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/BL 14 = C65LOFL - BL/WH 15 = C66DREN - BL 16 = (UNUSED) 17 = C68PBD - RD 18 = (UNUSED) 19 = C70PBE - BL/WH 20 = C71PBE - BL/BK 21 = (UNUSED) 22 = (UNUSED) 23 = V74PRLO - RD 24 = V75PRLO - RD/WH 25 = SNSR GND - BR 26 = (UNUSED) 27 = G119SR - BL 28 = (UNUSED) 29 = C77AS - WH 30 = (UNUSED) 31 = (UNUSED) 32 = (UNUSED) 33 = (UNUSED) 34 = (UNUSED) 35 = VLVRET1 - BR
1 = (UNUSED) 2 = R35RPM - BK/RD 3 = C21IGN - WH 4 = C34SA - BK/WH 5 = V30FWD - WH 6 = V31REV - WH/BK 7 = C46HRN - WH 8 = (UNUSED) 9 = C33STR - BK 10 = C30EDC - WH 11 = C31EDC - WH/BK 12 = C25PSR - WH/BK 13 = C26TSR - WH/RD 14 = RET85TTSR - BR 15 = P85TTSR - GN 16 = VLVRET2 - BR 17 = (UNUSED) 18 = C41RPM - OR/BK 19 = C107AF - RD 20 = C83TAX - GR/WH 21 = C84TAY - GR/BK 22 = C45GEN - GR/WH 23 = VLVRET3 - BR
TCON
TURNTABLE CONTROLLER
J5
1 = BATVLV - RD 2 = BATGND - BR 3 = BATGND - BR 4 = BATECU - RD
S-100 • S-105 • S-120 • S-125
J4
1 = VLVRET4 - BR 2 = C03PBF - RD/WH 3 = C09PERF - BK/RD 4 = C06TRF - WH/RD 5 = (UNUSED) 6 = (UNUSED) 7 = C01PBU - RD 8 = C02PBD - RD/BK 9 = C07PBE - BK 10 = C08PBR - BK/WH 11 = (UNUSED) 12 = (UNUSED) 13 = R49LP - WH/BK 14 = VLVRET5 - BR 15 = S2PLD2 - GN/BK 16 = S7PLE2 - GR/WH 17 = S7PLE1 - BL/BK 18 = S2PLD1 - BL.RD 19 = (UNUSED) 20 = (UNUSED) 21 = (UNUSED) 22 = (UNUSED) 23 = C113MFV - OR/RD 24 = (UNUSED) 25 = C0RTRL - WH 26 = C05TRR - WH/BK 27 = VLVRET7 - BR 28 = (UNUSED) 29 = (UNUSED) 30 = VLVRET6 - BR 31 = (UNUSED) 32 = C27AUX - RD 33 = (UNUSED) 34 = (UNUSED) 35 = (UNUSED)
6 - 13
October 2015
Section 6 • Schematics
Engine Relay and Fuse Panel Legend - Deutz TD2011 and Perkins 1104D Models Deutz TD2011L04i and Perkins 1104D-44T Models
1 CR77A
4
CR28
5
CR77B
CR41
7 F20
8 F23
9
10
F22
F7
CR17
6
13
CR5
11
12
15
16
CR1
CR15
14
Number
Component
Description
1
CR77A
PCE#1
2
CR28
Engine / Fule Relay
3
CR17
Hydraulic Oil Cooler Fan Relay
4
CR77B
PCE#2
5
CR41
Flashing Beacon Relay
6
CR5
Horn Relay
7
F20
Fuse, 20A, RPM Solenoid
8
F23
Fuse, 30A, Eng / Start / Fuel
9
F22
Fuse, 60A, Glow Plug
10
F7
Fuse, 20A, Hydraulic Oil Cooler / Horn
11
B3BAT
Fused Power from B1
12
B1BAT
Power from Battery
13
R21PIGN
Ignition
14
02PGND
Ground
15
CR1
Start Relay
16
CR15
Glow Plug Relay
6 - 14
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models
Deutz TD2.9 Models
1
2
3
4
CR39
CR77A
CR2
CR17
5
6
7
9 F27
10 F23
11
12
F22
F7
8
CR77B
CR41
17
30
CR5 16
Number
Component
1
CR39
Engine Shutdown
2
CR77A
PCE # 1
3
CR2
Engine Alt. Relay
4
CR17
Hydraulic Oil Cooler / Fan Relay
5
CR28
Fuel Pump
6
CR77B
PCE#2
7
CR41
Flashing Beacon Relay
8
CR5
Horn Relay
9
F27
Fuse, 20A, RPM Solenoid
10
F23
Fuse, 30A, Eng / Start / Fuel
85 87
CR15
Description
11
F22
Fuse, 60A, Glow Plug
12
F7
Fuse, 20A, Hydraulic Oil Cooler / Horn
13
B3BAT
Fused Power from B1
14
B1BAT
Power from Battery
15
R21PIGN
Ignition
16
02PGND
17
CR17
Ground Glow Plug Relay
Part No. 102916
14
15 86
CR28
13
S-100 • S-105 • S-120 • S-125
6 - 15
October 2015
Section 6 • Schematics
Engine Relay and Fuse Panel Legend - Perkins 854F Models Perkins 854F-34T Models
86
1 CR77A
30
87
2
3
CR2
CR17
85
4 CR77B
2
4
5
FX1
FX2
1
3
7
7
9 F27
10 F23
11
12
F22
F7
8
18
30
CR5 16
Number
Component
1
CR77A
PCE # 1
2
CR2
Engine Alt
3
CR17
Hydraulic Oil Cooler Fan Relay
4
CR77B
PCE#2
5
FX1
Fuse, 30A, ECU Power
85 87
CR81
Description
6
FX2
Fuse, 20A, Key Switch Power
7
CR41
Flashing Beacon Relay
8
CR5
Horn Relay
9
F27
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
14
B1BAT
Power from Battery
15
R21PIGN
Ignition
16
02PGND
17
CR1
Ground Engine Starter
18
CR81
ECU Power
6 - 16
14
15 86
CR41
13
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Telematics Connector Pin Legend
Genie installed Telematics connector is wried with an Active High digital input. Connector Pin Numbering
Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector. Pin
Circuit Type
Circuit Properties
Genie Machine Function(s)
Telematics Use Case
1
System Power
12VDC 5 Amp Max. allowed draw
Battery Positive - constant power
Supply power to device
2
System Ground 0VDC
Battery Negative
Device Ground
3
Digital Output 1 12VDC
Engine Run Hour Meter 12V = engine run, 0V = engine off
Monitor Engine Hours
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 12V = active, 0V = inactive
Monitor mechine utilization
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 Message
8*
Databus L
CAN LOW
Genie Databus
J1939 Engine Messages, Receive Proprietary Genie Telematics Message
*Tier IV engine models only, J1939 engine message available. *Genie proprietary databus support. Wireless Certifications Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply with the following: North America
PTCRB, FCC/IC
Europe
CE, R&TTE
Part No. 102916
S-100 • S-105 • S-120 • S-125
6 - 17
October 2015
Section 6 • Schematics
Electrical Symbols Legend
FS1
CB1
BLK
WHT
Quick disconnect terminal
OPS1 N.C.
PR1
15A
BLK
Foot switch
Circuit breaker with amperage Power relay
Oil pressure switch normally closed P1
H1 T-circuits connect
Emergency Stop button normally closed
Horn or alarm Sending unit
Toggle switch
Control relay contact normally open
G1
Circuits crossing no connection
Gauge
C
FAN
Hydraulic oil cooling fan
Fuel or RPM solenoid
OTS2 N.O.
Aux Pump
Oil temperature switch normally open
HM
Diode
B
HOLD
Flashing beacon
A
CR4 N.O.
PULL IN
FB
Connection no terminal
Auxiliary pump Coil
Hour meter +
CTS1 N.O.
KS2 RUN
SERVICE BYPASS/ RECOVERY KEY SWITCH
SERVICE BYPASS
A-A 1
2
RECOVERY
L3
A-B
Coolant temperature switch normally open
-
Battery
3
4
3
4
3
4
1
2
1
2
B-B
LED
Tilt sensor
C-B
2 30
C-A
87a 85
A
B C
BL
RD
BK
B-A
25A
Fuse with amperage
1
86
F1
5
87
4
Relay Service bypass/ recovery key switch
Starting aid: glow plug or flame ignitor Steer sensor
OFF
KS1
STARTER PCON 1
A-A 2
D1 ALTERNATOR
Starter motor Chassis ground
Power relay
A-B 3
4
1
B-A 2
3
4
EXCT BAT
BAT
-
+
AUX MAIN
MAIN KEYSWITCH
TCON
B-B
STA.
LS3 REGULATOR
N.O.H.C
Battery separator
6 - 18
N.C.H.O
Limit switch
IND.
ALTERNATOR
S-100 • S-105 • S-120 • S-125
Main key switch
Current limiting device
Part No. 102916
October 2015
Section 6 • Schematics
Hydraulic Symbols Legend
25 psi (1.7 bar) Accumulator
Filter with bypass valve relief setting
Differential sensing valve
.035" (0.89 mm)
Directional valve pilot operated 2 position, 2 way
Orifice with size
Shut off valve
Solenoid operated proportional valve
Pump fixed displacement
Solenoid operated 3 position, 4 way, directional valve
Check valve 200 psi (13.8 bar)
2 position, 3 way, shuttle valve Pump bi-directional, variable displacement
Relief valve with pressure setting
Priority flow regulator valve
o
Hydraulic oil cooler
Solenoid operated 2 position, 3 way, directional valve Motor bi-directional Directional valve (mechanically activated)
3000 psi (206.8 bar) 3:1
Brake
Motor 2-speed, bi-directional
Pilot operated 3 position, 3 way, shuttle valve
Counterbalance valve with pressure and pilot ratio
E Pump prime mover (engine or motor)
50%
50%
Flow divider/combiner valve with pressure balancing orifice and flow percentages 2 position, 2 way solenoid valve
Double acting cylinder
Part No. 102916
S-100 • S-105 • S-120 • S-125
6 - 19
October 2015
Section 6 • Schematics
This page intentionally left blank.
6 - 20
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Safety Circuit Schematic
CB1
D23
VR1
PWR STAT IN 1 OUT 1 IN 2 OUT 2
P_15
40A
(K2)
30
87a
CR11
86 87
30
(K3)
85
87a
CR12
86 87
(K4)
85
30
87a
86 87
D14
P_9A
CR17
5A
P_6R1
P_6R2
(K8) P_9A
P_7R
TCON/J2/4
TCON/J2/5
TCON/J2/3
TCON/J2/6
87a
30
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
TCON/J3/4
87 TCON/J4/8
TO TURNTABLE FLOW CONTROL ROTATE VALVE
TO BOOM DOWN VALVE
85 86 CHOKE
NFET
(K7)
87a
P_7R
LSB9AS 65 DEGREES DCON/J1/3
P_16
LSB2RS 101' (30.8 m)
LSB7DS
88
88
NFET
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2 NFET
PWR STAT OUT 1 IN 1 OUT 2 IN 2
GND
BOOM DOWN
TO DRIVE LP RELAY 20 K R3
SJ1
TO STARTER RELAY
LSAX1ES AXLE EXTEND
SJ2
TCON/J4/35 TCON/J3/9
NFET
PWR STAT OUT 1 IN 1 OUT 2 IN 2
GND
D16
TO ROTATE CCW VALVE LSB4ES 80' (24.4 m)
NFET
LSAX2ES AXLE EXTEND
PWR STAT OUT 1 IN 1 OUT 2 IN 2
P_14
GND P_11
LSB8AS 50 DEGREES
TCON/J4/10
TO ROTATE CW VALVE
TCON/J4/25 TCON/J4/26
TCON/J4/3
TCON/J3/5
TO FORWARD VALVE
TCON/J3/6 TO REVERSE VALVE
NFET
30
TCON/J3/2
87
TO HI/LO SOLENOID
85 86 HI/LO
TCON/J2/23
TO PRIMARY 1 LOCKOUT VALVE
TCON/J2/24
TO PRIMARY 2 LOCKOUT VALVE
TCON/J4/23
TO MULTIFUNCTION VALVE
NFET
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2 NFET
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
88
88
TO ROTATE CCW VALVE
P57PBD
P57PBD
C60AXEX
S62BSTO
P53LS
P58LS
NFET
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
TO AUXILIARY RELAY
NFET
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
CR17
P54ENG
TCON/J4/32
NFET
P53LS
P53LS
P53LS
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
P57PBD
P57PBD
TO TURNTABLE FLOW CONTROL ROTATE VALVE
NFET
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
85
CR16
P_7R
TCON/J2/23
CR10 (K6)
C60AXEX
S62BSTO
P58LS
TCON/J2/7
C60AXEX
TCON/J2/9
S62BSTO
P_9B D13
NFET
TCON/J2/11
P63LS
(P_14)
LSB3RS BOOM RETRACT
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
P_11 D17
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2
87a
30
TCON/J3/3
TO FUEL SOLENOID
TCON/J4/7
TO BOOM UP VALVE
TCON/J4/9
TO BOOM EXTEND VAVLE
87 86
85
NFET P63LS
TCON/J2/12
88
(P_18)
LSB6S CABLE TENSION
P_10
PWR GND STAT IN 1 OUT 1 IN 2 OUT 2 NFET
S59CNBK
TCON/J2/8
C61AXRT
TCON/J2/10 MONITORED BY ECU
P53LS
DCON/J1/3
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-21
Section 6 • Schematics
October 2015
Safety Circuit Schematic
6-21
6-22
October 2015
Section 6 • Schematics
Engine Options - Perkins and Cummins S-100/105 to serial number 218) S-120/125 to serial number 932)
6-23
6-24
STARTER AUX. PUMP
S-100 • S-105 • S-120 • S-125 REGULATOR IND.
Part No. 102916 STA. C26TSR-WT/RD
RET85TTSR-BR
0-20 DEGREE SENSOR ALARM SET AT 4.5 DEGREES
TURNTABLE TILT SENSOR
P85TTSR-GR
OIL TEMP SENDER
70 A FUSE
C34SA-BK/WH
+ + -
C25PSR-WT/BK
C21IGN-WH
R34SA-BK/WH
VLVRET2-BR
FLAMMSTART RELAY
BATGND(A) - BK
C83TAX-GN/WH
OIL PRESSURE
3
V31REV-WH/BK
RD-HOLD
C84TAY-GN/WH
FUEL SOLENOID RELAY
2
BAT GND-BR
SERVICE HORN 1 86
BAT GND-BR
BAT. -
2
FLAMMSTART IGNITOR
EXCT.
REV VLV B SOLENOID
ALTERNATOR
V30FWD-WH
87a 87 85 4 5 WH-PULL IN
P114BAT-RD
FWD VLV A SOLENOID
COM HORN RELAY
BK
S-500 2 86
RD
1 30
HI/LO SPEED SOLENOID
BAT. + C41RPM-OR/BK
C107AF-RD
-BAT
WH
+AUX
HOLD
+BAT
PULL IN
87a 87 85 4 5 STARTER WAS 10A BEFORE: RELAY S100/105- SN 159 S120/125- SN 619
VLVRET2-BR
TROMBETTA MOM N.O. TIME DELAY
VLVRET2-BR
86
P46HRN(A)-WH
2
30
RD-HOLD
P1-01 SYS_BAT_PWR P1-02 SYS_BAT_GND P1-03 AUX/START_BAT_GND P1-04 AUX/START_BAT_PWR
BATVLV-RD BATGND-BR BATGND-BR BATECU-RD
IGNITION/FUEL STARTER_RELAY FWD REV OIL_PRESSURE
P1-09
P1-11 P1-12
C30EDC-WH C31EDC-WH/BK C25PSR-WH/BK
TT_TILT_SNSR_GND TT_TILT_SNSR_PWR VALVE_RTN2
P1-15 P1-16
P85TTSR-GR VLVRET2-BR
VALVE_RTN3
P1-21 P1-22 P1-23
C84TAY-GR/BK C45GEN-GR/WH VLVRET3-BR
J31-TILT SNSR
P31-ENG HARN
TT_TILT_X_AXIS TT_TILT_Y_AXIS AC_GENERATOR
P1-20 C83TAX-GR/WH
ALTENATOR_RPM ALT_FIELD_WIRE
P1-18 P1-19
C41RPM-OR/BK C107AF-RD
P1-17
OIL/WATER_TEMP
P1-13 P1-14
C26TSR-WH/RD RET85TTSR-GR
C33STR-BK
P1-10
SERVICE_HORN
P1-06 P1-07
V31REV-WH/BK C46HRN-WH
P1-08
P1-05 V30FWD-WH
CHOKE/GLOW PLUG
P1-03 P1-04
C21IGN-WH C34SA-BK/WH
VALVE RTN1 THROTTLE
P1-01 P1-02
VLVRET1-BR R35RPM-BK/RD
ENGINE HARN
WH-PULL IN
CB 25A
J3 WHITE 23 PIN
BAT GND-BR
1
C27AUX-RD
15 A FUSE
TO J4-32 WHITE 35 PIN
PR1
J29 PWR HARN P29 ENG HARN
VLVRET6-BR
P46HRN-WH
AUX MAIN
POWER HARN
BAT GND-BR
P33STR-BK
BAT CBL(A)-RD
P114BAT-RD
J5 BLACK 4 PIN
TO J4-30 WHITE 35 PIN
ENGINE BLOCK START BAT
+
6-24 +
MAIN (SYS) BAT
Section 6 • Schematics October 2015
Engine Option - Perkins and Cummins S-100/105 to serial number 218) S-120/125 to serial number 932)
BAT GND-BR
J32-ENG HARN C45GEN-GR/WH 1 2 3
1
PERKINS 1004-42 ENGINE CUMMINS 4B3.9L ENGINE
BAT CBL(A)-RD
1 30
85 87 87a 5 4
-
STARTER AUX. PUMP REGULATOR IND.
STA.
Part No. 102916
FUEL PUMP
S-100 • S-105 • S-120 • S-125
BAT GND-BR
C26TSR-WT/RD
C25PSR-WT/BK
86
TURNTABLE TILT SENSOR
RET85TTSR-BR
C21IGN-WH
C34SA-BK/WH
P85TTSR-GN
C21IGN-WH
2
COLD START ADVANCE
GLOW PLUG RELAY
BK-COM
R34SA-RD
VLVRET2-BR
C30EDC-WH
WH-PULL RD-HOLD
+ + -
OIL TEMP SENDER
3 C31EDC-WH/BK
C83TAX-GN/WH
OIL PRESSURE
2
BK-COM
C84TAY-GN/BK
FUEL SHUTDOWN
1 VLVRET2-BR
RD-HOLD
P114BAT-RD
GLOW PLUGS
BAT. -
WH-PULL IN
J32-ENG HARN C45GEN-GN/WH 1 2 BAT GND-BR
FWD VLV A SOLENOID
EXCT. BK
87a 87 85 4 5
HORN RELAY
REV VLV B SOLENOID
ALTERNATOR
2 86
HI/LO SPEED SOLENOID
BAT. +
1 30
RD
87a 87 85 4 5
WH
2 86
HOLD
S-500
PULL IN
+BAT
R46HRN-WH
+AUX -BAT
VLVRET2-BR
70 A FUSE
C107AF-RD
P1-01 P1-02 P1-03 P1-04
BATVLV-RD BATGND-BR BATGND-BR BATECU-RD
SYS_BAT_PWR
V31REV-WH/BK C46HRN-WH
OIL/WATER_TEMP TT_TILT_SNSR_GND TT_TILT_SNSR_PWR VALVE_RTN2
P1-15 P1-16
P85TTSR-GN VLVRET2-BR
ALTENATOR_RPM ALT_FIELD_WIRE TT_TILT_X_AXIS TT_TILT_Y_AXIS AC_GENERATOR VALVE_RTN3
P1-18 P1-19 P1-20 P1-21 P1-22 P1-23
C84TAY-GN/BK C45GEN-GN/WH VLVRET3-BR
J31-TILT SNSR
P31-ENG HARN
C41RPM-OR/BK C107AF-RD C83TAX-GN/WH
P1-17
OIL_PRESSURE P1-13 P1-14
C25PSR-WH/BK
P1-12
P1-11 C30EDC-WH
C26TSR-WH/RD
P1-10
C31EDC-WH/BK
RET85TTSR-BR
C31EDC-WH/BK C30EDC-WH
P1-09 C33STR-BK
STARTER_RELAY
FWD REV SERVICE_HORN
P1-06 P1-07
V30FWD-WH
P1-08
CHOKE/GLOW PLUG
P1-04 P1-05
C34SA-BK/WH
THROTTLE IGNITION/FUEL
P1-02 P1-03 C21IGN-WH
AUX/START_BAT_PWR
AUX/START_BAT_GND
SYS_BAT_GND
R35RPM-BK/RD
P1-01
ENGINE HARN
C41RPM-OR/BK
CB 25A
J3 WHITE 23 PIN
BAT GND-BR
C27AUX-RD
1 30
TO J4-32 WHITE 35 PIN
PR1
STARTER RELAY
VLVRET6-BR
AUXMAIN
POWER HARN
BAT GND-BR
P114BAT-RD
J5 BLACK 4 PIN
TO J4-30 WHITE 35
ENGINE BLOCK START BAT
+
+
MAIN (SYS) BAT
October 2015 Section 6 • Schematics
Engine Option - Perkins
S-100/105 from serial number 219 to 247) S-120/125 from serial number 933 to 984)
0-20 DEGREE SENSOR ALARM SET AT 4.5 DEGREES
3
SEE GENERATOR OPTIONS PAGE
PERKINS 1104C-44 ENGINE
15 A FUSE
P46HRN-WH P34SA-RD
TROMBETTA TIME DELAY MOM N.O.
1 30
85 87 87a 5 4
SERVICE HORN
6-25
Section 6 • Schematics
October 2015
Engine Option - Perkins
S-100/105 from serial number 219 to 247) S-120/125 from serial number 933 to 984)
6-25
6-26
October 2015
Section 6 • Schematics
Engine Options- Perkins
S-100/105 (from serial number 248) S-120/125 (from serial number 985)
6-27
6-28
-
STARTER AUX. PUMP REGULATOR
S-100 • S-105 • S-120 • S-125 IND.
Part No. 102916
STA.
FUEL PUMP OIL TEMP SENDER
BAT GND-BR
C26TSR-WT/RD
85 87 87a 5 4 86
C25PSR-WT/BK
C116HYD-OR
TURNTABLE TILT SENSOR
RET85TTSR-BR
OIL PRESSURE
2
P116HYD-OR
P85TTSR-GN
C21IGN-WH
1 30
+ + -
C21IGN-WH
86
R116HYD-OR
2
HYD COOLER RELAY
CB7
COLD START ADVANCE
15A C34SA-BK/WH
WH-PULL RD-HOLD
R34SA-RD
VLVRET2-BR
GLOW PLUG RELAY
C83TAX-GN/WH
FUEL SHUTDOWN
3
C30EDC-WH
C84TAY-GN/BK
BAT GND-BR
2
C31EDC-WH/BK
TROMBETTA TIME DELAY MOM N.O.
BAT GND-BR
SERVICE HORN 1 BK-COM
P114BAT-RD
GLOW PLUGS
BAT. WH-PULL IN
J32-ENG HARN C45GEN-GN/WH 1 2 BAT GND-BR
FWD VLV A SOLENOID
EXCT.
VLVRET2-BR
87a 87 85 4 5
HORN RELAY
REV VLV B SOLENOID
ALTERNATOR
2 86
HI/LO SPEED SOLENOID
BAT. +
1 30
BK
CB7 ADDED S100- S/N 710 S125- S/N 2589
PULL IN
87a 87 85 4 5
WH
S-613
HOLD
2 86
RD-HOLD
BK-COM
RD
+BAT
R46HRN-WH
+AUX -BAT
VLVRET2-BR
70 A FUSE
C41RPM-OR/BK
P1-01 P1-02 P1-03 P1-04
BATVLV-RD BATGND-BR BATGND-BR BATECU-RD
SYS_BAT_PWR
SERVICE_HORN
P1-07
V31REV-WH/BK C46HRN-WH
OIL/WATER_TEMP TT_TILT_SNSR_GND TT_TILT_SNSR_PWR VALVE_RTN2
P1-15 P1-16
P85TTSR-GN VLVRET2-BR
J31-TILT SNSR
P31-ENG HARN
TT_TILT_Y_AXIS AC_GENERATOR VALVE_RTN3
P1-21 P1-22 P1-23
C84TAY-GN/BK
P1-20 C83TAX-GN/WH
C45GEN-GN/WH
ALT_FIELD_WIRE TT_TILT_X_AXIS
P1-19 C107AF-RD
VLVRET3-BR
ALTENATOR_RPM
P1-18 C41RPM-OR/BK
P1-17
OIL_PRESSURE P1-13 P1-14
C26TSR-WH/RD RET85TTSR-BR
C31EDC-WH/BK C30EDC-WH
P1-11 C25PSR-WH/BK
P1-12
C30EDC-WH
P1-09 P1-10
C33STR-BK C31EDC-WH/BK
STARTER_RELAY
FWD REV P1-06
V30FWD-WH
P1-08
CHOKE/GLOW PLUG
P1-04 P1-05
C34SA-BK/WH
THROTTLE IGNITION/FUEL
P1-02 P1-03 C21IGN-WH
AUX/START_BAT_PWR
AUX/START_BAT_GND
SYS_BAT_GND
R35RPM-BK/RD
P1-01
ENGINE HARN
C107AF-RD
CB 25A
J3 WHITE 23 PIN
BAT GND-BR
C27AUX-RD
STARTER RELAY
TO J4-32 WHITE 35 PIN
PR1
1 30
VLVRET6-BR
AUXMAIN
POWER HARN
BAT GND-BR
P114BAT-RD
J5 BLACK 4 PIN
TO J4-30 WHITE 35
ENGINE BLOCK START BAT
+
6-28 +
MAIN (SYS) BAT
Section 6 • Schematics October 2015
Engine Option - Perkins
S-100/105 from serial number 248) S-120/125 from serial number 985)
0-20 DEGREE SENSOR ALARM SET AT 4.5 DEGREES
3
SEE GENERATOR OPTIONS PAGE
PERKINS 1104C-44 ENGINE PERKINS 804D-33T ENGINE
15 A FUSE
P46HRN-WH P34SA-RD
20 A FUSE P116HYD-OR
OTS1 N.O.
1 30
85 87 87a 5 4
October 2015
Section 6 • Schematics
Engine 2ELAY ,AYOUT - Perkins from serial number 874
6-29
6-30
October 2015
Section 6 • Schematics
Engine 2ELAY ,AYOUT - Perkins (from serial number 874)
Number
Component
Description
1
Horn Relay
2
Engine Fule Relay
3
Oil Cooler
4
Start Relay
5
Glow Plug Relay
6
Speed Solenoid
7
Fuse, 30A, Eng / Start / Fuel
8
Fuse, 60A, Glow Plug
9
Fuse, 20A, Hydraulic Oil Cooler / Horn
10
B3PBAT
Fused Power from B1
11
B1PBAT
Power from Battery
12
R21PIGN
Ignition Fuse, 20A, RPM Solenoid
13
02PGND
Ground
6-30
S-100 • S-105 • S-120 • S-125
Part No. 102916
STARTER AUX. PUMP REGULATOR IND.
STA.
SERVICE HORN
Part No. 102916 S-100 • S-105 • S-120 • S-125
BAT GND-BR
86
C26TSR-WT/RD
2
TURNTABLE TILT SENSOR
RET85TTSR-BR
OIL TEMP SENDER
BK-COM
275 A FUSE
P85TTSR-GN
C25PSR-WT/BK
+AUX
C34SA-BK/WH
WH-PULL
C21IGN-WH
GRID HEATER RELAY
RD-HOLD
R34SA-RD
VLVRET2-BR
C30EDC-WH
TROMBETTA TIME DELAY MOM N.O.
+ + -
OIL PRESSURE
3 C31EDC-WH/BK
C84TAY-GN/BK
FUEL SOLENOID RELAY
2
BK-COM
C83TAX-GN/WH
BAT GND-BR
1 VLVRET2-BR
RD-HOLD
P114BAT-RD
GRID HEATER
BAT. -
WH-PULL IN
C45GEN-GN/WH 1 BAT GND-BR 2
FWD VLV A SOLENOID
EXCT. BK
87a 87 85 4 5
HORN RELAY
REV VLV B SOLENOID
ALTERNATOR
2 86
RD
P34SA-RD
HI/LO SPEED SOLENOID
BAT. +
1 30
WH
S-500
HOLD
-BAT
PULL IN
85 5
R46HRN-WH
+BAT
VLVRET2-BR
70 A FUSE
C107AF-RD
SYS_BAT_PWR SYS_BAT_GND AUX/START_BAT_GND AUX/START_BAT_PWR
P1-01 P1-02 P1-03 P1-04
BATVLV-RD BATGND-BR BATGND-BR BATECU-RD
FWD REV SERVICE_HORN
P1-06 P1-07
C34SA-BK/WH V30FWD-WH V31REV-WH/BK C46HRN-WH
OIL_PRESSURE OIL/WATER_TEMP
P1-10 P1-11 P1-12 P1-13
C31EDC-WH/BK C30EDC-WH C25PSR-WH/BK C26TSR-WH/RD
VALVE_RTN2
P1-16 VLVRET2-BR
ALTENATOR_RPM ALT_FIELD_WIRE TT_TILT_X_AXIS
P1-19 P1-20
C107AF-RD C83TAX-GN/WH
VALVE_RTN3
P1-23 VLVRET3-BR
P31-ENG HARN J31-TILT SNSR
TT_TILT_Y_AXIS AC_GENERATOR
P1-21 P1-22
C84TAY-GN/BK C45GEN-GN/WH
C41RPM-OR/BK
P1-18
P1-17
TT_TILT_SNSR_GND TT_TILT_SNSR_PWR
P1-14 P1-15
RET85TTSR-BR P85TTSR-GN
C31EDC-WH/BK C30EDC-WH
P1-09 C33STR-BK
STARTER_RELAY
CHOKE/GLOW PLUG
P1-04 P1-05
C21IGN-WH
P1-08
THROTTLE IGNITION/FUEL
P1-02 P1-03
R35RPM-BK/RD
P1-01
J3 WHITE 23 PIN
C41RPM-OR/BK
CB 25A
ENGINE HARN
BAT GND-BR
2 86
C27AUX-RD
1 30 STARTER RELAY 87a 87 4
TO J4-32 WHITE 35 PIN
PR1
AUXMAIN
J5 BLACK 4 PIN
BAT GND-BR
P114BAT-RD
POWER HARN
VLVRET6-BR TO J4-30 WHITE 35 PIN
ENGINE BLOCK START BAT
+
+
MAIN (SYS) BAT
October 2015 Section 6 • Schematics
Engine Option - Cummins
S-100/105 from serial number 219 to 247) S-120/125 from serial number 933 to 984)
0-20 DEGREE SENSOR ALARM SET AT 4.5 DEGREES
J32-ENG HARN
3
SEE GENERATOR OPTIONS PAGE
CUMMINS B4.5 C80 ENGINE
P46HRN-WH P34SA-RD
1 30
85 87 87a 5 4
6-31
Section 6 • Schematics
October 2015
Engine Option - Cummins
S-100/105 from serial number 219 to 247) S-120/125 from serial number 933 to 984)
6-31
6-32
October 2015
Section 6 • Schematics
Engine Option - Cummins
S-100/105 from serial number 248) S-120/125 from serial number 985)
6-33
6-34
STARTER AUX. PUMP
S-100 • S-105 • S-120 • S-125 REGULATOR IND.
Part No. 102916 STA. BAT GND-BR
C26TSR-WT/RD
86
C25PSR-WT/BK
2
TURNTABLE TILT SENSOR
RET85TTSR-BR
OIL TEMP SENDER
85 87 87a 5 4 P116HYD-OR
P85TTSR-GN
OIL PRESSURE
1 30
+ + -
FUEL SOLENOID RELAY
15A C116HYD-OR
275 A FUSE
C84TAY-GN/BK
C21IGN-WH
86
R116HYD-OR
2
HYD COOLER RELAY
CB7
R34SA-RD
WH-PULL
C34SA-BK/WH
C83TAX-GN/WH
BAT GND-BR
3
VLVRET2-BR
GRID HEATER RELAY
RD-HOLD
BAT GND-BR
2
C30EDC-WH
TROMBETTA TIME DELAY MOM N.O.
BAT GND-BR
SERVICE HORN 1
C31EDC-WH/BK
P114BAT-RD
GRID HEATER
BAT. BK-COM
C45GEN-GN/WH 1 BAT GND-BR 2
FWD VLV A SOLENOID
EXCT.
VLVRET2-BR
87a 87 85 4 5
HORN RELAY
REV VLV B SOLENOID
ALTERNATOR
2 86
WH-PULL IN
P34SA-RD
HI/LO SPEED SOLENOID
BAT. +
1 30
BK
CB7 ADDED S100- S/N 710 S125- S/N 2589
WH
S-613
PULL IN
85 5 RD-HOLD
BK-COM
RD
-BAT
HOLD
+AUX
R46HRN-WH
+BAT
VLVRET2-BR
70 A FUSE
C107AF-RD
SYS_BAT_PWR SYS_BAT_GND AUX/START_BAT_GND AUX/START_BAT_PWR
P1-01 P1-02 P1-03 P1-04
BATVLV-RD BATGND-BR BATGND-BR BATECU-RD
FWD REV SERVICE_HORN
P1-04 P1-05 P1-06 P1-07
C34SA-BK/WH V30FWD-WH V31REV-WH/BK C46HRN-WH
OIL/WATER_TEMP TT_TILT_SNSR_GND TT_TILT_SNSR_PWR VALVE_RTN2
P1-12 P1-13 P1-14 P1-15 P1-16
C25PSR-WH/BK C26TSR-WH/RD RET85TTSR-BR P85TTSR-GN VLVRET2-BR
ALTENATOR_RPM ALT_FIELD_WIRE TT_TILT_X_AXIS TT_TILT_Y_AXIS AC_GENERATOR VALVE_RTN3
P1-19 P1-20 P1-21 P1-22 P1-23
C107AF-RD C83TAX-GN/WH C84TAY-GN/BK C45GEN-GN/WH VLVRET3-BR
P31-ENG HARN J31-TILT SNSR
C41RPM-OR/BK
P1-18
P1-17
OIL_PRESSURE
P1-10 P1-11
C33STR-BK C31EDC-WH/BK C30EDC-WH
C31EDC-WH/BK C30EDC-WH
P1-09
STARTER_RELAY
CHOKE/GLOW PLUG
P1-03 C21IGN-WH
P1-08
THROTTLE IGNITION/FUEL
P1-02 R35RPM-BK/RD
P1-01
J3 WHITE 23 PIN
C41RPM-OR/BK
CB 25A
ENGINE HARN
BAT GND-BR
2 86
C27AUX-RD
1 30 STARTER RELAY 87a 87 4
TO J4-32 WHITE 35 PIN
PR1
AUXMAIN
J5 BLACK 4 PIN
BAT GND-BR
P114BAT-RD
POWER HARN
VLVRET6-BR TO J4-30 WHITE 35 PIN
ENGINE BLOCK START BAT
+
6-34 +
MAIN (SYS) BAT
Section 6 • Schematics October 2015
Engine Options- Cummins
S-100/105 (from serial number 248) S-120/125 (from serial number 985)
0-20 DEGREE SENSOR ALARM SET AT 4.5 DEGREES
J32-ENG HARN
3
SEE GENERATOR OPTIONS PAGE
CUMMINS B4.5 C80 ENGINE CUMMINS B3.3T ENGINE
P46HRN-WH P34SA-RD
20 A FUSE P116HYD-OR
OTS1 N.O.
1 30
85 87 87a 5 4
October 2015
Section 6 • Schematics
Electrical Schematic - Generator Options
6-35
6-36
October 2015
Section 6 • Schematics
Electrical Schematic - Generator Options Hydraulic Generator Option
Belt-Driven Generator Option
J32-ENG HARN
P32-GEN HARN WT
2 86 85 5
GN
3
BK
BLACK WHITE GREEN RED AC BLACK BLUE GENERATOR YELLOW
RED BLACK
BLACK
YELLOW WHITE
BLACK
L1
GREEN
GND
T1
4
1 30 87
C45GEN-GN/WH 1 2 BAT GND-BR P114BAT-RD
30A
87a 3 RD/12VDC
RD
BR/R45GEN(A)
BR
WHITE T2
YL/BAT GND
RD
YL
BR/P45GEN(B)
BR
PURPLE/F45GEN
PR
WHITE WHITE T3
1 2 3 4 DTP04-4P
WHITE T4
1 2 3 4 GENERATOR JUMPER HARNESS
L2
RD BK BL PLUG
CB
GREEN BLACK
110 VAC REGULATOR BLACK
WHT-NEUTRAL
5
120VAC AUTO RESET CB
8
PURGE-BL
BLACK
PLUG PLUG
BLK-120VAC 15A 120VAC, 50Hz, 1 PH
C45GEN-GR/WH BATGND-BR P114 BAT-RD PLUG
120VAC GENERATOR W/REGULATOR.
C45GEN-GR/WH BATGND-BR P114 BAT-RD PLUG
120VAC, 60Hz, 1 PH
87a 3 P32-GEN HARN
30A
WT
BAT GND-BR
2
GR
P114BAT-RD
3
BK
2 86
4
RD/12VDC
RD
87 BR/R45GEN(A)
BR
YL/BAT GND
YL
85 5 BR/P45GEN(B)
RD
BR PURGE-BL
PURPLE/F45GEN
PR RED BLACK
WHITE
L2 PLUG BL BK RD
T1
220 VAC REGULATOR
WHT-NEUTRAL
1 2 3 4 T2
220VAC AUTO RESET CB BLK-220VAC 12.5A
YELLOW
WHITE
WHITE
WHITE
T4
GREEN BLACK BLACK
220VAC GENERATOR W/REGULATOR. BLACK
240VAC, 50Hz, 1 PH
Part No. 102916
GND
BLACK
L1
WHITE
BLACK 8
S-100 • S-105 • S-120 • S-125
GREEN
GENERATOR JUMPER HARNESS DTP04-4P
1 2 3 4
T3
5
6-36
ENGINE HARNESS
PLUG PLUG
J32-ENG HARN C45GEN-GN/WH 1
1 30
ENGINE HARNESS
YELLOW AC BLUE GENERATOR BLACK RED GREEN WHITE BLACK
October 2015
Section 6 • Schematics
Electrical Schematic - 12 kW Generator (welder option)
NEUTRAL BUSS BAR
12.5 KW HYDRAULIC GENERATOR NEMA 4 CONTROL BOX
L1
MODIFIED ENCLOSURE WIRING
L3
L2
X
Y 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
208 VAC OUTLET L2
SX CONTROLLER SAUER #K23334
WHITE
N
TERMINAL
CIRCUIT
COLOR
A1
P23PWR
RD/WH
SENSOR POWER +5V
A3
BATTERY-
BR
V151HG
GR
NC V150HG
GR/BK
C1
TxD
YEL
C2
RxD
GR
B3
L3
C3
/BOOT JOYSTICK
D2
NC
D3
NC
5
4
1
2
BLACK
L1 BLACK
NOT USED
E2
NOT USED
E3
NOT USED
F1
NOT USED
GROUND MADE UP OF MULTIPLE 8GA CONDUCTORS BETWEEN MAJOR ASSEMBLIES
GREEN
BLACK 12GA
20 AMP CIRCUIT BREAKER GROUND STUD ON PANEL
WH
SILVER
E1
WHITE
N
GREEN
D1
Z
RED
RD
A2
B1 B2
6
3
RED
BRASS
6 GA 4 CONDUCTOR SILVER
BLACK 10GA
WHITE
120 VAC GFI
GREEN
BRASS
110 VAC GFI
6 GA 4 CONDUCTOR GREEN
BLACK GREEN 10GA
F2
C45GEN
F3
NOT USED
GR/WH
ENCLOSURE
10 GA 3 CONDUCTOR
10 GA 3 CONDUCTOR
EDC-
J159-3
WH/BK
J159-2
WH
8
EDC+
1 32 4
7
EDC -
2
J159-7
EDC +
1
J159-6
2 3 J159-4 BYPASS COIL
J159-10 J159-1
V151HG GR
TCON
P23PWR(A)
BK
BK-2
V150HG GR/BK
RD/WH
J159-5 BK
J3-22
GND1
124 ohms
124 ohms
BATTERY
GR
AUXILIARY PUMP
RD FUSE 10A WH
P23PWR (12V STUD)
3
2
1
9 10 11 12
RD/WH
P23PWR
J1-18
4
D81CAN- GR
5
D82CAN+ YL
8
J21-17
7
J21-18
TIME DELAY MODULE 4 SECOND
U36
6
PCON
J159-1 P23PWR BK
8 N.C.
J159
1 N.O.
BL/RD
2 COM
WH/BK BK/RD
3 GND 5 SW INPUT
WH
RD/WH
A1 BATTERY + A2 SENSOR POWER +5 VDC A3 BATTERY-
GR/WH
3 J1-17
RD CR4 HIGH IDLE RELAY
RD/BK
J3-2
OR/RD
J31-18
DCON
RD/WH MOTOR STROKE VALVE
J32-4
J31-17
RD/WH
C45GEN GR/WH
1K
2 1
WH/RD
C1 TxD
GR/BK GR
B1 VALVE 0 FWD COIL B2 VALVE 1 NC B3 DIGITAL OUTPUT BYPASS/OMRON
7
A RS232TxD
CIRCUIT # P23PWR(A) C30EDC+ C31EDCGND1 P23PWR C30EDC+(A) C31EDC-(A) GND2 C45GEN V150HG P23PWR GND
C3 BOOT
COLOR WH/RD WH WH/BK BK/RD BL/RD RD RD/BK OR/RD GR/WH GR/BK RD/WH GR
GND AUXILIARY PUMP
1 2 3 4 5 6 7 8 9 10 11 12
C2 RxD
SX CONTROLLER
8 PIN#
D1 ANALOG 0 JOYSTICK D2 ANALOG 1 NC D3 DIG IN 3 NC
5
J159 (TO EDC HARNESS)
E1 NOT USED E2 NOT USED E3 NOT USED
6
CR50 OMRON RELAY
F1 DIG IN 0
3
F2 DIG IN 1 GENERATOR ON F3 DIG IN 2
4
C
GND
J129 B RS232RxD
RxD
C
J159-9
B
1
2
C57-1
TxD
PRESSURE SWITCH 200 PSI
CIRCUIT
A
RD-1
TERM
PS4
J129 RS232 CONNECTOR
N.O.
BR
C57-2
C
Y75-1
A
PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD
DIVERTER MANIFOLD
YEL B
J159
J159-12 GND Y75-2
GR
J129
P23PWR(A) C30EDC+ C31EDCGND1 P23PWR C30EDC+(A) C31EDC-(A)
6
5
U4
1 RD
J3-11
WH BR
J3-10
SX CONTROLLER
CKT#
F
PIN# COLOR
E
C45GEN V150HG P23PWR GND
D
BK WH WH/BK BR BK WH WH/BK PLUG GR/WH GR/BK BK BR
C
1 2 3 4 5 6 7 8 9 10 11 12
B
CR50 OMRON RELAY
A
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-37
Section 6 • Schematics
October 2015
Electrical Schematic - 12 kW Generator (welder option)
6-37
6-38
October 2015
Section 6 • Schematics
Perkins 1104D-44T Engine Electrical Schematic
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-39
Section 6 • Schematics
October 2015
Perkins 1104D-44T Engine Electrical Schematic
6-39
6-40
October 2015
Section 6 • Schematics
Perkins 854F-34T Engine Electrical Schematic
6-41
6-42
Section 6 • Schematics
October 2015
Perkins 854F-34T Engine Electrical Schematic
6-42
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Perkins 854F-34T Engine Electrical Harness
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-43
Section 6 • Schematics
October 2015
Perkins 854F-34T Engine Harness
6-43
6-44
October 2015
Section 6 • Schematics
Deutz TD2.9 Engine Electrical Schematic
6-45
6-46
Section 6 • Schematics
October 2015
Deutz TD2.9 Engine Electrical Schematic
6-46
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Deutz TD2.9 Engine Electrical Harness
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-47
Section 6 • Schematics
October 2015
Deutz TD2.9 Engine Electrical Harness
6-47
6-48
October 2015
Section 6 • Schematics
Hydraulic Schematic - 12 kW Generator (welder option)
B
DRIVE PUMP
3.5 GPM / 13.25L/min
OIL COOLER
A
PMP B
CLR
PMP A
WELDER MANIFOLD
CW
0.030 inch / 0.76 mm
PRESSURE SWITCH 200 PSI / 13.8 BAR N.O.
CV CX CU
270 PSI / 18.6 BAR @ 3.5 GPM / 13.25 L/min
CY G2
21 GPM / 79.5 L/min G1
4 3
HYDRAULIC ROTARY COUPLER
MTR A
21 GPM / 79.5 L/min
MTR B
TANK
21CC G2
G1
GENERATOR 12.5 KW
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-49
Section 6 • Schematics
October 2015
Hydraulic Schematic - 12 kW Generator (welder option)
6-49
6-50
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models (serial number 136)
6-51
6-52
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models (serial number 136)
P1 TURNTABLE ROTATE 3GPM
T2
P3 OUT
PRIMARY LIFT 11GPM/5GPM
CHARGE FILTER
TEST
PRL
CD
CE
D
CO G
AC
E
P1 OUT
AD
0.030 CA
G
CC
E
0.030 D
A
P2 IN
B
0.1GPM
P2 OUT
AF
CI
CF
PLU
AA
AE
AB P2A IN
PRR
T1
3.0 GPM
100 PSI
100 PSI
CP A
P3A IN
CH
C
CG
B
PLD
87 PSI
PLATFORM MANIFOLD S-105
PLATFORM LEVEL 0.63 GPM
HIGH PRESS FILTERS
3 gpm CB
PRIMARY1 EXT. 18GPM/6GPM
T1 3000 psi
AG
P1 IN
P
PLATFORM ROTATE 0.3 GPM
DISTRIBUTION MANIFOLD
T 3 gpm
C
J
CJ 2500 psi Fa
1-2 EXT
Fe TRL
TRR
UP
DWN
CL
1-2 RET
1-2 EXT
JU JIB 1.25 GPM / 0.75 GPM
Ps
B
CM
D
CK
FH a
b
H 25 PSI
3000 psi
1.7 .3
M
D 500 psi 4.6 in.cu.
FR
FD
FF
FG 4250 PSI
FB
PLATFORM ROTATE 0.3 GPM
P1 290 PSI
R
T1
T2
25 PSI
25 PSI
Ma X2
CN CQ
FC
AUX. PUMP
6 17 10
E
X1
FQ
FA
LS
4250 PSI
A
JD
1800psi
Mb
0.030
TEST GE
GO
FL
FJ
GD
FM
GB
PRL
D
GA
S B T1
LS A
GC
T1
0.030
P
FK 0.040 DIA
FP
D
GF GI
TP
GH PLU
0.1GPM FE
FI
3 PSI
3 PSI
PRR
P2 OUT
C
GG
2600 psi
TANK
FUNCTION MANIFOLD
T
T1
PLD GJ
HYDRAULIC SWIVEL
LS J
4 WHEEL DRIVE MANIFOLD
B A
T
B
P
FRONT LEFT STEERING
FRB
FRONT AXLE EXTENSION
FRONT RIGHT STEERING
I
D
I
FRONT DL DH
FLR
P
A
50% 50%
50%
DE DF
50%
50%
2.0 GPM
DB
DI 2.7 GPM
AUXILIARY DRIVE OPTION
FLB
REAR LEFT STEERING
REAR RIGHT STEERING
COUNTERBALANCE VALVE
FRB
FRR
FAE
FAR
RAE
RAR
RLR
RLB
RRB
EG
EH
RRR
DD
JF
JE
B
250 PSI
JD
1.40 GPM EQ
JC
EB
LEFT TEST TANK
2.00 GPM ER
S-100 • S-105 • S-120 • S-125
EPP
EMM
2 SPD
Part No. 102916
1.40 GPM EW
EX
LS
P1
P1 3000 psi
1.40 GPM
EQQ
ET
1800 psi
2.00 GPM
2.00 GPM
EE
EU
EA
RATIO
PRESS
A
2:1
5000 PSI
ELL
B
4.5:1
5000 PSI
C
1.5:1
ED
1.40 GPM EJ
3000 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
I
3:1
2200 PSI
900 PSI
EC
EZ EO 0.1GPM
T1
FOUR WHEEL STEER MANIFOLD 2 SPD
EOO
EII
ES LS
T
BRAKE
2.00 GPM EV
JB
EP DN 0.030
DA
EKK
EY
FLA
DM
DO
EJJ
TP JA
DP
EM
0.1GPM
FRONT DG
DJ
EK ENN
2.0 GPM
50% DC
6-52
D
FLB
LB
BRAKE
PLATFORM MANIFOLD S-100
RIGHT
FRA
DK
RA
PLATFORM LEVEL 0.47 GPM
REAR AXLE EXTENSION
RIGHT
LA
3 gpm
A
REAR
LEFT
500 psi 4.6 in.cu.
A
B
RB
REAR
GQ
3 gpm
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290)
TURNTABLE ROTATE 3 GPM
3 gpm
CB
3 gpm
TEST
PRL
CD
CE
D
CO
PRIMARY 1 EXT. 18 GPM / 6 GPM
PRIMARY LIFT 11 GPM / 5 GPM
PLATFORM MANIFOLD S-105
P
0.030 CA
CC G E
0.030 D 0.1GPM
Ps
Fa
CF
Fe
A
CI
B
PLU CP
CH
PLD
a
b Mb
A
4250
C
CG
B
C
PSI
J
CJ
6 17 10
E
AUX. PUMP
4250 PSI
290
Drive pump changed to 9 GPM at Serial No. 253
PSI Ma A
X2
X1
R
T1
S
T2
.3 1.7
Oil cooler location before Serial No. 248
P3
T2
TRL
UP
TRR
1-2 EXT
DWN
1-2 RET
1-2 EXT
CM
CL
D
CK
OIL COOLER
FH AE
M
1800psi H
P3A
JD
FA
CN
FQ
25 PSI
LS FC
CQ
FR
FD
25 PSI
25 PSI
FG
FB
FF
3000 psi
Oil cooler location after Serial No. 247
3 PSI
D 500 psi 4.6 in.cu.
TP3
3 PSI
JU
JIB 1.25 GPM / 0.75 GPM
B
PRR
T1
G
E
PLATFORM LEVEL 0.63 GPM
100 PSI
100 PSI
87 PSI
T P1
PLATFORM ROTATE 0.3 GPM
Primary extension CB valve ratio changed to 'K' at Serial No. 150
HIGH PRESS FILTERS
CHARGE FILTER
PLATFORM ROTATE 0.3 GPM
P1 AC
TANK
0.030
TEST P2
OIL COOLER
FL AF
FJ
GE
GO
GD
GB
PRL
GC
T1
25 PSI
TP
FK .040 DIA
AA
PRR
0.030
D
FP
4
1
3
2
GF
5
GI
AB
P2A
FI
4
1
3
2B
PLU 0.1GPM
5
2A
GH
230 psi
TP2
HYDRAULIC SWIVEL
2600 psi
PLD GJ
T3
P2 OUT
LS
Valve FP changed from 110 psi to 230 psi at Serial No. 151
4 WHEEL DRIVE MANIFOLD
LS
FUNCTION MANIFOLD
J T
GQ
3 gpm
B
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu.
B
RB
C
GG
FE
T1
A
D
GA
AD
AG
P1
Hydraulic Swivel numbered at Serial No. 255
FM
PLATFORM MANIFOLD S-100
3 gpm
P
A
REAR FRB RIGHT FRONT DL
FRONT AXLE EXTENSION
FRONT RIGHT STEERING
I
DH
DK
RA
FRONT LEFT STEERING
RIGHT
FRA
D
COUNTERBALANCE VALVE
REAR AXLE EXTENSION
I
D
REAR LEFT STEERING
FLB
REAR RIGHT STEERING
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
50% 50%
50%
DC
2.0 GPM
50%
LB
DE DF
50%
50%
REAR
P
DD
A
DI 2.7 GPM
FRONT DG
LA
DJ
250 PSI DP
EK
1.40 GPM EQ
LEFT JE
JD
JC
TEST
FAE
DA
RAE
RAR
RLR
RLB
EG
RRB
RRR
EH
EJJ
EKK
EOO
EII
EPP
EMM
2.00 GPM EV
2.00 GPM ER
1.40 GPM EW
EX EQQ
ET
1800 psi
2.00 GPM
2.00 GPM
EE
EU
EA ES
JB LS
LS
P1
P1 3000 psi
ELL
ED
EC
1.40 GPM EJ
900 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
EZ EP
The manifold relief valve EZ was removed at Serial No. 148
1.40 GPM
EY EB
BRAKE
2 SPD
FAR
EM
TP TANK
DN 0.030
2 SPD
FRR
B
DM
DO
FRB
FLA
JA
BRAKE
FLB
0.1GPM
JF LEFT
AUXILIARY DRIVE OPTION
ENN
2.0 GPM
DB
FLR
T
T1
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
EO 0.1GPM
FOUR WHEEL STEER MANIFOLD
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-53
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-100 • S-105 Models (from serial number 137 to serial number 290)
6-53
6-54
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738)
6-55
6-56
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models (from serial number 291 to serial number 738)
TURNTABLE ROTATE 3 GPM
HIGH PRESS FILTERS
100 PSI
P1
PLATFORM MANIFOLD S-105
P
3 gpm
3 gpm CB
TEST
D
CO
0.030 CA
E
E
100 PSI
PRL
CD
CE
G
K 87 PSI
T
PRIMARY1 EXT. 18 GPM / 6 GPM
PLATFORM ROTATE 0.3 GPM
CHARGE FILTER
PRIMARY LIFT 11 GPM / 5 GPM
CC
PRR
T1
B
A
0.030 D 0.1GPM
CI
CF
PLU
E
CP
A
D
CH
B
C
CG PLD
C
PLATFORM LEVEL 0.63 GPM
M1 315 PSI M5
P3
3625 PSI
T2
TRL
TRR
UP
1-2 EXT
DWN
J
CJ
1-2 RET
1-2 EXT
CM
FQ
E
AUX. PUMP
.3 1.7 B
H
P3A
JD
FH CN
FR 1800psi
LS
FC
TP3-4
D
FD
M
D
CK
FA
AE
9 17 10
3625 PSI
JU
CL
JIB 1.25 GPM / 0.75 GPM
A M4
CQ 500 psi 4.6 in.cu.
L1
M2
L2
S
FF
FB
FG
3000 psi AC 25 PSI
25 PSI
PLATFORM ROTATE 0.3 GPM
P1
P2
FJ
FL
FM 0.030
TEST
3 PSI
AF
3 PSI
P1
TANK
AD
TP
25 PSI
AA FP
CHECK VALVE REMOVED AT S/N 291
P2A
GE
GO
GD
PRL
GC
T1
FK .040 DIA
PRR 0.030
D
GF
AB
GI
230 psi FI
GH PLU
0.1GPM FE
TP2 2600 psi
3
1
2
PLD GJ
5
T3
P2 OUT
LS-4
HYDRAULIC SWIVEL
LS J
FUNCTION MANIFOLD 4
3
1
2B
2A
GQ
3 gpm
TEST
REAR RIGHT
3 gpm P
T
PLATFORM MANIFOLD S-100
X
TO FUNCTION MANIFOLD T2
M7
M8 FR
REAR AXLE EXTENSION
B
A
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu.
5
FRONT AXLE EXTENSION T
C
GG
T1 4
D
GA
GB
AG
FRONT LEFT STEERING
FRONT RIGHT
FRONT RIGHT STEERING
I
D
I
D
TO FUNCTION MANIFOLD P3
FH
REAR LEFT STEERING
FE
REAR RIGHT STEERING
CDR FF
M6
M5
FN
FQ 50%
2.0 GPM
FAE
FAR
RAE
RAR
RLR
RLB
RRB
RRR
EK
EG
EM
EH
ENN
EJJ
EKK
EOO
EII
EPP
EMM
ELL
50% FD
FK
1.40 GPM EQ
M4 FG
FD
FB
FC
LBRAKE
LBRAKE
L2SPEED
EA
FRONT LEFT M2
LS
COUNTERBALANCE VALVE RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
EP R2SPEED
RBRAKE
RBRAKE
T
EO 0.1GPM
T1
FOUR WHEEL STEER MANIFOLD
4WD TRACTION MANIFOLD
S-100 • S-105 • S-120 • S-125
Part No. 102916
EX EQQ 1800 psi
1.40 GPM ET
2.00 GPM EE
2.00 GPM EU
1.40 GPM EJ
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
ED
900 PSI
G
3:1
EC
600 PSI
H
3:1
3200 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
P1
L2SPEED
R2SPEED
1.40 GPM EW
EY EB
FI
2.00 GPM ER
ES
CDL FA
2.00 GPM EV
TP
0.030
6-56
FRR
2.0 GPM FM
M3
M1
FRB
FL
50%
50%
REAR LEFT
FLB
FJ
280 PSI
2.0 GPM
FLR
P
50%
50% FP
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models (from serial number 739)
PRIMARY LIFT 11 GPM / 5 GPM
TURNTABLE ROTATE 3 GPM HIGH PRESS FILTERS
87 PSI
3 gpm
3 gpm CB
A
100 PSI
B
TEST
G
K
D 0.030 CA
CC
B
A
PRL
CD
CE CO
E
E 100 PSI
P1
PLATFORM MANIFOLD S-105
P
PLATFORM ROTATE 0.3 GPM
CHARGE FILTER
T
PRIMARY1 EXT. 18 GPM / 6 GPM
PRR
T1 0.030
D 0.1GPM
CI
CF
C
PLU
E
CH
C
CG
PLATFORM LEVEL 0.63 GPM
CP
C M1
D PLD
315 PSI M5
P3
3625 PSI
TRL
T2
TRR
UP
1-2 EXT
DWN
J
CJ
1-2 RET
1-2 EXT
CM
CL
FQ
E
3625 PSI
AUX. PUMP
.3 1.7
P3A
D
CK
FA
AE
9 17 10
JU
JIB 1.25 GPM / 0.75 GPM
A M4
JD
FR
CN
1800psi FC
TP3-4
LS
FD
M
D CQ
B
L1
M2
L2
S
FF
500 psi 4.6 in.cu.
FB
FG
3000 psi AC 25 PSI
25 PSI
P2
FJ
FL
FM
PLATFORM ROTATE 0.3 GPM
P1 3 PSI
AF
3 PSI
AD
0.030
TEST
AG
P1
TANK
GE
GO
TP
GD
GB
AA FP AB
0.1GPM FE
TP2 3
1
2
PRR 0.030
230 psi FI
4
2600 psi
5
GI
GH PLU
1
2B
2A
C
GG
HYDRAULIC SWIVEL 3
D
GF
T1
4
D
GC
T1
P2A
PRL GA
FK .040 DIA
T3
P2 OUT
LS-4
FUNCTION MANIFOLD
5
PLD GJ LS J GQ
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu. 3 gpm
3 gpm P
T
TEST
REAR RIGHT
B
A
M7
M8 FR
FRONT AXLE EXTENSION
X
T
FRONT RIGHT
FRONT LEFT STEERING
FH
REAR AXLE EXTENSION
TO FUNCTION MANIFOLD P3
FRONT RIGHT STEERING I
D
I
D
FAR
RAE
RAR
REAR LEFT STEERING
FE CDR FF
PLATFORM MANIFOLD S-100
TO FUNCTION MANIFOLD T2
REAR RIGHT STEERING
M6
M5 50%
50% FP FN
FJ
280 PSI
2.0 GPM
FQ 50%
2.0 GPM
FLR
P FL
EK
50%
ENN
50%
50% FD
FLB
FRB
1.40 GPM EQ
FD
EJJ
EKK
2.00 GPM EV
2.00 GPM ER
TP FI
RLB EG
EOO
EII
1.40 GPM EW
EX EQQ 1800 psi
ES
0.030 CDL FA
RLR
EM
M4 FG
M1
FAE
EPP
RRB
RRR
FB
FC
LBRAKE
1.40 GPM ET
2.00 GPM EE
EMM
ELL
2.00 GPM EU
1.40 GPM EJ
EY EB
FRONT LEFT
EA
ED
M2
COUNTERBALANCE VALVE RATIO
EH
2.0 GPM FM
FK
M3
REAR LEFT
FRR
EC
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
900 PSI
G
3:1
600 PSI
I
3:1
2200 PSI
LS
J
1.5:1
2000 PSI
P1
K
1:1
600 PSI
LBRAKE
L2SPEED
L2SPEED
R2SPEED
R2SPEED
RBRAKE
RBRAKE
EP T
4WD TRACTION MANIFOLD
PRESS
A
T1
EO 0.1GPM
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
FOUR WHEEL STEER MANIFOLD
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-57
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-100 • S-105 Models (from serial number 739)
6-57
6-58
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430)
6-59
6-60
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 404 to serial number 430)
T2
100 PSI
P 3 gpm
PLATFORM MANIFOLD S-125 CB
T1
G
AC
E
P1 OUT
AD
G
PRL
CD
CE
D
CO
G
F
0.030 CA
E
3.0 GPM
CC A
P2 IN AF
100 PSI
0.030
P2A IN
D
AA
AE
PRR
T1
B
P2 OUT
AB
87 PSI
T 3 gpm
PLATFORM ROTATE 0.3 GPM
CHARGE FILTER
P1 TEST
DISTRIBUTION MANIFOLD 3000 psi AG
P1 IN
HIGH PRESS FILTERS
PRIMARY 2 EXT. 18 GPM / 5 GPM
PRIMARY 1 EXT. 18 GPM / 6 GPM
0.1GPM A
P3A IN
CI
CF
PLU
B
CP
CH
C
C
CG PLD
PLATFORM LEVEL 0.63 GPM
P3 OUT
PRIMARY LIFT 11 GPM / 5 GPM
TURNTABLE ROTATE 3 GPM
2500 psi Fa
1-2 EXT
Fe TRR
TRL
UP
DWN
J
CJ
0-1 RET
CM
H
JD
BQ
4250 PSI
25 PSI
3000 psi
M
1.7 .3
6 17 10
E
CN BC
BR
BD
AUX. PUMP
LS CQ
25 PSI
25 PSI
Ma X2
X1
BB
BG
290 PSI
R
T1
T2
D 500 psi 4.6 in.cu.
BF
4250 PSI
D
CK
1800psi BA
Mb
A
JU
CL
BO
BN
BH a
b
1-2 RET
0-1 EXT
1-2 EXT
JIB 1.25 GPM / 0.75 GPM
Ps
B
PLATFORM ROTATE 0.3 GPM
P1 BL
BJ
S
0.030
TEST
BM
GE
GO
GD
GB
PRL
D
GA
LS B T1
A
P2 OUT P
GC
T1
PRR
BK BP
0.040 DIA
0.030
D
TP
GF
BI
3 PSI
3 PSI
GI
GH PLU
0.1 GPM
2600 psi
TANK
BE T
FUNCTION MANIFOLD
C
GG
T1
HYDRAULIC SWIVEL
PLD GJ LS
4 WHEEL DRIVE MANIFOLD
B A
J
A
B
T
GQ
3 gpm
A
FRB
FRONT AXLE EXTENSION
FRONT RIGHT STEERING
REAR AXLE EXTENSION
RIGHT I
D
I
FRONT DL DH
A
50%
50%
DE DF
50%
50%
2.0 GPM
DB
DI 2.7 GPM
AUXILIARY DRIVE OPTION
COUNTERBALANCE VALVE
FRB
FRR
FAE
FAR
RAE
RAR
RLR
RLB
RRB
EG
EH
RRR
DJ
250 PSI
DD
JF
JE
JD
1.40 GPM EQ
JC
EKK
TANK
2.00 GPM ER
S-100 • S-105 • S-120 • S-125
EPP
EMM
Part No. 102916
EX
LS
P1
P1 3000 psi
1.40 GPM
EQQ
ET
1800 psi
2.00 GPM
2.00 GPM
EE
EU
EA
RATIO
PRESS
A
5:1
5000 PSI
ELL
B
4.5:1
5000 PSI
C
1.5:1
ED
1.40 GPM EJ
3000 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
900 PSI
EC
EZ EO 0.1GPM
T1
FOUR WHEEL STEER MANIFOLD 2 SPD
1.40 GPM EW
ES LS
T
BRAKE
2.00 GPM EV
JB
EP DN 0.030
2 SPD
EOO
EII
EY EB
LEFT TEST
DA
EJJ
TP
FLA
DM
DO
EM
B
FRONT DG
DP
6-60
REAR RIGHT STEERING
0.1GPM
JA
BRAKE
FLB
EK ENN
2.0 GPM
50% DC
LA
FLR
P
50%
LEFT
REAR LEFT STEERING
FLB
LB
REAR
D
RIGHT
FRA
DK
RA
PLATFORM MANIFOLD S-120
3 gpm
P FRONT LEFT STEERING
REAR
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu.
B RB
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194)
Primary extension CB valve ratio changed to ‘K’ at Serial No. 562
HIGH PRESS FILTERS
CHARGE FILTER
TURNTABLE ROTATE 3 GPM
PRIMARY 1 EXT. 18 GPM / 6 GPM
PRIMARY LIFT 11 GPM / 5 GPM
PRIMARY 2 EXT. 18 GPM / 5 GPM
P1
T
P
3 gpm
3 gpm
PLATFORM MANIFOLD S-125 CB
100 PSI
G
G E
PRL
CD
CE
G
F
D
CO
0.030 CA
E
A
CC
B
PRR
T1 0.030
D Fa
0.1GPM
Fe
Drive Pump changed to 9 GPM at Serial No. 1029
A
CI
CF
B
PLU
C
CP
CH
C
CG
a
PLD
b Mb
4250 PSI P3
4250 PSI
AUX. PUMP
290 PSI
.3 1.7
Ma
TRR
TRL
T2
UP
1-2 EXT
DWN
Oil Cooler location before Serial No. 985
6 17 10
E
1-2 EXT
R
T1
T2
H
P3A
BH
CM
1800psi BA
D
CK
BC
JD
BR
CN
25 PSI
LS
30 PSI BS 3000 psi
Oil Cooler location after Serial No. 984
25 PSI
P2
D 500 psi 4.6 in.cu.
Check valve BS added at Serial No. 575
BJ
BL
CQ
BB
BF
BG
AC
OIL COOLER 3 PSI
3 PSI
JU
CL
BQ
M
S
25 PSI
J
CJ
AE
OIL COOLER
BD X2
X1
0-1 RET
BO
BN
TP3 A
1-2 RET
0-1 EXT
BM
PLATFORM ROTATE 0.3 GPM
P1 AF
TANK
AD
AG
P1
AA BP
3
1
2
GD
GB
BK .040 DIA
AB
BI
PRL
D
GA
GC
T1
P2A 4
GE
GO
25 PSI
Hydraulic Swivel numbered at Serial No. 1032
0.030
TEST
TP-4
PLATFORM LEVEL 0.63 GPM
Ps
B
JIB 1.25 GPM / 0.75 GPM
100 PSI
87 PSI
PLATFORM ROTATE 0.3 GPM
TEST
PRR
230 psi
5
0.030
0.1GPM BE
TP2-4 2600 psi
D
GF
HYDRAULIC SWIVEL 4 WHEEL DRIVE MANIFOLD
GI
T1 4
3
1
2B
2A
GH PLU
5
T3
P2 OUT
LS
Valve BP changed from 110 psi to 230 psi at Serial No. 575
FUNCTION MANIFOLD
C
GG
PLD
B
GJ
A
LS B RB
J
A FRONT LEFT STEERING
FRB
REAR RIGHT
FRONT AXLE EXTENSION
FRONT RIGHT STEERING
REAR AXLE EXTENSION
T
P I
D
I
D
FAE
FAR
RAE
RAR
GQ
3 gpm
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu.
PLATFORM MANIFOLD S-120
3 gpm
FRONT DL
P
A
50%
2.0 GPM
50% DI 2.7 GPM
FRR
RLR
REAR RIGHT STEERING
RLB
RRB
EG
EH
RRR
COUNTERBALANCE VALVE
DJ
EK
DD
JF
JE
JD
1.40 GPM EQ
JC
250 PSI
EB
LEFT TEST TANK
EKK
EOO
EII
LS
LS
P1
P1 3000 psi
EPP
2 SPD
2.00 GPM ER
1.40 GPM EW
EX
1.40 GPM
EQQ
ET
1800 psi
2.00 GPM
EMM
2.00 GPM
EE
EU
EA ED
EZ
T
BRAKE
2.00 GPM EV
ES
JB
EP DN 0.030
DA
EJJ
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
ELL
1.40 GPM EJ
EY
FLA
DM
DO
EM
TP
FRONT DG
DP
2 SPD
FRB
0.1GPM
JA
BRAKE
FLB
B ENN
DE DF
DB
AUXILIARY DRIVE OPTION
50%
50%
DC
2.0 GPM
50%
LB
LA
FLR
FLB
50%
REAR LEFT
REAR LEFT STEERING
DH
DK
RA
RIGHT
FRA
EO 0.1GPM
T1
Manifold relief valve EZ was removed at Serial No. 522
EC
900 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
FOUR WHEEL STEER MANIFOLD
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-61
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models (from serial number 431 to serial number 1194)
6-61
6-62
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634)
6-63
6-64
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 1195 to serial number 2634)
PRIMARY 2 EXT. 18 GPM / 5 GPM T P1
CHARGE FILTER
87 PSI
G
K
HIGH PRESS FILTERS
E
3 gpm
G
F
CB TEST
E
PRL
CD
CE
D
CO
A
0.030 CA
B CC
100 PSI
100 PSI
PLATFORM MANIFOLD S-125
P
3 gpm
PLATFORM ROTATE 0.3 GPM
PRIMARY 1 EXT. 18 GPM / 6 GPM
PRIMARY LIFT 11 GPM / 5 GPM
TURNTABLE ROTATE 3 GPM
PRR
T1 0.030
D
E
0.1GPM
D
A
CI
CF
B
PLU
C
CP
CH
C
CG PLD
315 PSI M5 3625 PSI
E
J
CJ
P3
T2
TRL
UP
TRR
1-2 EXT
DWN
9 17 10
3625 PSI
0-1 EXT
1-2 EXT
BN
AUX. PUMP
H
P3A
.3 1.7
0-1 RET
CM
JD
BQ CN LS
BR
D
BC
CQ
BD B
L1
M2
L2
D
CK
BH
M TP3
JU
CL
BO
1800psi BA
AE
1-2 RET
JIB 1.25 GPM / 0.75 GPM
A M4
PLATFORM LEVEL 0.63 GPM
M1
S
500 psi 4.6 in.cu.
30psi BS BG
BB
BF
3000 psi 25 PSI
25 PSI P2
3 PSI
3 PSI
PLATFORM ROTATE 0.3 GPM
P1
AC BJ
BL
0.030
TEST
BM
GE
GO
AF
TANK P1
GD
GB
PRL
D
GA
AD
AG
GC
T1
AA
TP
PRR 0.030
BK BP
0.040 DIA
D
GF GI
GH PLU
4
3
1
2
5
P2A
1
2A
2B
C
GG
230 psi 0.1GPM
BI
HYDRAULIC SWIVEL 3
4
AB
TP2 BE
2600 psi
PLD GJ
5 T1
LS J
P2 OUT
T3
LS
GQ
FUNCTION MANIFOLD FRONT AXLE EXTENSION TEST
REAR RIGHT
PLATFORM MANIFOLD S-120
TO FUNCTION MANIFOLD T2 TO FUNCTION MANIFOLD P3
M7
FRONT RIGHT
M8 FR
3 gpm P
T
REAR AXLE EXTENSION
B
A
X
T
FRONT LEFT STEERING
FRONT RIGHT STEERING
I
I
D
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu. 3 gpm
D
FH
REAR LEFT STEERING
REAR RIGHT STEERING
FE CDR FF
M6
M5
FN
FJ 2.0 GPM
280 PSI
2.0 GPM
FQ 50%
FLR
P
50%
50% FP
FLB
EK
FRB
FAR
RAE
RAR
RLR
RLB
EG
EM
RRB
RRR
ENN
EJJ
EKK
EOO
EII
EPP
EH EMM
ELL
COUNTERBALANCE VALVE
50% FD
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
LS
F
3:1
P1
G
3:1
600 PSI
H
3:1
3200 PSI
2.0 GPM FM
FK
M3
1.40 GPM EQ
M4 FG
FD
2.00 GPM EV
2.00 GPM ER
EB
EA
CDL FI
FB
FC
FRONT LEFT M2
LBRAKE
LBRAKE
L2SPEED
L2SPEED
EP
R2SPEED
RBRAKE
RBRAKE
EO 0.1GPM
T R2SPEED
EX EQQ 1800 psi
1.40 GPM ET
2.00 GPM EE
2.00 GPM EU
1.40 GPM EJ
EY
0.030
FA
1.40 GPM EW
ES
TP
M1
FAE
FL
50%
50%
REAR LEFT
FRR
ED
EC
900 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
T1
FOUR WHEEL STEER MANIFOLD
4WD TRACTION MANIFOLD
6-64
S-100 • S-105 • S-120 • S-125
Part No. 102916
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to serial number 3145)
PRIMARY LIFT 11 GPM / 5 GPM
PRIMARY 2 (SECONDARY) EXT. P1 18 GPM / 5 GPM
PRIMARY 1 EXT. 18 GPM / 6 GPM
T
P
3 gpm
3 gpm CB
TEST
87 PSI
E
G
K
B
A
HIGH PRESS FILTERS
0.030 CA
E CC
A
B
PRR
T1 0.030
D 0.1GPM
E
D
CO
100 PSI
100 PSI M1
PRL
CD
CE
G
F
D
CI
CF
C
PLU CP
C
CH
C
CG
PLATFORM LEVEL 0.63 GPM
CHARGE FILTER
PLATFORM ROTATE 0.3 GPM
TURNTABLE ROTATE 3 GPM
315 PSI PLD
M5 3625 PSI P3
E
T2
TRL
UP
TRR
1-2 EXT
DWN
9 17 10
3625 PSI
BN
AUX. PUMP
J
CJ
0-1 RET
CM
JU
CL
BO
D
CK
1800psi BA
AE
1-2 RET
0-1 EXT
1-2 EXT
BQ JD
P3A
.3 1.7
BR
M
CN
BC
TP3
LS
BD B
L1
M2
L2
D
S
30psi BS BG
CQ 500 psi 4.6 in.cu.
BB
BF
PLATFORM MANIFOLD S-125
3000 psi 25 PSI
25 PSI
AC P2
3 PSI
3 PSI P1
BJ
BL AF
TANK
0.030
TEST
AD
GE
GO
BP
0.040 DIA
230 psi
3
1
2B
2A
GI
BE
GH PLU C
GG T3
HYDRAULIC SWIVEL 4
D
GF
T1
5
D
PRR
0.1GPM
2600 psi
2
PRL GA
0.030 BI
1
GB
GC
T1
AB
TP2
3
GD
BK
AA
P2A
PLATFORM ROTATE 0.3 GPM
P1
BM
AG
TP
4
JIB 1.25 GPM / 0.75 GPM
A M4
P2 OUT
LS
PLD
FUNCTION MANIFOLD
GJ LS
5
J GQ
PLATFORM LEVEL 0.47 GPM
500 psi 4.6 in.cu. 3 gpm
3 gpm P
T
TEST
B
A
X
T REAR RIGHT
FRONT AXLE EXTENSION
M7
M8 FR
FRONT RIGHT
FRONT LEFT STEERING
FH
FRONT RIGHT STEERING
I
TO FUNCTION MANIFOLD P3
I
D
PLATFORM MANIFOLD S-120
TO FUNCTION MANIFOLD T2
REAR AXLE EXTENSION
REAR LEFT STEERING
D
REAR RIGHT STEERING
COUNTERBALANCE VALVE
FE CDR FF
M6
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
900 PSI
G
3:1
600 PSI
M5 50%
50% FP FN
FJ 2.0 GPM
280 PSI
2.0 GPM
FQ 50%
FLR
P FL
EK
50%
ENN
50%
50% FD
FK
M4 FG
1.40 GPM EQ
FD
0.030
FA
FI
FRR
FAE
FAR
RAE
RAR
RLR
EJJ
EKK
RLB
EG
EM
2.00 GPM EV
2.00 GPM ER
EOO
EII
FB
FC
EPP
RRB
RRR
EH EMM
ELL
LBRAKE
LBRAKE
L2SPEED
L2SPEED
R2SPEED
R2SPEED
RBRAKE
RBRAKE
EQQ 1800 psi
1.40 GPM ET
2.00 GPM EE
2.00 GPM EU
1.40 GPM EJ
EY EB
FRONT LEFT M2
1.40 GPM EW
EX
ES
TP
CDL M1
FRB
2.0 GPM FM
M3
REAR LEFT
FLB
EA
ED
EC
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
LS P1 EP
Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section.
EO 0.1GPM
T
T1
4WD TRACTION MANIFOLD
FOUR WHEEL STEER MANIFOLD
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-65
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models (from serial number 2635 to serial number 3145)
6-65
6-66
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921)
6-67
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models (from serial number 3146 to S12514D-921)
6-68
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922)
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-69
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models (from serial number S12514D-922)
6-70
Electrical Schematic P63LS-OR/RD
P53LS-WH/BK
31 24 31 24
J264 WAY1 2
31
3
24 31
4
24 31 24 31 24 31
AXLE EXTENTION LIMIT SWITCHES 24 31 24
LIMIT SWITCHES S-120/125
1
ENGINE BLOCK
P46HRN-WH
2
P33STR-BK
15 A +BAT
1 30
WAS 10A BEFORE: S100/105- SN 159 S120/125- SN 619
STARTER
2 86
87a 87 85 4 5 STARTER RELAY
C61AXRT-GN P264 WAY
C60AXEX-GN/WH
AUX. PUMP
OTS1 N.O.
RD-HOLD
WH-PULL
+AUX -BAT COM
ALTERNATOR
BAT. + EXCT.
BAT. -
IND.
1 30 2 86
HORN 87a 87 85 RELAY 5 4
1
REGULATOR
SERVICE HORN
2
HI/LO SPEED SOLENOID
3 FLAMMSTART 2 RELAY 86 30
1 HYD COOLER 2 RELAY 86
85 87 87a 5 4
1 30
85 87 87a 5 4
2 86 1 30
85 87 87a 5 4 FUEL SOLENOID RELAY
STA.
FAN FUEL SOLENOID RELAY
VLVRET6-BR
C27AUX-RD
P P 2 86 85 5
J27
C08PBR-BK/WH
C07PBE-BK
C02PBD-RD/BK
C01PBU-RD
C06TRF-WH/RD
C09PERF-BK/RD
C03PBF-RD/WH
C27AUX-RD
VALVE RTN6
VALVE RTN7
C06TTR-WH/BK
C05TTL-WH
C113MFV-OR/RD
BATGND-BR
P1-01
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
P1-16
P1-15
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
P1-02
VALVE_RTN3
AC_GENERATOR
TT_TILT_Y_AXIS
TT_TILT_X_AXIS
ALT_FIELD_WIRE
ALTENATOR_RPM
VALVE_RTN2
TT_TILT_SNSR_PWR
TT_TILT_SNSR_GND
OIL/WATER_TEMP
OIL_PRESSURE
C30EDC-WH
C31EDC-WH/BK
STARTER_RELAY
SERVICE_HORN
REV
FWD
CHOKE/GLOW PLUG
VALVE_RTN4
BOOM_EXT/RET_VLV
BOOM_EXTEND_VLV BOOM_RETRACT_VLV
P4-08 P4-09 P4-10
VALVE_RTN7 P4-27
P_11 P_12 P_14 P_18 OPER SW PWR FST1S LST10
P2-10 P2-11 P2-12 P2-13 P2-14 P2-15
C61AXRT-GN S62BSTO-OR P63LS-OR/RD C64LS-OR/BL C65LOFL-BL/WH C66DREN-BL
J21 8 WAY 3 4
LIMIT SWITCHES S-100/105
P54ENG-BK/WH
P20 12 WAY
P53LS-WH/BK
5 1 2
31
LSB3EO
P2-20
24 31 24
9 10 11 12 J20 12 WAY
31 24 31
31
24
24 31 1 2 3
VLVRET1-BR
C77AS-WH
G119SR-BL
4
P
4
C64LS-OR/BK 31 24 31
C64LS-OR/BK
P56PRV-RD
SJ3-WH
C68PBD-BL
S62BSTO-OR
P53LS-WH/BK
C60AXEX-GN/WH
3
S56PRV-RD
C77AS-WH
C64LS-OR/BK
24
C65LOFL-BL/WH
C64LS-OR/BK
C66DREN-BL
P57PBD-RD/WH
P58LS-RD/BK
P54ENG-BK/WH
P53LS-WH/BK
S56PRV-RD
SJ3-WH
LSB4EO LSB13AO LSB14AO
P2-28 P2-29 P2-30
P2-35
P2-34
P2-33
P2-32
VLV RET
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
PRI#2 LO
P2-22
P2-21
LSB3RO
P2-19
P2-25
C71PBE-BL/BK
LSB2RO
P2-18
SNSR GND-BR
C70PBE-BL/WH
LSB1DO
P2-17
C71PBE-BL/BK
8
PRI#1 LO
7
P2-24
6
P2-23
P57PBD-RD/WH
5
V75PRLO-RD/WH
C61AXRT-GN
4
C64LS-OR/BK
S62BSTO-OR
24
V74PRLO-RD
P63LS-OR/RD
3 C70PBE-BL/WH
C68PBD-RD
P_10 P2-09
C60AXEX-GN/WH
8
2
P2-16
P_9B P2-08
S59CNBK-GN/WH
7
1
LSB6S CHNBRK
P_9A P2-07
P58LS-RD/BK
AUX_RELAY
P_7R
P4-35
P4-34
P4-33
P4-32
P4-31
P4-30
P4-29 VALVE_RTN6
ROTATE_CCW_VLV P4-26
P4-28
ROTATE_CW_VLV P4-25
P4-24
P4-23
P4-22
P4-21
P4-20
MULTI_FUNCT_VLV
BOOM REVERSE LOAD
P4-18 P4-19
HYD_FILTER2 BOOM OVERLOAD
HYD_FILTER1 P4-15
P4-17
VALVE_RTN5 P4-14
P4-16
DRIVE LIGHTS RELAY
P4-13
P4-12
P4-11
BOOM_UP_VLV BOOM_DOWN_VLV
P4-07
P4-06
P4-05
6
FUSE
4
2 1 K8 86 30 87 87a 85 5 4
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO PLD
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
1 30 87 87a
TO MICRO
P4-04 TURNTABLE_ROTATE_VLV
P4-03
P4-02 BOOM_UP/DOWN_VLV
P4-01
THROTTLE IGNITION/FUEL
5
85
2 K7 86
AUX/START_BAT_GND AUX/START_BAT_PWR
P1-03 P1-04
P2-06
C14LS-BK/RD
C15LS-RD/BK
VLVRET5-BR
R49LP - WT/BK
J31-TILT SNSR
P31-ENG HARN
VLVRET3-BR
C45GEN-GN/WH
C84TAY-GN/BK
C83TAX-GN/WH
C107AF-RD
C41RPM-OR/BK
VLVRET2-BR
P85TTSR-GN
RET85TTSR-BR
C26TSR-WH/RD
C25PSR-WH/BK
C30EDC-WH
C31EDC-WH/BK
C33STR-BK
C46HRN-WH
V31REV-WH/BK
V30FWD-WH
C34SA-BK/WH
C21IGN-WH
R35RPM-BK/RD
VLVRET1-BR
BATECU-RD
SYS_BAT_PWR SYS_BAT_GND
P1-01
TO MICRO
TO PLD TO MICRO
P1-02
P57PBD-RD/WH
3-10A
BATVLV-RD
P_6R2
P21 8 WAY
P2-05
P56PRV-RD
S56PRV-RD
P56PRV-RD P27
P_6R1
P53LS-WH/BK
P2-04
P63LS-OR/RD
P54ENG-BK/WH
C60AXEX-GN/WH
DCON ECU PWR
C61AXRT-GN
P2-03
P21DCON-RD
P53LS-WH/BK
P57PBD-RD/WH
DCON ECU GND
S56PRV-RD
P2-02
GNDDCON-BR P2-01
J32-ENG HARN
P21DCON-RD
J1 BLACK 23 PIN
GNDDCON-BR
31
2
LSB1DO 10 DEG
P
1
LSB7DS 11 DEG
P116HYD-OR FAN BELT BREAK SWITCH
TO MICRO
TO MICRO TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
5
1 30 85 87 87a 4
2 K1 86
5
1 30 85 87 87a 4
2 K2 86
J11
J10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
5 85 87a 87 K5 86 30 2 1
TO MICRO
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
5
85
4
1 30 87 87a
2 K6 86
5 5 85 85 87 87a 87a 87 30 30 K4 86 K3 86 2 1 2 1
Y
LSB13AO 53 DEG
P56PRV-RD 4
FST1S LOW FUEL FS
87
LST1O DRV ENABLE
1 30
LSB8AS 50 DEG
P56PRV-RD TO DRIVELAMPS
C64LS-OR/BK
24
87a 3
SJ3-WH
FUSE 12 VOLT
S56PRV-RD
S56PRV-RD
31
DEUTZ F4L913
86
C70PBE-BL/WH
24
TROMBETTA TIME DELAY MOM N.O.
4.5 DEGREE TURNTABLE TILT SENSOR
30
P57PBD-RD/WH
31
FUSE
86
P58LS-RD/BK
P27 P LSB20LO NO
86
K1 POWERS CKT P22R OR CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE) K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD, VALVES AUX RELAY, BOOM EXT/RET, 85 87 87a K8 TURNTABLE ROTATE VLV. K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH 86 30 85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES: PRIMARY VALVES 1 & 2, THROTTLE (IGN), 86 GLOW PLUG, STARTER RELAY, AC GENERATOR, 30 BOOM RETRACT, MULTIFUNCTION VALVE, ROTATE CW, AND ROTATE CCW. 85 87 87a 85 87 87a 85 87 87a K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY 86 86 86 K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD. 30 30 30 (FUEL ON/OFF SOLENOID AND ALT FIELD) K3 K5 K2 K7 POWERS THROTTLE OR HI/LOW SOLENOID 85 87 87a K6 85 87 87a K1 (CKT C35RPM-BK/RD) K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
87 87a
P54ENG-BK/WH
20 A
85
P53LS-WH/BK
24
P7R
C61AXRT-GN
P
31
SEE OPTIONS FOR OTHER ENGINES
1
X
P57PBD-RD/WH
DIAG/TETHER PWR
BATGND-BR
P2-35
P2-34
P2-33
P2-32
TO MICRO
TO PLD
P10
P63LS-OR/RD
C61AXRT-GN
3
W
S62BSTO-OR
J24
V
C64LS-OR/BK
4
DEUTZ ENGINE 4
TO AUX HYD RELAY PR1
P29 ENG HARN
3
P58LS-RD/BK
DIAG/TETHER GND
SEE GENERATOR OPTIONS
TURNTABLE ROT CCW VLV
P53LS-WH/BK
3
MULTI FUNC VLV
85
P114BAT-RD
TURNTABLE ROT CW VLV
C47OUT-WH/BK
1 MANIFOLD HARN
BOOM RET VLV
GNDDCON-BR C45GEN-GN/WH 1 2 BAT GND-BR
U
C71PBE-BL/BK
3
P9A P6R1
BOOM EXTEND VLV
P63LS-OR/RD
J4 WHITE 35 PIN
BOOM UP VLV
P21DCON-RD
RET85TTSR-BR
VLVRET4-BR
BOOM HARN
TCON
BOOM DWN VLV
S56PRV-RD
P11
BOOM EXT/RET F.C.
J29 PWR HARN
P10
TURNTABLE CW/CCW F.C.
P57PBD-RD/WH
P85TTSR-GN
BOOM UP/DWN F.C.
C83TAX-GN/WH
BAT GND-BR
P
4
C84TAY-GN/BK
OIL TEMP SENDER
LSB14AO
P2-30
C78PS-WH/BK
J2 BLACK 35 PIN LIMIT SWITCH HARNESS
C26TSR-WT/RD
3
OPTIONAL HYDRAULIC PRESSURE SENSOR ENGINE HARN
BAT CBL(A)-RD
LSB13AO
P2-29
C77AS-WH
VLV RET
LSB4EO
P2-28
C76PBE-BL
VLVRET1-BR
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
PRI#2 LO P2-25
SNSR GND-BR
G119SR-BL
PRI#1 LO P2-24
V75PRLO-RD/WH
P2-22 P2-23
V74PRLO-RD
POWER HARN
P33STR-BK
LSB3EO
P2-20
C71PBE-BL/BK
TO MICRO
TO PLD
TO MICRO
P_22
C116HYD-OR
LSB3RO
P2-19
C70PBE-BL/WH
J5 BLACK 4 PIN
TO MICRO
P116HYD-OR
LSB2RO
P2-18
C69PBE-BK
P2-21
LSB1DO
P2-17
C68PBD-RD
P11
70 A FUSE
WAS 40A BEFORE S100/105- SN 134 S120/125- SN 369 CB
P2-15
C66DREN-BL
TCON
25A
LST10
P2-14
C65LOFL-BL/WH
TCON
BAT CBL(A)-RD
TO WORK LIGHTS 87a
AUX MAIN
FST1S
P2-13
C64LS-OR/BL
P6R1
C34SA-BK/WH
C60AXEX-GN/WH
P114BAT-RD
OPER SW PWR
P2-12
P63LS-OR/RD
BM U/D FC O
BM E/R FC O
TN
PK
GR
BOOM UP/DWN FC RECOVERY SIGNAL
OIL PRESSURE
24
C64LS-OR/BK
P_18
P2-11
S62BSTO-OR
BM RET O BM DWN O
YL
BL
PR
BOOM UP/DWN FC RECOVERY SIGNAL
C25PSR-WT/BK
D81CAN- -GN
31
C64LS-OR/BK
P_14
P2-10
C61AXRT-GN
BM 3' I
BM 100' I
PRI LO#1 O
PWR IN SERV OR BM DWN ST I RECOVERY PROVIDES PWR AUX HYD O TO MINIMAL MLT FNC VLV O HARDWARE
SERVICE OR RECOVERY MODE
PWR TO TCON ESTOP 1
TCON ESTOP 2
TETHER ESTOP 3
TCON OR PCON MODE 4
PCON MODE 5
GY
BR
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
C21IGN-WH
D80SHLD-N/A
24
C65LOFL-BL/WH
P_12
P2-09
C60AXEX-GN/WH
P6R1
WT
OR
BOOM DWN RECOVERY SIGNAL
E35ESPK-BK/RD
31
C64LS-OR/BK
P_11
P2-08
S59CNBK-GN/WH
7
LT GR
BOOM EXT/RET FC RECOVERY SIGNAL
HOLD
P20 12 WAY C66DREN-BL
P_10
P2-07
P58LS-RD/BK
8
OUTPUT PWR ENABLE 6
9 P7R
10 SERV. OR OPER. REC.
P22
BOOM DWN RECOVERY SIGNAL
PULL IN
D82CAN+ -YL J20 12 WAY
P56PRV-RD
P_9B
P2-06
P57PBD-RD/WH
12
BOOM DWN RECOVERY SIGNAL
BAT GND-BR
9 10 11 12
SJ3-WH
P_9A
P2-05
S56PRV-RD
13 P7
FUEL TYPE
SPARE 2
COORD STEER
CRAB STEER
REAR STEER
FRONT STEER
DRIVE SPEED
AXLE EXTEND
ENGINE SPEED
AXLE RETRACT
SPARE 1
BOOM EXT/RET FC RECOVERY SIGNAL
R116HYD-OR
8
C68PBD-BL
P_7R
P2-04
P54ENG-BK/WH
14 P11
10
9
8
7
6
START DRIVE ENABLE
6
5
4
H4_THUMB_RT
H4_THUMB_LT
3
BOOM RET RECOVERY SIGNAL
BAT GND-BR
7
S62BSTO-OR
P_6R1 P_6R2
P2-03
P53LS-WH/BK
TO PLD
DCON ECU PWR P2-02
P21DCON-RD
P2-16
DCON ECU GND P2-01
GNDDCON-BR
P15
SERV. OR OPER. REC.
TO MICRO
P15
15 TCON MODE
OPER. REC. 11
16 ALARM GND ALARM PWR
GR/WT
YL/WT
PR
LT BL
BK RD
P2
P2
P2
P2
P2
5
4
3
2
1
10
9
8
7
6
START ASSIST
AUXILIARY
AC GENERATOR
HORN
H4_PWR H4_XOUT H4_YOUT
P4
P3
P2
P1
BOOM RET RECOVERY SIGNAL
BAT GND-BR
6
P53LS-WH/BK
P1-23
P1-22
P1-21
P2
P2
P2
P2
P2
P1
P1
P1
P1
P1
5
4
3
2
1
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
P4
P3
P2
P1
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
R34SA-RD
5
C60AXEX-GN/WH
P1-19
10
9
8
7
6
5
4
3
2
1
P1
P1
P1
P1
P1
H4_GND
H3_YOUT
H3_PWR
H3_GND
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
MULTI FUNCTION VLV RECOVERY SIGNAL
FLAMMSTART IGNITOR
4
S56PRV-RD
CANRS232_GND
P1-18
P9A
VLVRET2-BR
3
C64LS-OR/BK
CAN+ P1-17
PWR-PCON ESTOP
HRN RLY CNTRL
P1-16
P1-20
OUT PWR ENBL
P1-15
PCON POWER P11
C30EDC-WH
2
P9A P6R1
FWD VLV A SOLENOID
1
C64LS-OR/BK
P1-13
P10
C31EDC-WH/BK
8 SJ1-WH/RD
RS232_TXD BOOT
P1-12
P1-14
CAN SHIELD RS232_RXD
P1-11
P22
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P7
PCON PWR P1-02 P1-03
PCON GND P1-01
PCON POWER
REV VLV B SOLENOID
7 C78AS-WH/BK
SAFE PL TILT PWR P1-23
U20
P7R
VLVRET2-BR
6 P54ENG-BK/WH
SAFE PL TILT GND P1-22
U32
RD-HOLD
5
P53LS-WH/BK
PL TILT SNSR PWR P1-21
P7R
WH-PULL IN
4
P57PBD-RD/WH
PL TILT SNSR P1-20
PWR-PCON ESTOP
BATGND(A)-BK
3
P58LS-RD/BK
PL TILT SNSR GND P1-19
P_22
RD
2
SJ1-WH/RD
FOOT SW RTN P1-17
P_7
WH
J21 1 8 WAY
S56PRV-RD
FOOT SW PWR P1-16
TCON MODE
BK
P56PRV-RD C71PBE-BL/BK
FUSE
3-10A
SAFE PL TILT OUT P1-15
TCON MODE
HOLD
P21 8 WAY C64LS-OR/BK
TET ESTOP RET
RS232 GND
CAN HIGH
CAN LOW
CAL FREQ 2
TET ESTOP PWR
CAL FREQ 1
BOOT
RS232 TXD
RS232 RXD
CAN SHIELD
FLASHING BEACON
WORK LT
P_22
P_7
LOAD SNSR PWR P1-14
P_7
PULL IN
TETHER ESTOP RET
P57PBD-RD/WH
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
P1-16
P1-15
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
PWR-PCON ESTOP
OUT PWR ENBL
LOAD SNSR OUT P1-13
OUT PWR ENABLE
VLVRET2-BR
TETHER ESTOP PWR
C61AXRT-GN
P95TET-OR
P96TET-RD
TETGND-BR
TETFUNC-WH
D82CAN+ -YL
D81CAN- -GN
P97TET-BK
D80SHLD-N/A
R49LP-WH/BK
R48LP-WH/RD
P56PRV-RD
S56PRV-RD/WH
P1-05
P1-04
LOAD SNSR GND P1-12
P_9B
C107AF-RD
TETHER FUNC ENABLE S62BSTO-OR
C47OUT-WH/BK
PROX KILL CMD P1-11
P1-18
PROX KILL GND P1-10
H1_GND
ESTOP_1
H4_THUMB_RT ESTOP_2
H4_THUMB_LT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
H1_GND
S3-3
S3-2
S3-1
S2-3
S2-2
S2-1
S1-3
S1-2
S1-1
AUXILIARY HYD RECOVERY SIGNAL
T
LSB3RO 3' EXT
P57PBD-RD/WH
P23PCON-BK
PROP VLV1_B P1-08
P_6R2
S
LSB4ES 75.5'
(before serial number 921) P27-LIMIT SW
OUT PWR ENABLE
R46HRN-WH
P21DCON-RD
HORN RELAY COIL
PROP VLV1_A P1-07
PRI BOOM DOWN STATUS
BAT GND-BR
Genie S-120/125
PCON POWER
P23PCON-BK
D81CAN- -YL
D82CAN+ -GR
C46HN-WH
C47OUT-WHT/BLK
P56PRV-RD
S56PRV-RD/WH
PROP VLV2_B P1-06
P1-09
PROP VLV2_A P1-05
PRI BOOM LENGTH 100' STATUS
C41RPM-OR/BK
J27-BOOM HARN
P_9B
C27AUX-RD
GNDDCON-BR
P1-03
5A
FUSE
P52PCON-WH
GNDPCON-BR
SAFE PL TILT OUT FOOT SW PWR
P1-15
P87PTS-RD
PTSRET-BR
P85PTS-GN
C84TAY-GN/BK
PLATRET-BR
C56PTS-RD
R56PTS-RD
C88PTS-RD/BK
P1-16
BK
WH
GN
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
C14PLU-OR
C44JD-GN/BK
C43JU-GN
LOCKOUT VALVE #1 SIG
VLVRET6-BR
(before serial number 231) P1-02
P1-01
PCON GND
C56PTS-RD
R56PTS-RD
OUT FRM TILT SWITCH
PWR TO TILT SWITCH
TILT SWITCH GND
TILT SENSOR PWR
TILT SENSOR SIG OUT
PLAT SENSOR GND
NOT USED
PLAT LEVEL DN
PLAT LEVEL UP
JIB DOWN
JIB UP
PRI BOOM LENGTH 3' STATUS
R
LSB3RS 3.5 EXT
Genie Part Number 228879 Rev A CAN SHIELD
Q
LSB3EO 75' EXT
ES105SD Rev C ES125SD Rev G CAN SHIELD
PR1
Genie S-100/105
AMP
BAT GND-BR
6 CAN LOW
P
P33STR-BK
6
AUXILIARY HYD RECOVERY SIGNAL
START BAT
5
MULTI FUNCTION VLV RECOVERY SIGNAL
MAIN (SYS) BAT
GN 5 D81CAN- -GN
V75PRLO-RD/WH
YL
P6R1 4 CAN HIGH
VLVRET1-BR
P11
88 4 D82CAN+ -YL
4
V74PRLO-RD
88 3
3
PRI 2 LO
YL
GN 3 P7-LIMIT SW HARN
O
PRI 1 LO
BL 2 J27
2
FST1S LOW FUEL FS
P18 BR 1
2 TETHER INTERFACE
1
LST1O DRV ENABLE
88 P12 J7 1
P6R1
LSB1DO 10 DEG
BL 88 OR P24
P7R
LSB7DS 11 DEG
P9A 86
PWR TO TCON ESTOP
C77AS-WH
DCON PWR RD
88 2
30
PWR TO TCON ESTOP
SJ2-BK/RD
88 1
2 87
SJ2-BK/RD
RD
OR WH P8-LIMIT SW HARN
TO FLASHING BEACON 87a
SJ3-WH
BR GNDPCON-BR
TO HORN BUTTON
LSB13AO 53 DEG
6 DCON GND BK S56PRV-RD/WH
85
N
LSB14AO 68 DEG
6 P7R
88 J8 1
30
TO HORN BUTTON
LSB9AS 65 DEG
5 88
BK C
87
LSB8AS 50 DEG
5 WH C C46HN-WH
P_7
C64LS-OR/BK
4 CAN SHIELD B
P52PCON-WH
86
P_22
SJ3-WH
4 88 B
P23PCON-BK
S56PRV-RD
3 GRN
FOOTSWITCH
PCON POWER
C70PBE-BL/WH
3 FOOTSWITCH
12 VOLT
P57PBD-RD/WH
2 CAN LOW P6-BOOM HARN
5A FUSE ADDED S100/105- SN 188 S120/125- SN 584
TCON
P58LS-RD/BK
P17 1 88 A
OPTIONAL PROXIMITY KILL WIRING
P11
SJ2-BK/RD
1
2 GRN J6 A
2
J1 BLACK 23 PIN BOOM HARN
P63LS-OR/RD
2 YEL
PROX KILL
1
4
C70PBE-BL/WH
2
(SLIP RING) 2
85 5
SJ1-WH/RD
24
ON/OFF VLV3_B
TCON MODE
LSB3RO 3' EXT
AXLE NOT EXT LIMIT SWITCHES 31 P18 1 1 PLATFORM TILT SENSOR ASSEMBLY
87
C61AXRT-GN
24 C 24
87a 3
PLD
P57PBD-RD/WH
P53LS-WH/BK C CAN HIGH
J31-TILT SNSR
5A
(SLIP RING)
5A FUSE ADDED S100/105- SN 188 S120/125- SN 584 4
P63LS-OR/RD
C60AXEX-GN/WH
ON/OFF VLV3_A
1 30
85 5
S62BSTO-OR
P63LS-OR/RD
P1-04
87
S59CNBK-GN/WH
D80SHLD-N/A 88
J2 WHITE 23 PIN PCON MANIFOLD
87a 3
C64LS-OR/BK
C61AXRT-GN
P1-03
P6R
C76PBE-BL
P21DCON-RD
C18PRR-GN/BK
P7R
C71PBE-BL/BK
J3-OR/BL C17PRL-GN
OUT PWR ENABLE
SJ2-BK/RD
P57PBD-RD/WH PLAT ROT CW
VLV RTN
ECU
SJ1-WH/RD
J17-DRIVE CHASSIS HARN B YEL
PCON MEMBRANE/LED INTERFACE CARD
C64LS-OR/BK
J2-BL/RD P1-02
P1-01
30
29
28
PCON MEMBRANE PANEL
C76PBE-BL
11 PLAT ROT CCW
VLVRET-BRN
6 2 86
C46HN-WH
P1-23
P1-22
P1-21
27
26
25
24
23
22
21
20
19
18
17
16
15
J3 10PIN
GNDPCON-BR
RS232 GND
P1-19
AXLE NOT EXT PWR
CAN HIGH
P1-18
P1-20
CAN LOW
P1-17
P1-16
P1-15
K2
J2 10PIN
P52PCON-WH
BOOT
P1-13
1 30
TCON
C69PBE-BK
S56PRV-RD B WH RD BK
RS232 TXD
P1-12
2 86
PCON
RECOVERY
LSB4ES 75.5'
WHEN AXLES ARE EXTENDED TERM 3 & 4 ARE CLOSED GN
RS232 RXD
P1-11
K1
SERV. BYPASS
M
LSB3RS 3.5 EXT
P P61LS(A)-GN
CAN SHIELD
P1-10
AXLE NOT EXT SIG
AXLE NOT RET PWR
P1-09
P1-14
AXLE NOT RET SIG
P1-08
14
13
12
11
10
9
8
7
6
5
4
3
2
1
P20
J1 10PIN
FUSE
LOAD SENSOR ASSEMBLY OPTION 24
Joystick Adaptor Harness
3
P54ENG-BK/WH
GNDDCON-BR P16 A 31
Deutsch 1
LSB3EO 75' EXT
P D82CAN+ -YL
D81CAN- -GN
C61LS(A)-GN
P12
P1-06 P1-07
P_7R
P1-05
10 WAY ENGINE HARN TO ENGINE 2
RUN
P53LS-WH/BK
D81CAN- -GN A 1
3
4
OFF
P58LS-RD/BK
D82CAN+ -YL NO
6
4
5
P54ENG-BK/WH
J16-DRIVE CHASSIS HARN NC
5
2
6
P63LS
C P63LS-OR/RD
PROX KILL SW. OPTIONAL
4
5
Pin1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7
LSB4EO 100' EXT
P 31
DCON 3 P33-PCON MANIFOLD
1
GND PWR XOUT YOUT RKOUT
S59CNBK
4 C60AXEX-GN/WH
P57PBD-RD/WH
10 J18-DRIVE CHASSIS HARN
JOYSTICK CONNECTORS (after serial number S120- 1616; S100- 419)
6
Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
C64LS-OR/BK
3 31
2
DRIVE & STEERING JOYSTICK
L
C69PBE-BK
4 1
NOT USED
K
LSB6S CHNBRK
AXLE RETRACTION LIMIT SWITCHES 3
J1 BLACK 23 PIN DRIVE CHASSIS HARN
BOOM EXT/RET JOYSTICK
J
LSB2RO 100'
WHEN AXLES ARE RETRACTED TERM 3 & 4 ARE CLOSED 4 D80SHLD-N/A
P_6R1
P1-03
7 BOOM UP/DWN & TURNTABLE ROTATE JOYSTICK
I
SJ1-WH/RD
3 P61LS-GN
DCON ECU PWR
P1-02
2 WAY DEUTSCH-PWR HARN/ENG HARN
PCON E-STOP
H
SJ2-BK/RD
4 J4-GN/BK
DRIVE & STEERING JOYSTICK
G
P53LS-WH/BK
3
NOT USED
F
LSB2RS 101'
J1-BL/BK
BOOM EXT/RET JOYSTICK
LSAX2ES
12 P1-04
DCON ECU GND
P1-01
J20
ALARM+
ALARM-
BOOM UP/DWN & TURNTABLE ROTATE JOYSTICK
LSAX1ES
P
LSAX2EO
B
LSAX1EO
A
J2 WHITE 23 PIN DRIVE CHASSIS HARN
C61LS-GN
LF STEER LEFT
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR 6 WAY ENGINE HARN TO TILT SENSOR 4 WAY ENGINE HARN-AC GENERATOR PCON MANIFOLD/TILT SENSOR
JIB
C61AXRT-GN
LF STEER RIGHT
P2-23
J30 J31 J32 J33
LSAX2RO
RF STEER LEFT
P2-22
P30 P31 P32 P33 9 WAY DEUTSCH TETHER CONNECTOR 8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN 4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN 2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
S56PRV-RD
STEER SNSR PWR
P2-21
12 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN 8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
P53LS-RD
STEER SNSR GND
P2-20
J20 J21 J23 J24 J25 J26 J27 J28 J29
P21DCON-WH
RF STEER RIGHT
P2-19
P20 P21 P23 P24 P25 P26 P27 P28 P29
GND-DCON-BR
LR STEER LEFT
P2-18
PCON PCB TO MEMBRANE SWITCH PCON PCB TO MEMBRANE SWITCH
LSAX1RO
LR STEER RIGHT
P2-17
J1 J2
LF STEER LEFT
BRAKE
P2-16
P1 P2
LF STEER RIGHT
VALVE RTN2
P2-15
TCON PCB TO MEMBRANE SWITCH TCON PCB TO MEMBRANE SWITCH
RF STEER LEFT
LR STEER SNSR
P2-14
J10 J11
RF STEER RIGHT
RF STEER SNSR
P2-13
P10 P11
LR STEER LEFT
LR STEER SNSR
P2-12
3 WAY DEUTSCH CAN CONNECTOR BOOM HARN TO SLIP RING 6 WAY DEUTSCH DCON SAFETY SW LIMIT SW TO SLIP RING 2 WAY DEUTSCH DCON ECU PWR LIMIT SW HARN TO SLIP RING 3 WAY DEUTSCH CAN CONNECTOR SLIP RING TO DCON HARN 6 WAY DEUTSCH DCON SLIP RING TO DCON HARN 2 WAY DEUTSCH SLIP RING TO DCON HARNESS
LR STEER RIGHT
RR STEER SNSR
P2-11
J6 J7 J8 J16 J17 J18
RR STEER LEFT
RR STEER LEFT
P2-10
P6 P7 P8 P16 P17 P18
RR STEER RIGHT
RR STEER RIGHT
P2-09
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN
V37LFS-BL/BK
AUX REVERSE
P2-07
J1 J2
V36LFS-BL
AUX FORWARD
P2-06
P2-08
P1 P2
V37RFS-BL/BK
MOTOR SPEED
P2-04 BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
BK
C P109ANG-GN/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BRN
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
V52AREV-BL/RD
V52AFV-BL/RD
AXLE EXTEND
P2-03
P2-05
AXLE RETRACT
P2-02
P_6R2
J1 J2
BL
RD
B
LF STEER RIGHT
A
BK
C
BL
RD
B
BK
A
BL
RD
C
RF STEER RIGHT
LR STEER RIGHT
B
BK
A
BL
RD
VALVE RTN1
P2-01 J144
V29MS-RD/WH
V60AXEX-GN/WH
V61AXRT-GN
VLVRET-BRN
9
BRAKE
5
AUX REVERSE
8
AUX FORWARD
MOTOR SPEED
4
AXLE EXTEND
RR STEER RIGHT
13 AXLE RETRACT
OUT PWR ENABLE
P1 P2
PLATFORM PLATFORM ROTATE LEVEL
E
-
PCON ALARM
D
-
3 CONNECTOR DESCRIPTION AND/OR LOCATION BLACK 23 PIN AMP CONNECTOR TCON TO BOOM HARN BLACK 35 PIN AMP CONNECTOR TCON TO LIMIT SWITCH WHITE 23 PIN AMP CONNECTOR TCON TO ENGINE HARN WHITE 35 PIN AMP CONNECTOR TCON TO FUNCTION MANIFOLD BLACK 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
C
+
2 PLUG NO JACK NO J1 P1 J2 P2 J3 P3 J4 P4 J5 P5
B
+
A Z
1 7
AUXILIARY HYD RECOVERY SIGNAL
TO HORN BUTTON
PWR TO TCON ESTOP U95
TCON MEMBRANE PANEL
TO HORN BUTTON
TO MICRO
P_22R
DETAIL E - TCON RELAY PARKING
30
K7
30
TCON
J2 BLACK 35 PIN LIMIT SWITCH HARNESS
OPTIONAL HYDRAULIC PRESSURE SENSOR
24
31 24
J264 WAY1 2
31
3
24 31
4
24 31 24 31 24 31
AXLE EXTENTION LIMIT SWITCHES 24 31 24 ENGINE BLOCK
-BAT
LIMIT SWITCHES S-120/125 AUX. PUMP
BR-COM
87a 87 85 4 5
15A
CB7 ADDED S100- S/N 710 S120- S/N 2589
P57PBD-RD/WH
BAT. + BAT. -
IND.
1 30
ALTERNATOR EXCT.
2 86
HORN 87a 87 85 RELAY 4 5
GLOW PLUG2 RELAY 86
P21DCON-RD
1
REGULATOR
SERVICE HORN
2
HI/LO SPEED SOLENOID
3 30
1 HYD COOLER 2 RELAY 86
85 87 87a 5 4
1 30
85 87 87a 5 4
STA.
FAN FUEL SOLENOID RELAY
VLVRET6-BR
C27AUX-RD
C27AUX-RD
VALVE RTN6
VALVE RTN7
C06TTR-WH/BK
C05TTL-WH
C113MFV-OR/RD
P63LS-OR/RD
P53LS-WH/BK
P27 P56PRV-RD
2 3
24
4 5 6 7 8
LIMIT SWITCHES S-100/105
1
LSB3RO LSB3EO
P2-19 P2-20
C70PBE-BL/WH C71PBE-BL/BK
LSB13AO LSB14AO
P2-29 P2-30
C77AS-WH C78PS-WH/BK
FUSE
3-10A
BATVLV-RD
REV P1-06
2 3 4 5 6
31
7 8
24 31 24
9 10 11 12 J20 12 WAY
31 24 31
31
24
24 31 24 3 4
P
31 24 31
C64LS-OR/BK
P56PRV-RD
SJ3-WH
C68PBD-BL
S62BSTO-ORN
P53LS-WH/BK
C60AXEX-GN/WH
P5-03 P5-04
AUX/START_BAT_GND
FWD REV SERVICE_HORN
P3-05 P3-06 P3-07
TT_TILT_SNSR_GND TT_TILT_SNSR_PWR VALVE_RTN2
P3-14 P3-15 P3-16
TT_TILT_X_AXIS TT_TILT_Y_AXIS AC_GENERATOR VALVE_RTN3
P3-20
P3-22 P3-23
P3-19
P3-21
ALTENATOR_RPM ALT_FIELD_WIRE
P3-18
P3-17
OIL_PRESSURE OIL/WATER_TEMP
P3-12 P3-13
C31EDC-WH/BK C30EDC-WH
P3-10 P3-11
STARTER_RELAY
P3-09
P3-08
IGNITION/FUEL CHOKE/GLOW PLUG
P3-03 P3-04
THROTTLE
BOOM_EXT/RET_VLV
P4-02 P4-03
BOOM_DOWN_VLV BOOM_EXTEND_VLV BOOM_RETRACT_VLV
P4-08 P4-09 P4-10
VALVE_RTN7 P4-27
DCON ECU PWR P_6R1 P_6R2 P_7R P_9A P_9B P_10 P_11 P_12 P_14 P_18 OPER SW PWR FST1S LST10
P2-03 P2-04 P2-05 P2-06 P2-07 P2-08 P2-09 P2-10 P2-11 P2-12 P2-13 P2-14 P2-15
P53LS-WH/BK P54ENG-BK/WH S56PRV-RD P57PBD-RD/WH P58LS-RD/BK S59CNBK-GN/WH C60AXEX-GN/WH C61AXRT-GN S62BSTO-OR P63LS-OR/RD C64LS-OR/BL C65LOFL-BL/WH C66DREN-BL
AUX_RELAY
DCON ECU GND
P4-35
P4-34
P4-33
P4-32
P4-31
P4-30
P4-29 VALVE_RTN6
ROTATE_CCW_VLV P4-26
P4-28
ROTATE_CW_VLV P4-25
P4-24
P4-23
P4-22
P4-21
P4-20
MULTI_FUNCT_VLV
BOOM REVERSE LOAD
P4-18 P4-19
HYD_FILTER2 BOOM OVERLOAD
C77AS-WH
G119SR-BL
SNSR GND-BR
LSB1DO LSB2RO LSB3RO LSB3EO
P2-17 P2-18 P2-19 P2-20
PRI#2 LO
P2-24
LSB4EO LSB13AO LSB14AO
P2-28 P2-29 P2-30
P2-35
P2-34
P2-33
P2-32
VLV RET
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
P2-25
PRI#1 LO
P2-23
P2-22
TO MICRO
TO MICRO
TO MICRO
TO PLD
HYD_FILTER1 P4-15
P4-17
VALVE_RTN5 P4-14
P4-16
TO MICRO TO PLD
DRIVE LIGHTS RELAY
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
2 1 K8 86 30 87 87a 85 5 4
TO MICRO
P4-13
P4-12
P4-11
BOOM_UP_VLV
P4-07
P4-06
P4-05
P2-02
P2-21
4
P4-04 TURNTABLE_ROTATE_VLV
VALVE_RTN4 BOOM_UP/DOWN_VLV
P4-01
P2-01
P2-16
5
85
1 30 87 87a
TO MICRO
TO MICRO
TO PLD TO MICRO
2 K7 86
AUX/START_BAT_PWR
P3-02
P3-01
SYS_BAT_PWR SYS_BAT_GND
P21DCON-RD
C64LS-OR/BK
2
S56PRV-RD
1
4
C77AS-WH
C64LS-OR/BK
P20 12 WAY C65LOFL-BL/WH
C64LS-OR/BK
C66DREN-BL
P57PBD-RD/WH
P58LS-RD/BK
P54ENG-BK/WH
P53LS-WH/BK
S56PRV-RD
SJ3-WH
C71PBE-BL/BK
C64LS-OR/BK
P57PBD-RD/WH
C61AXRT-GN
S62BSTO-OR
P5-01 P5-02
TO MICRO
TO PLD
TO MICRO
TO PLD
TO MICRO
GNDDCON-BR
C14LS-BK/RD
C15LS-RD/BK
VLVRET5-BR
R49LP - WH/BK
J31-TILT SNSR
P31-ENG HARN
VLVRET3-BR
C45GEN-GN/WH
C84TAY-GN/BK
C83TAX-GN/WH
C107AF-RD
C41RPM-OR/BK
VLVRET2-BR
P85TTSR-GN
RET85TTSR-BR
C26TSR-WH/RD
C25PSR-WH/BK
C30EDC-WH
C31EDC-WH/BK
C33STR-BK
C46HRN-WH
DETAIL B
C34SA-BK/WH
C21IGN-WH
R35RPM-BK/RD
FWD P1-05
BATECU-RD
BATGND-BR
BATGND-BR
P2-35
P2-34
P2-33
P2-32
VLV RET
LSB4EO
P2-28
C76PBE-BL
VLVRET1-BR
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
PRI#2 LO P2-25
SNSR GND-BR
G119SR-BL
PRI#1 LO P2-24
V75PRLO-RD/WH
P2-22 P2-23
V74PRLO-RD
C71PBE-BL/BK
C60AXEX-GN/WH
P63LS-OR/RD
C61AXRT-GN
C70PBE-BL/WH
P21DCON-RD
C70PBE-BL/WH
P57PBD-RD/WH
C68PBD-RD
S56PRV-RD
P54ENG-BK/WH
GNDDCON-BR
3
LSB1DO 10 DEG
C08PBR-BK/WH
C07PBE-BK
C02PBD-RD/BK
C01PBU-RD
C06TRF-WH/RD
J32-ENG HARN
2
LSB7DS 11 DEG
1
1
LSB13AO 53 DEG
J21 8 WAY
TO MICRO
TO MICRO TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
5
1 30 85 87 87a 4
2 K1 86
YL
BL
PR
GY
BR
WT
LT GN
5
BK RD
J11
J10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
85 87a 87 K5 86 30 2 1
5
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P1
P1
P1
P1
TO MICRO
OR
GN/WH
YL/WH
PR
LT BL
85 87 87a 4
1 30
2 K2 86
TN
PK
GN
10
9
8
7
6
5
4
3
2
1
P1
P1
P1
P1
P1
P1
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
5
85
2 K6 86
4
1 30 87 87a
FUEL TYPE
SPARE 2
COORD STEER
CRAB STEER
REAR STEER
FRONT STEER
DRIVE SPEED
AXLE EXTEND
ENGINE SPEED
AXLE RETRACT
SPARE 1
DRIVE ENABLE
START
START ASSIST
AUXILIARY
AC GENERATOR
HORN
5 85 85 87 87a 87a 87 30 30 K4 86 K3 86 2 1 2 1
5
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
NOT USED
H4_RKOUT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
P4
P3
P2
P1
Y
FST1S LOW FUEL FS
P21 8 WAY
LST1O DRV ENABLE
P56PRV-RD
LSB8AS 50 DEG
CB 7
C64LS-OR/BK
2
+AUX
SJ3-WH
1
WH-PULL
S56PRV-RD
GNDDCON-BR
24 2 86
RD-HOLD
31
86
C70PBE-BL/WH
S56PRV-RD
31
+BAT OTS1 N.O.
J27
30
P57PBD-RD/WH
24
P34SA-RD 85 5
P53LS-WH/BK
2 86
86
K1 POWERS CKT P22R OR CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE) K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD, VALVES AUX RELAY, BOOM EXT/RET, 85 87 87a K8 TURNTABLE ROTATE VLV. K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH 86 30 85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES: PRIMARY VALVES 1 & 2, THROTTLE (IGN), 86 GLOW PLUG, STARTER RELAY, AC GENERATOR, 30 BOOM RETRACT, MULTIFUNCTION VALVE, ROTATE CW, AND ROTATE CCW. 85 87 87a 85 87 87a 85 87 87a K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY 86 86 86 K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD. 30 30 30 (FUEL ON/OFF SOLENOID AND ALT FIELD) K3 K5 K2 K7 POWERS THROTTLE OR HI/LOW SOLENOID 85 87 87a K6 85 87 87a K1 (CKT C35RPM-BK/RD) K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
87 87a
P58LS-RD/BK
P46HRN-WH
87a 3 TO DRIVE LAMPS 4 1 30 87
85
P54ENG-BK/WH
31
70 A FUSE
86
P53LS-WH/BK
24 1 30
TO MICRO
C61AXRT-GN
P
31 STARTER RELAY
TO HORN BUTTON
P57PBD-RD/WH
4
TROMBETTA TIME DELAY MOM N.O.
12 VOLT
P63LS-OR/RD
D81CAN- -GN
P LSB20LO NO
X
S62BSTO-OR
P116HYD-OR P
1
C64LS-OR/BK
20 A
4.5 DEGREE TURNTABLE TILT SENSOR
C71PBE-BL/BK
FUSE P
W
LSB6S CHNBRK
P56PRV-RD 3
P58LS-RD/BK
P27 4
TO AUX HYD RELAY PR1
DEUTZ BF4L-2011/TD2011-L04I ENGINES SHOWN
3
TURNTABLE ROT CW VLV
P
BOOM RET VLV
S56PRV-RD
TURNTABLE ROT CCW VLV
D82CAN+ -YL
MULTI FUNC VLV
P7-LIMIT SW HARN
SEE GENERATOR OPTION PAGE
BOOM DWN VLV
P63LS-OR/RD
P9A P6R1
BOOM EXTEND VLV
C60AXEX-GN/WH
3
BAT GND-BR
P114BAT-RD
BOOM UP VLV
GNDDCON-BR C45GEN-GN/WH 1 2 BAT GND-BR
OIL TEMP SENDER
P56PRV-RD
RET85TTSR-BR
C09PERF-BK/RD
P85TTSR-GR
C26TSR-WH/RD
C47OUT-WH/BK
C83TAX-GR/WH
OIL PRESSURE
BOOM HARN
C84TAY-GR/BK J4 WHITE 35 PIN MANIFOLD HARN
BOOM EXT/RET F.C.
P53LS-WH/BK
DETAIL B HIGH CURRENT VALVE PROPEL OUTPUT
TCON
TURNTABLE CW/CCW F.C.
C61AXRT-GN
P11
C03PBF-RD/WH
LSB2RO
P2-18
C69PBE-BK
P2-21
LSB1DO
P2-17
C68PBD-RD
J2 BLACK 35 PIN LIMIT SWITCH HARNESS
P10
C25PSR-WH/BK
3
OPTIONAL HYDRAULIC PRESSURE SENSOR J3 WHITE 23 PIN ENGINE HARN
VLVRET4-BR
P2-15
C66DREN-BL
J5 BLACK 4 PIN POWER HARN
BOOM UP/DWN F.C.
LST10
P2-14
C65LOFL-BL/WH
P11
C21IGN-WH
P21DCON-RD
P6R1
BAT GND-BR
FST1S
P2-13
C64LS-OR/BL
TCON
R116HYD-OR
P57PBD-RD/WH
P7R
BAT GND-BR
OPER SW PWR
P2-12
P63LS-OR/RD
BM U/D FC O
BM E/R FC O
BM DWN O
BM RET O
PWR IN SERV OR BM DWN ST I RECOVERY PROVIDES PWR AUX HYD O TO MINIMAL MLT FNC VLV O HARDWARE
BM 3' I
BM 100' I
PRI LO#1 O
PWR TO TCON ESTOP 1
TCON ESTOP 2
TETHER ESTOP 3
TCON OR PCON MODE 4
PCON MODE 5
OUTPUT PWR ENABLE 6
7 P6R1
10
8
P22
P10
P116HYD-OR
P_18
P2-11
S62BSTO-OR
P11
C116HYD-OR
P_14
P2-10
C61AXRT-GN
P6R1
V31REV-WH/BK
P_12
P2-09
C60AXEX-GN/WH
P9A
R34SA-RD
J1 BLACK 23 PIN
V30FWD-WH
CB
P_11
P2-08
S59CNBK-GN/WH
TCON
25A
P_10
P2-07
P58LS-RD/BK
12
9
SERVICE OR RECOVERY MODE
PCON POWER
C34SA-BK/WH
TO WORK LIGHTS 87a
AUX MAIN
P_9B
P2-06
P57PBD-RD/WH
13 P7
P7R
P9A P6R1
VLVRET2-BR
85
P114BAT-RD
P_9A
P2-05
S56PRV-RD
14 P11
SERV. OR OPER. REC.
P10
C30EDC-WH
P
4
C64LS-OR/BK
P_7R
P2-04
P54ENG-BK/WH
15 TCON MODE
OPER. REC. 11
16 ALARM GND ALARM PWR
PCON POWER
BAT GND-BR
C60AXEX-GN/WH
3
C64LS-OR/BK
P_6R1 P_6R2
P2-03
P53LS-WH/BK
TO PLD
DCON ECU PWR P2-02
P21DCON-RD
P2-16
DCON ECU GND P2-01
GNDDCON-BR
P15
SERV. OR OPER. REC.
TO MICRO
P15
P7R
GLOW PLUG
P264 WAY
24
C65LOFL-BL/WH
P1-23
P1-22
P1-21
U32
FWD VLV A SOLENOID
C61AXRT-GN
31
C64LS-OR/BK
P1-19
P7R
C31EDC-WH/BK
D81CAN- -GN
24
C66DREN-BL
CANRS232_GND
P1-18
P_22
C41RPM-OR/BK
31
P56PRV-RD
CAN+ P1-17
PWR-PCON ESTOP
HRN RLY CNTRL
P1-16
P1-20
OUT PWR ENBL
P1-15
PWR-PCON ESTOP
REV VLV B SOLENOID
D82CAN+ -YL J20 12 WAY
C68PBD-BL
P1-13
P_22
VLVRET2-BR
9 10 11 12
S62BSTO-OR
RS232_TXD BOOT
P1-12
P1-14
CAN SHIELD RS232_RXD
P1-11
P22
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P7
PCON PWR P1-02 P1-03
PCON GND P1-01
P_7
BK-COM
8
P_7
BK
7
P53LS-WH/BK
SAFE PL TILT PWR P1-23
U20
BOOM EXT/RET FC RECOVERY SIGNAL
RD-HOLD
6
C60AXEX-GN/WH
SAFE PL TILT GND P1-22
BOOM EXT/RET FC RECOVERY SIGNAL
WH-PULL IN
5
S56PRV-RD
PL TILT SNSR PWR P1-21
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
RD
4
C64LS-OR/BK
PL TILT SNSR P1-20
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
WH
3
C64LS-OR/BK
PL TILT SNSR GND P1-19
TCON MODE TCON MODE
VLVRET2-BR
2
SJ1-WH/RD
P1-17
P_6R2
R46HRN-WH
1
C78AS-WH/BK
FOOT SW RTN
P1-16
OUT PWR ENABLE
J144-8
8 P54ENG-BK/WH
FOOT SW PWR
P1-15
P_9B
C107AF-RD
7 P53LS-WH/BK
SAFE PL TILT OUT
P1-14
PWR TO TCON ESTOP
J144-2
6 P57PBD-RD/WH
LOAD SNSR PWR
P1-13
P_6R2
J144-1
5
P58LS-RD/BK
FUSE
3-10A
LOAD SNSR OUT
OUT PWR ENABLE
HOLD
P63LS-OR/RD
4
SJ1-WH/RD
TET ESTOP RET
RS232 GND
CAN HIGH
CAN LOW
CAL FREQ 2
TET ESTOP PWR
CAL FREQ 1
BOOT
RS232 TXD
RS232 RXD
CAN SHIELD
FLASHING BEACON
WORK LT
P_22
P_7
PWR-PCON ESTOP
OUT PWR ENBL
HORN RELAY COIL
PCON POWER
LOAD SNSR GND P1-12
H1_XOUT
H1_PWR
H1_GND
P4
P3
P2
P1
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
V
LSB3RO 3' EXT
24
3
S56PRV-RD
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
P1-16
P1-15
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
PCON GND
P23PCON-BK
D81CAN- -YL
D82CAN+ -GR
C46HN-WH
C47OUT-WH/BK
P56PRV-RD
S56PRV-RD/WH
P52PCON-WH
PROX KILL CMD P1-11
P1-18
PROX KILL GND P1-10
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
U
LSB4ES 75.5'
31
2
C71PBE-BL/BK
P95TET-OR
D82CAN+ -YL
D81CAN- -GN
P97TET-BK
R117FB-RD
R48LP-WH/RD
P56PRV-RD
S56PRV-RD/WH
P23PCON-BK
C47OUT-WH/BK
C46HN-WH
P1-02
P1-01
5A
FUSE
FOOT SW PWR P1-16
GNDPCON-BR
SAFE PL TILT OUT P1-15
P87PTS-RD
PTSRET-BR
P85PTS-GN
C84TAY-GN/BK
C56PTS-RD
R56PTS-RD
C88PTS-RD/BK
PLATRET-BR
BK
PROP VLV1_B P1-09
PROP VLV1_A P1-08
P_9B
C27AUX-RD
J21 1 8 WAY
C64LS-OR/BK
GNDPCON-BR
C56PTS-RD
R56PTS-RD
OUT FRM TILT SWITCH
PWR TO TILT SWITCH
TILT SWITCH GND
TILT SENSOR PWR
TILT SENSOR SIG OUT
PLAT SENSOR GND
NOT USED
WH
GN
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
PROP VLV2_B P1-07
ESTOP_1
NOT USED ESTOP_2
H4_RKOUT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
H1_GND
S3-3
BOOM UP/DWN FC RECOVERY SIGNAL
T
LSB3RS 3.5 EXT
ES0427G Genie Part Number 228880 Rev A P53LS-WH/BK
TO HORN BUTTON
S
LSB3EO 75' EXT
Electrical Schematic P56PRV-RD P20 12 WAY
R
PULL IN
(from s/n 921 to s/n 2709)
LOCKOUT VALVE #1 SIG
VLVRET6-BR
P21 8 WAY
Q
BAT GND-BR
Genie S-120/125 P27-LIMIT SW
P33STR-BK
J27-BOOM HARN
PR1
(from s/n 231 to s/n 809)
PRI BOOM DOWN STATUS
BAT GND-BR
Genie S-100/105
PRI BOOM LENGTH 100' STATUS
START BAT
6
PRI BOOM LENGTH 3' STATUS
MAIN (SYS) BAT
6
V75PRLO-RD/WH
5
P
VLVRET1-BR
GN 5
V74PRLO-RD
YL
P6R1 4
PRI 2 LO
P11
88 3
4
PRI 1 LO
88 3
4
FST1S LOW FUEL FS
YL
GN 2
3
LST1O DRV ENABLE
BL 1
2 J27
2
SJ3-WH
BR J7 1
87
1
LSB1DO 10 DEG
P12 2
86
O
LSB7DS 11 DEG
88 2
P8-LIMIT SW HARN 30
C77AS-WH
BR S56PRV-RD/WH
TO FLASHING BEACON 87a
LSB13AO 53 DEG
P18
GNDPCON-BR
LSB14AO 68 DEG
OR
C
P6R1
SJ2-BK/RD
P9A C
P7R
LSB9AS 65 DEG
DCON PWR RD
88 C46HN-WH
P52PCON-WH
85
SJ2-BK/RD
88 1
30
SJ3-WH
RD
OR B
P_7
C64LS-OR/BK
88 DCON GND BK J8 1
87
LSB8AS 50 DEG
6 BL WH
A
B
86
P_22
SJ3-WH
6
(SLIP RING) P23PCON-BK
PCON POWER
S56PRV-RD
5
PLAT LEVEL DN
PROP VLV2_A P1-06
TCON MODE
C70PBE-BL/WH
5
C14PLU-OR
C44JD-GN/BK
OUT PWR ENABLE
P57PBD-RD/WH
3
4
PLAT LEVEL UP
JIB DOWN
ON/OFF VLV3_B P1-05
30
29
28
27
PWR TO TCON ESTOP
P58LS-RD/BK
3
4 CAN SHIELD J6 A P6-BOOM HARN
FOOTSWITCH
P57PBD-RD/WH
2 88 P7R GN
PROX KILL
2
C61AXRT-GN
2 24
12 VOLT
S62BSTO-OR
P17 1 1 BK 88
PLATFORM TILT SENSOR ASSEMBLY
5A
(SLIP RING)
OPTIONAL PROXIMITY KILL WIRING
TCON
P63LS-OR/RD
2 WH
FOOTSWITCH
1
J1 BLACK 23 PIN BOOM HARN
SJ2-BK/RD
C 2 88 CAN LOW
J31-TILT SNSR
P11
SJ1-WH/RD
24 P18 1 88 YL
P33-PCON MANIFOLD
FUSE
LOAD SENSOR ASSEMBLY OPTION
24
TO HORN BUTTON
LSB3RO 3' EXT
AXLE NOT EXT LIMIT SWITCHES 31 1 GN CAN HIGH
31
85 5
C61AXRT-GN
24 C 88
2
4
P57PBD-RD/WH
J3-OR/BL
P1-04
2 86
87
P63LS-OR/RD
P53LS-WH/BK C YL
6
87a 3
PLD
S62BSTO-OR
C60AXEX-GN/WH
C43JU-GN
1 30
85 5
C64LS-OR/BK
P63LS-OR/RD
C18PRR-GR/BK
K2
4
C71PBE-BL/BK
C61AXRT-GN JIB UP
87
C70PBE-BL/WH
P21DCON-RD B
J2 WHITE 23 PIN PCON MANIFOLD
87a 3
C76PBE-BL
P57PBD-RD/WH PLAT ROT CW
P6R
SJ2-BK/RD
J17-DRIVE CHASSIS HARN
ON/OFF VLV3_A
P7R
SJ1-WH/RD
GNDDCON-BR
P1-03
OUT PWR ENABLE
S59CNBK-GN/WH
S56PRV-RD
C17PRL-GN
VLV RTN
ECU
C64LS-OR/BK
J2-BL/RD
P1-02
P1-01
6 MEMBRANE/LED INTERFACE CARD
C76PBE-BL
11 PLAT ROT CCW
VLVRET-BR
2 86
P52PCON-WH
P1-23
P1-22
P1-21
26
25
24
23
22
21
J3 10PIN
C69PBE-BK
J18-DRIVE CHASSIS HARN P16 A
B
WH RD BK
RS232 GND
P1-19
AXLE NOT EXT PWR
CAN HIGH
P1-20
CAN LOW
P1-18
1 30
J2 10PIN
N
LSB4ES 75.5'
WHEN AXLES ARE EXTENDED TERM 3 & 4 ARE CLOSED P1-17
P1-16
P1-15
20
19
18
PCON MEMBRANE PANEL
LSB3RS 3.5 EXT
P 31 GN
P1-13
K1
TCON
LSB3EO 75' EXT
P P61LS(A)-GN
BOOT
P1-12
17
16
15
14
13
12
11
10
J1 10PIN
RECOVERY
LSB4EO 100' EXT
P D82CAN+ -YL
RS232 TXD
P1-11
AXLE NOT EXT SIG
RS232 RXD
P1-10
P1-14
AXLE NOT RET PWR CAN SHIELD
P1-09
10 WAY ENGINE HARN TO ENGINE
AMP
P54ENG-BK/WH
D81CAN- -GN A NO
PCON
1
PCON
P53LS-WH/BK
D82CAN+ -YL
JOYSTICK CONNECTORS (before serial number S120- 1617; S100- 420) Joystick Adaptor Harness
RUN
SERV. BYPASS
P58LS-RD/BK
J16-DRIVE CHASSIS HARN NC
5
Deutsch
3
2
OFF
P63LS
4 P63LS-OR/RD
PROX KILL SW. OPTIONAL 1
4
3
5
M
S59CNBK
3
DCON 3
4
4
C64LS-OR/BK
4 31
2
2
Pin1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7
C69PBE-BK
J4-GN/BK
J1 BLACK 23 PIN DRIVE CHASSIS HARN 1
1
5
GND PWR XOUT YOUT RKOUT
L
SJ1-WH/RD
3 D81CAN- -GN
C61LS(A)-GN
P61LS-GN
AXLE NOT RET SIG
P1-08
P1-07
P12
P1-06
7 6
Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
K
LSB6S CHNBRK
AXLE RETRACTION LIMIT SWITCHES C61LS-GN
C61AXRT-GN
P_7R
P1-05
P1-04
2 WAY DEUTSCH-PWR HARN/ENG HARN
DRIVE & STEERING JOYSTICK
J
LSB2RO 100'
WHEN AXLES ARE RETRACTED TERM 3 & 4 ARE CLOSED 4 C60AXEX-GN/WH
P57PBD-RD/WH
10 DRIVE & STEERING JOYSTICK NOT USED
I
SJ2-BK/RD
3
NOT USED BOOM EXT/RET JOYSTICK
H
P54ENG-BK/WH
4
9
S3-2
S3-1
S2-3
S2-2
S2-1
S1-3
S1-2
S1-1
BOOM UP/DWN & TURNTABLE ROTATE JOYSTICK
G
P53LS-WH/BK
J1-BL/BK
BOOM EXT/RET JOYSTICK PCON E-STOP
F
LSB2RS 101'
3 S56PRV-RD
P_6R1
P1-03
8
7
6
5
4
3
2
1
P20
BOOM UP/DWN & TURNTABLE ROTATE JOYSTICK
LSAX2ES
12 P53LS-RD
J20
ALARM+
ALARM-
JIB
LSAX1ES
P
LSAX2EO
B
LSAX1EO
A
LSAX2RO
C
J2 WHITE 23 PIN DRIVE CHASSIS HARN DCON ECU PWR
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR 6 WAY ENGINE HARN TO TILT SENSOR 4 WAY ENGINE HARN-AC GENERATOR PCON MANIFOLD/TILT SENSOR
P1-02
J30 J31 J32 J33
P21DCON-WH
P30 P31 P32 P33 9 WAY DEUTSCH TETHER CONNECTOR 8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN 4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN 2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
DCON ECU GND
12 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN 8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
P1-01
J20 J21 J23 J24 J25 J26 J27 J28 J29
GND-DCON-BR
P20 P21 P23 P24 P25 P26 P27 P28 P29
LSAX1RO
LF STEER LEFT
PCON PCB TO MEMBRANE SWITCH PCON PCB TO MEMBRANE SWITCH
LF STEER LEFT
LF STEER RIGHT
P2-23
J1 J2
LF STEER RIGHT
RF STEER LEFT
P2-22
TCON PCB TO MEMBRANE SWITCH TCON PCB TO MEMBRANE SWITCH
RF STEER LEFT
STEER SNSR PWR
P2-21
J10 J11
RF STEER RIGHT
STEER SNSR GND
P2-20
P10 P11
LR STEER LEFT
RF STEER RIGHT
P2-19
3 WAY DEUTSCH CAN CONNECTOR BOOM HARN TO SLIP RING 6 WAY DEUTSCH DCON SAFETY SW LIMIT SW TO SLIP RING 2 WAY DEUTSCH DCON ECU PWR LIMIT SW HARN TO SLIP RING 3 WAY DEUTSCH CAN CONNECTOR SLIP RING TO DCON HARN 6 WAY DEUTSCH DCON SLIP RING TO DCON HARN 2 WAY DEUTSCH SLIP RING TO DCON HARNESS
LR STEER RIGHT
LR STEER LEFT
P2-18
J6 J7 J8 J16 J17 J18
RR STEER LEFT
LR STEER RIGHT
P2-17
P6 P7 P8 P16 P17 P18
V37LFS-BL/BK
BRAKE
P2-16
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN
BK
VALVE RTN2
P2-15
J1 J2
V36LFS-BL
LR STEER SNSR
P2-14
P1 P2
V37RFS-BL/BK
RF STEER SNSR
RR STEER SNSR
P2-10
P2-13
RR STEER LEFT
P2-09
LR STEER SNSR
RR STEER RIGHT
P2-08
P2-12
AUX REVERSE
P2-07
P2-11
AUX FORWARD
P2-06
P1 P2
P109ANG-GN/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BR
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
V52AREV-BL/RD
V52AFV-BL/RD
MOTOR SPEED
P2-04 P2-05
AXLE EXTEND
P2-03 BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
BL
RD
B
LF STEER RIGHT
A
BK
C
BL
RD
B
BK
A
BL
RD
C
RF STEER RIGHT
LR STEER RIGHT
B
BK
A
BL
RD
AXLE RETRACT
P2-02
J144
V29MS-RD/WH
VALVE RTN1
P2-01
P1 P2 J1 J2
RR STEER RIGHT
13 RR STEER RIGHT
V60AXEX-GN/WH
V61AXRT-GN
VLVRET-BR
9
BRAKE
5
AUX REVERSE
8
AUX FORWARD
MOTOR SPEED
4
AXLE EXTEND
AXLE RETRACT
3 CONNECTOR DESCRIPTION AND/OR LOCATION BLACK 23 PIN AMP CONNECTOR TCON TO BOOM HARN BLACK 35 PIN AMP CONNECTOR TCON TO LIMIT SWITCH WHITE 23 PIN AMP CONNECTOR TCON TO ENGINE HARN WHITE 35 PIN AMP CONNECTOR TCON TO FUNCTION MANIFOLD BLACK 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
PLATFORM PLATFORM ROTATE LEVEL
E
-
PCON ALARM
D
-
1 C
+
2 PLUG NO JACK NO J1 P1 J2 P2 J3 P3 J4 P4 J5 P5
B
+
A Z
6
7
TO HORN BUTTON BOOM UP/DWN FC RECOVERY SIGNAL
U95
PWR TO TCON ESTOP
TCON MEMBRANE PANEL
TO MICRO
DETAIL E - TCON RELAY PARKING
30
K7
30
P_22R
P_22R
P7R
J2 BLACK 35 PIN LIMIT SWITCH HARNESS
OPTIONAL HYDRAULIC PRESSURE SENSOR
24
AXLE RETRACTION LIMIT SWITCHES AXLE EXTENTION LIMIT SWITCHES
5 31 24 6 31 24 31 24 31 24 31 24 31 24
5 31 24 6 31 24
LIMIT SWITCHES S-120/125 ENGINE BLOCK
C61AXRT-GR
AUX. PUMP
87a 87 85 5 4
P57PBD-RD/WH
P264 WAY BAT. + BAT. -
IND.
1 30
ALTERNATOR EXCT.
2 86 GLOW PLUG2 RELAY 86
HORN 87a 87 85 RELAY 4 5
P21DCON-RD
1
REGULATOR
2
HI/LO SPEED SOLENOID
3
SERVICE HORN
S7PLE1-BL/BK S2PLD2-GR/BK
1
30
HYD COOLER 2 RELAY 86
85 87 87a 5 4
FUEL SOLENOID 2 RELAY 86
1 30
85 87 87a 5 4
STA.
FAN
1 30
85 87 87a 5 4
FUEL SOLENOID RELAY
2 3 4
C27AUX-RD
S2PLD1-BL/RD
VLVRET6-BR S7PLE2-GR/WH
ES0509C
C27AUX-RD
VALVE RTN6
VALVE RTN7
C06TTR-WH/BK
C05TTL-WH
12 VOLT
P56PRV-RD
24
5 6 7 8 1
REV
FWD
FUSE
3-10A
2
LIMIT SWITCHES S-100/105
3 4 5 6
31
7 8
24 31 24
9 10 11 12 J20 12 WAY
5 31 24 6
5 31
31
24 6 3 1 24 3 4
P
31 24 31
C64LS-OR/BK
P56PRV-RD
SJ3-WH
C68PBD-BL
S62BSTO-ORN
P53LS-WH/BK
C60AXEX-GN/WH
SERVICE_HORN
P3-07
TT_TILT_SNSR_GND TT_TILT_SNSR_PWR VALVE_RTN2
P3-14 P3-15 P3-16
TT_TILT_X_AXIS TT_TILT_Y_AXIS AC_GENERATOR VALVE_RTN3
P3-20
P3-22 P3-23
P3-19
P3-21
ALTENATOR_RPM ALT_FIELD_WIRE
P3-18
P3-17
OIL_PRESSURE OIL/WATER_TEMP
P3-12 P3-13
C31EDC-WH/BK C30EDC-WH
P3-10 P3-11
STARTER_RELAY
P3-09
P3-08
FWD REV
P3-05
CHOKE/GLOW PLUG
P3-04
P3-06
THROTTLE IGNITION/FUEL
P3-03
P3-01
BOOM_EXT/RET_VLV
P2-09
C77AS-WH
G119SR-BL
SNSR GND-BR
P2-35
P2-34
P2-33
P2-32
P2-31
P2-30
P2-29
P2-28
P2-27
P2-26
P2-25
P2-24
P2-23
P2-22
P2-21
P2-20
P2-19
P2-18
P2-17
P2-16
P2-15
P2-14
C66DREN-BL
P2-13
C65LOFL-BL/WH
P2-12
P2-11
C64LS-OR/BL
P63LS-OR/RD
S62BSTO-OR
P2-10
P2-08
P2-06
P2-05
P2-04
P2-03
P2-02
P2-01
AUX_RELAY
VALVE_RTN6
VALVE_RTN7
ROTATE_CCW_VLV
ROTATE_CW_VLV
MULTI_FUNCT_VLV
LSB4ES MONITOR INPUT
LSB8RS MONITOR INPUT
LSB9AS MONITOR INPUT
LSB2RS MONITOR INPUT
DRIVE LIGHTS RELAY
BOOM_RETRACT_VLV
BOOM_EXTEND_VLV
BOOM_DOWN_VLV
BOOM_UP_VLV
C60AXEX-GR/WH
P4-35
P4-34
P4-33
P4-32
P4-31
P4-30
P4-29
P4-28
P4-27
P4-26
P4-25
P4-24
P4-23
P4-22
P4-21
P4-20
P4-19
P4-18
P4-17
P4-16
P4-15
P4-14
P4-13
P4-12
P4-11
P4-10
P4-09
P4-08
P4-07
P4-06
P4-05
P4-04 TURNTABLE_ROTATE_VLV
P4-03
VALVE_RTN4 BOOM_UP/DOWN_VLV
P4-02
P4-01
P2-07
C61AXRT-GR
5
85
2 K7 86
4
TO MICRO
3 TETHER ESTOP
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO PLD
BM 3' I
BM 100' I
PRI LO#1 O
PWR TO TCON ESTOP
1
BM U/D FC O
BM E/R FC O
BM DWN O
BM RET O
TO MICRO
TO MICRO TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
YL
BL
PR
GY
BR
WT
LT GR
5
1 30 85 87 87a 4
2 K1 86
PWR IN SERV OR BM DWN ST I RECOVERY PROVIDES PWR AUX HYD O TO MINIMAL MLT FNC VLV O HARDWARE
TO MICRO
TO MICRO
4 TCON OR PCON MODE
SERVICE OR RECOVERY MODE
TO MICRO
TO PLD
TO MICRO
TO MICRO
2 1 K8 86 30 87 87a 85 5 4
TO MICRO
1 30 87 87a
AUX/START_BAT_PWR
AUX/START_BAT_GND
SYS_BAT_GND
SYS_BAT_PWR
P3-02
S59CNBK-GR/WH
C64LS-OR/BK
2
S56PRV-RD
1
4
C77AS-WH
C64LS-OR/BK
P20 12 WAY C65LOFL-BL/WH
C64LS-OR/BK
C66DREN-BL
P57PBD-RD/WH S7PLE1-BL/BK
P58LS-RD/BK
P54ENG-BK/WH
P53LS-WH/BK
S56PRV-RD
SJ3-WH
C71PBE-BL/BK
C64LS-OR/BK
P57PBD-RD/WH
C61AXRT-GN
S62BSTO-OR
P5-04
P58LS-RD/BK
P57PBD-RD/WH
S56PRV-RD
P54ENG-BK/WH
P53LS-WH/BK
P21DCON-RD
GNDDCON-BR
S2PLD1-BL/RD
S7PLE1-BL/BK
S7PLE2-GR/WH
S2PLD2-GR/BK
R49LP - WH/BK
J31-TILT SNSR
P31-ENG HARN
VLVRET3-BR
C45GEN-GR/WH
C84TAY-GR/BK
C83TAX-GR/WH
C107AF-RD
C41RPM-OR/BK
VLVRET2-BR
P85TTSR-GR
RET85TTSR-BR
C26TSR-WH/RD
C25PSR-WH/BK
C30EDC-WH
C31EDC-WH/BK
C33STR-BK
C46HRN-WH
(DETAIL B )
C34SA-BK/WH
C21IGN-WH
R35RPM-BK/RD
P3-06
P3-05
C71PBE-BL/BK
P53LS-WH/BK
P63LS-OR/RD
C60XES-GR/WH
C70PBE-BL/WH
C61AXRT-GR
C70PBE-BL/WH
P63LS-OR/RD
C68PBD-RD
P21DCON-RD P57PBD-RD/WH
P54ENG-BK/WH
S56PRV-RD
3
LSB1DO 10 DEG
S2PLD1-BL/RD
LSB6S CHNBRK
C08PBR-BK/WH
C07PBE-BK
C02PBD-RD/BK
C01PBU-RD
C06TRF-WH/RD
C09PERF-BK/RD
C03PBF-RD/WH
GNDDCON-BR 2
LSB7DS 11 DEG
4
1
LSB13AO 53 DEG
3
TN
PK
GR
5
1 30
5
TO MICRO
OR
GR/WH
YL/WH
PR
LT BL
BK RD
J11
J10
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P1
P1
P1
P1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
85 87a 87 K5 86 30 2 1
85 87 87a 4
2 K2 86
10
9
8
7
6
5
4
3
2
1
P1
P1
P1
P1
P1
P1
FUEL TYPE
SPARE 2
COORD STEER
CRAB STEER
REAR STEER
FRONT STEER
DRIVE SPEED
AXLE EXTEND
ENGINE SPEED
AXLE RETRACT
SPARE 1
DRIVE ENABLE
START
START ASSIST
AUXILIARY
AC GENERATOR
HORN
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
5
85
4
1 30 87 87a
2 K6 86
5 85 85 87 87a 87a 87 30 30 K4 86 K3 86 2 1 2 1
5
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
P4
P3
Y
FST1S LOW FUEL FS
2
LST1O DRV ENABLE
1 1
C64LS-OR/BK
15A
J21 8 WAY
SJ3-WH
CB 7
P21 8 WAY
S56PRV-RD
BR-COM
LSB8AS 50 DEG
P34SA-RD
C70PBE-BL/WH
+AUX
31
P57PBD-RD/WH S2PLD1-BL/RD
P116HYD-OR P27
P58LS-RD/BK
RD-HOLD
RELAY ADDED S100- S/N 865 S120- S/N 2782
85 5
J27
P54ENG-BK/WH
WH-PULL P
86
P53LS-WH/BK P53LS-WH/BK
-BAT
OTS1 N.O. TO DRIVELAMPS
S56PRV-RD
30
C61AXRT-GN
2 86
4
TO AUX HYD RELAY PR1
87
X
P57PBD-RD/WH
TROMBETTA TIME DELAY MOM N.O.
86
P53LS-WH/BK
1 30
P58LS-RD/BK
P56PRV-RD
TURNTABLE ROT CCW VLV
87a 3
TURNTABLE ROT CW VLV
85
C113MFV-OR/RD
12 VOLT
MULTI FUNC VLV
P46HRN-WH
P
BOOM RET VLV
P
BOOM DWN VLV
FUSE
BOOM EXTEND VLV
S56PRV-RD
VLVRET4-BR
V31REV-WH/BK
V30FWD-WH
HIGH CURRENT VALVE PROPEL OUTPUT
BATECU-RD
P5-03
P5-02
P5-01
TO MICRO
TO MICRO
TO PLD
5 PCON MODE
P9A
K1 POWERS CKT P22R OR CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE) K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD, VALVES AUX RELAY, BOOM EXT/RET, 85 87 87a K8 TURNTABLE ROTATE VLV. K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH 86 30 85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES: PRIMARY VALVES 1 & 2, THROTTLE (IGN), GLOW PLUG, STARTER RELAY, AC GENERATOR, 86 30 BOOM RETRACT, MULTIFUNCTION VALVE, ROTATE CW, AND ROTATE CCW. 85 87 87a 85 87 87a 85 87 87a K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD. 86 86 86 30 30 30 (FUEL ON/OFF SOLENOID AND ALT FIELD) K3 K5 K2 K7 POWERS THROTTLE OR HI/LOW SOLENOID 85 87 87a K6 85 87 87a K1 (CKT C35RPM-BK/RD) K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
87 87a
P63LS-OR/RD
2
2 86
SEE GENERATOR OPTIONS
BOOM UP VLV
P63LS-OR/RD
DEUTZ BF4L-2011/TD2011-LO4I ENGINES SHOWN S2PLD1-BL/RD
J32-ENG HARN
BOOM EXT/RET F.C.
C60AXEX-GR/WH
4.5 DEGREE TURNTABLE TILT SENSOR
86
S62BSTO-OR
S56PRV-RD
1
BATGND-BR
MANIFOLD HARN
85
C64LS-OR/BK
GNDDCON-BR
24
1 30
J4 WHITE 35 PIN
TURNTABLE CW/CCW F.C.
C61AXRT-GR
BOOM UP/DWN F.C.
20 A
TCON
W
C71PBE-BL/BK
31
+BAT
P10
J23 4WAY
D82CAN+ -YL
3
P23 4WAY
P114BAT-RD
S7PLE2-GR/WH
GNDDCON-BR C45GEN-GR/WH 1 2 BAT GND-BR
S7PLE1-BL/BK
KILL PROX
S2PLD2-GR/BK
BOOM HARN
BAT GND-BR
24
STARTER RELAY
RET85TTSR-BR
C26TSR-WH/RD
31
70 A FUSE
P85TTSR-GR
OIL TEMP SENDER
D81CAN- -GR
C83TAX-GR/WH
OIL PRESSURE
P7-LIMIT SW HARN
DETAIL B
J1 BLACK 23 PIN C84TAY-GR/BK
P21IGN-WH
30
BATGND-BR
LIMIT SWITCH HARNESS
C25PSR-WH/BK
24
BATVLV-RD
P2-35
P2-34
P2-33
P2-32
J2 BLACK 35 PIN
J144-7
87
ENGINE HARN
C21IGN-WH
TO FLASHING BEACON 87a
J3 WHITE 23 PIN
C116HYD-OR
CB
OPTIONAL HYDRAULIC PRESSURE SENSOR
25A
LSB14AO
P2-30
POWER HARN
R21IGN-WH
31
P11
VLVRET2-BR
4
P11
P116HYD-OR
AUX MAIN
LSB13AO
P2-29
VLV RET
LSB4EO
P2-28
P2-31
AUX HYD PRESS SIG
P2-27
J5 BLACK 4 PIN
C34SA-BK/WH
P53LS-WH/BK
P114BAT-RD
P21DCON-RD
P6R1
R116HYD-OR
P
C64LS-OR/BK
P57PBD-RD/WH
P9A P6R1
GLOW PLUG
3
C64LS-OR/BK
SNSR GND
P2-25
TCON P_22R
R34SA-RD
4
C65LOFL-BL/WH
PRI#2 LO
P2-24
P2-26
PRI#1 LO
P2-23
P2-22
TO PLD TO MICRO
6 OUTPUT PWR ENABLE
P_22
VLVRET2-BR
P
C64LS-OR/BK
LSB3EO
P2-20
P11
C30EDC-WH
P20 12 WAY C66DREN-BL
LSB3RO
P2-19
TO MICRO
7 P6R1
2
8
TCON ESTOP
9 P7R
10 P22 SERV. OR OPER. REC.
12
13
11
14 P11
OPER. REC.
15 TCON MODE
P7
16
ALARM GND ALARM PWR
P7R
FWD VLV A SOLENOID
3
P56PRV-RD
LSB2RO
P2-18
P2-21
LSB1DO P2-17
TO PLD LST10 P2-16
FST1S P2-15
P_12
OPER SW PWR
P_11 P2-10
P2-14
P_10 P2-09
P_18
P_9B P2-08
P2-13
P_9A P2-07
P_14
P_7R P2-06
P2-12
P_6R2 P2-05
P2-11
P_6R1 P2-04
DCON ECU PWR
DCON ECU GND
P2-03
P2-02
P2-01
P15
SERV. OR OPER. REC.
TO MICRO
P15
P6R1
C31EDC-WH/BK
Genie S-100/105 24 6
C68PBD-BL
VLVRET1-BR
C78PS-WH/BK
C77AS-WH
C76PBE-BL
G119SR-BL
SNSR GND-BR
V75PRLO-RD/WH
V74PRLO-RD
C71PBE-BL/BK
C70PBE-BL/WH
C69PBE-BK
C68PBD-RD
C66DREN-BL
C65LOFL-BL/WH
C64LS-OR/BL
P63LS-OR/RD
S62BSTO-OR
C61AXRT-GR
C60AXEX-GR/WH
S59CNBK-GR/WH
P58LS-RD/BK
P57PBD-RD/WH
S56PRV-RD
P54ENG-BK/WH
P53LS-WH/BK
P21DCON-RD
GNDDCON-BR
P1-23
P1-22
P1-21
P6R1
REV VLV B SOLENOID
D81CAN- -GR
24 6
4
S62BSTO-OR
FUSE
3-10A
P1-19
P9A
VLVRET2-BR
5 31
3
P53LS-WH/BK
P1-23
P1-22
P1-21
CANRS232_GND
P1-18
PCON POWER
BK-COM
J20 12 WAY
2
C60AXEX-GN/WH
RS232 GND
P1-19
CAN+ P1-17
PWR-PCON ESTOP
HRN RLY CNTRL
P1-16
P1-20
OUT PWR ENBL
P1-15
PCON POWER
BK
9 10 11 12
1
S56PRV-RD
CAN HIGH
P1-18
P1-13
U32
RD-HOLD
8
C64LS-OR/BK
CAN LOW
P1-17
RS232_TXD BOOT
P1-12
P1-14
CAN SHIELD RS232_RXD
P1-11
P22
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P7
PCON PWR P1-02 P1-03
PCON GND P1-01
U20
P_22
WH-PULL IN
7
C77AS-WH
NOT USED
P1-16
P1-23
PWR-PCON ESTOP
RD
6
C64LS-OR/BK
TET ESTOP PWR
P1-15
SAFE PL TILT GND SAFE PL TILT PWR
P1-22
P_7
V
LSB3RO 3' EXT
4 5
SJ1-WH/RD S7PLE2-GR/WH
LOAD SENSOR INPUT
P1-14
PL TILT SNSR PWR P1-21
P_7
WH
D82CAN+ -YL C78AS-WH/BK
BOOT
P1-13
PL TILT SNSR P1-20
TCON MODE
VLVRET2-BR
4
5 31
SJ2-BK/RD
RS232 TXD
P1-12
PL TILT SNSR GND P1-19
TCON MODE
R46HRN-WH
3
P54ENG-BK/WH
RS232 RXD
P1-11
FOOT SW RTN P1-17
P_6R2
U
LSB3RS 3.5 EXT
3
2
P53LS-WH/BK P53LS-WH/BK
CAN SHIELD
P1-10
FOOT SW PWR P1-16
OUT PWR ENABLE
T
LSB3EO 75' EXT
2
1
P57PBD-RD/WH S7PLE1-BL/BK
FLASHING BEACON
P1-09
SAFE PL TILT OUT P1-15
P_9B
TO MICRO
BAT GND-BR
J264 WAY1
8 P58LS-RD/BK
WORK LT
P1-08
LOAD SNSR PWR P1-14
P_6R2
C107AF-RD
7
SJ2-BK/RD
P_22
P1-07
LOAD SNSR OUT P1-13
LOCKOUT VALVE #1 SIG
J144-2
6
P53LS-WH/BK SJ1-WH/RD
P_7
P1-06
LOAD SNSR GND P1-12
PRI BOOM DOWN STATUS
C41RPM-OR/BK
5
S56PRV-RD
PWR-PCON ESTOP
P1-05
P23PCON-BK
D81CAN- -YL
D82CAN+ -GR
C46HN-WH
C47OUT-WH/BK
P56PRV-RD
S56PRV-RD/WH
P52PCON-WH
PROX KILL CMD P1-11
P1-18
PROX KILL GND P1-10
6
5
4
3
2
1
6
5
4
3
2
1
P2
P1
BOOM UP/DWN FC RECOVERY SIGNAL
HOLD
P63LS-OR/RD
4
C71PBE-BL/BK
OUT PWR ENBL
P1-04
TET ESTOP RET
HORN RELAY COIL
P1-03
P1-20
PCON POWER
P1-02
SAFE PL TILT OUT FOOT SW PWR
PROP VLV1_B
OUT PWR ENABLE
J144-1
3
C64LS-OR/BK
P95TET-OR
D82CAN+ -YL
D81CAN- -GR
P97TET-BK
S132LDS-BL/WH
R117FB-RD
R48LP-WH/RD
P56PRV-RD
S56PRV-RD/WH
PCON GND
P1-01
5A
FUSE
C56PTS-RD
GNDPCON-BR
P1-15 P1-16
R56PTS-RD
P87PTS-RD
PTSRET-BR
P85PTS-GR
PROP VLV1_A P1-08 P1-09
PROP VLV2_B P1-07
ESTOP_1
ESTOP_2
NOT USED
H4_RKOUT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
6
5
4
3
2
1
6
5
4
3
2
1
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
BAT GND-BR
C60AXEX-GR/WH
2
P57PBD-RD/WH
C47OUT-WH/BK P23PCON-BK
OUT FRM TILT SWITCH
PWR TO TILT SWITCH
TILT SWITCH GND
TILT SENSOR PWR
C84TAY-GR/BK
C56PTS-RD
R56PTS-RD
C88PTS-RD/BK
PLATRET-BR
BK
OR
GR/YL
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
C14PLU-OR
PROP VLV2_A P1-06
30
29
28
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
H1_GND
S3-3
S3-2
BOOM EXT/RET FC RECOVERY SIGNAL
S
LSB4ES 75.5'
ES0509C Genie Part Number 228882 Rev A P53LS-WH/BK
P_9B
PRI BOOM LENGTH 100' STATUS
R
BAT GND-BR
Electrical Schematic
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
PULL IN
(from serial number 2710)
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
J144-8
Genie S-120/125 P27-LIMIT SW J21 1 8 WAY
P9A
Q
BAT GND-BR
(from serial number 810)
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
C27AUX-RD
J27-BOOM HARN
PR1
P56PRV-RD
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
VLVRET6-BR
P21 8 WAY
P
BAT GND-BR
6
PCON POWER
P33STR-BK
5
6
PRI BOOM LENGTH 3' STATUS
START BAT
5
P10
MAIN (SYS) BAT
GR
P7R
P10
V75PRLO-RD/WH
P6R1
P7R
VLVRET1-BR
88
P_22
PRI 2 LO
YL
GR BL
P_7
V74PRLO-RD
P11
O
PRI 1 LO
P18
88 4
PWR TO TCON ESTOP
FST1S LOW FUEL FS
88
YL 3
4
PWR TO TCON ESTOP
LST1O DRV ENABLE
BL 3
TO HORN BUTTON
SJ3-WH
BR P27
TO HORN BUTTON
LSB1DO 10 DEG
P12 2
TILT SENSOR SIG OUT
PLAT SENSOR GND
BK RD
PLAT LEVEL DN
PLAT LEVEL UP
C44JD-GR/BK
ON/OFF VLV3_B
TCON MODE
LSB7DS 11 DEG
88 1
2
J27
LSB13AO 53 DEG
BR 2 P56PRV-RD
N
LSB14AO 68 DEG
OR
86
LSB9AS 65 DEG
P9A P56PRV-RD
C64LS-OR/BK
DCON PWR RD
88 J7 1
S132LDS-BL/WH
SJ3-WH
88 P8-LIMIT SW HARN
SJ3-WH
RD
OR 2
1
C61AXRT-GN
C47OUT-WH/BK
85
S62BSTO-OR
DCON GND BK J8 1
86
P63LS-OR/RD
88 S56PRV-RD/WH
C70PBE-BL/WH
BK WH C
30
C76PBE-BL
P7R
C
87
C70PBE-BL/WH
6 88 C46HN-WH
P52PCON-WH
LSB8AS 50 DEG
5
6
(SLIP RING) B
P57PBD-RD/WH S2PLD1-BL/RD
5 WH A
B
TO WORK LIGHTS 87a
P58LS-RD/BK
3
4 GNDPCON-BR
SJ2-BK/RD
P23PCON-BK
S56PRV-RD
C 3
4 CAN SHIELD
J157
SJ2-BK/RD
24 2 GR
J6 A P6-BOOM HARN
2
LSB3RO 3' EXT
AXLE NOT EXT LIMIT SWITCHES 31 2 2 88 CAN LOW
YEL
FOOTSWITCH
SJ1-WH/RD
(SLIP RING)
P157 1
TCON
LSB4ES 75.5'
24 P17 1 1 88 CAN HIGH
2 24
J1 BLACK 23 PIN
P53LS-WH/BK SJ1-WH/RD
12 2 P18 1 GR
FOOTSWITCH LOAD SENSOR OPTION S132LDS-BL/WH
31
BOOM HARN
C61AXRT-GN
J3-OR/BL C 88
PLATFORM TILT SENSOR ASSEMBLY
OPTIONAL PROXIMITY KILL WIRING P11
P57PBD-RD/WH
P53LS-WH/BK C YEL
J31-TILT SNSR
85 5
P63LS-OR/RD
P63LS-OR/RD B
P33-PCON MANIFOLD
4
S62BSTO-OR
C60AXEX-GR/WH P16 A
B
6
87
C64LS-OR/BK
C61AXRT-GR A 1
5
87a 3
PLD
S2PLD2-GR/BK
9 24
4
85 5
C71PBE-BL/BK
P21DCON-RD
P1-05
87
C64LS-OR/BK
P57PBD-RD/WH 1
JIB DOWN
DCON 3
PCON MANIFOLD
5A
OPTIONAL PROX KILL SW.
2
J2 WHITE 23 PIN
4
S2PLD1-BL/RD
GNDDCON-BR
P1-04
2 86
FUSE
31
1
PCON 87a 3
C76PBE-BL
J17-DRIVE CHASSIS HARN
C43JU-GR
J20
S59CNBK-GN/WH
S56PRV-RD
C18PRR-GR/BK
P6R
C69PBE-BK
J18-DRIVE CHASSIS HARN JIB UP
P7R
P54ENG-BK/WH
D81CAN- -GR
PLAT ROT CW
OUT PWR ENABLE
P53LS-WH/BK
D82CAN+ -YL
ON/OFF VLV3_A
ECU
P58LS-RD/BK
J16-DRIVE CHASSIS HARN
P1-03
1 30
C46HN-WH
DRIVE CHASSIS HARN
C17PRL-GR
VLV RTN
P20
P63LS
J2-BL/RD
P1-02
P1-01
K2
GNDPCON-BR
J1 BLACK 23 PIN
PLAT ROT CCW
VLVRET-BR
AXLE NOT EXT PWR
5 2 86
P52PCON-WH
P1-23
P1-22
27
26
25
24
23
22
21
20
19
18
17
16
PCON MEMBRANE PANEL
S59CNBK
31 WH
P61LS(A)-GR
P1-21
P1-20
1 30
TCON
M
LSB3RS 3.5 EXT
WHEN AXLES ARE EXTENDED TERM 3 & 4 ARE CLOSED RS232 GND
K1
RECOVERY
LSB3EO 75' EXT
P P1-19
10 WAY ENGINE HARN TO ENGINE
MEMBRANE/LED INTERFACE CARD
PCON
LSB4EO 100' EXT
P CAN HIGH
CAN LOW
7 RUN OFF
LSB6S CHNBRK
P P1-18
6 PCON E-STOP
C64LS-OR/BK
4 P1-17
AXLE NOT EXT SIG
BOOT
RS232 TXD
RS232 RXD
15
14
13
J3 10PIN
SERV. BYPASS
L
LSB2RO 100'
3 D82CAN+ -YL
P1-16
P1-15
P1-14
P1-13
AXLE NOT RET SIG CAN SHIELD
2 WAY DEUTSCH-PWR HARN/ENG HARN
J2 10PIN
K
C69PBE-BK
4 P1-12
P1-11
P1-10
P1-09
AXLE NOT RET PWR
12
11
10
J1 10PIN
J
SJ1-WH/RD S2PLD2-GR/BK
3 D81CAN- -GR
C61LS(A)-GR
C61LS-GR
P1-08
P12
P_7R
9
BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
I
SJ2-BK/RD
J4-GR/BK P63LS-OR/RD
10 DRIVE & STEERING JOYSTICK
H
LSB2RS 101'
WHEN AXLES ARE RETRACTED TERM 3 & 4 ARE CLOSED 4 C60AXEX-GR/WH
P57PBD-RD/WH
11 NOT USED
G
P54ENG-BK/WH
J1-BL/BK
BOOM EXT/RET JOYSTICK
F
P53LS-WH/BK P53LS-WH/BK
3 P1-07
P1-06
P1-05
P1-04
P_6R1
8
S3-1
1
P61LS-GR
C61AXRT-GR
S56PRV-RD
P1-03
DCON ECU PWR
7
S2-3
S2-2
S2-1
S1-3
S1-2
S1-1
BOOM UP/DWN & TURNTABLE ROTATE JOYSTICK
LSAX2ES
4 P53LS-RD
P1-02
DCON ECU GND
6
5
4
3
2
1
ALARM+
ALARM-
JIB
LSAX1ES
P
LSAX2EO
3 P21DCON-WH
P1-01
J2 WHITE 23 PIN
LSAX1EO
B
DRIVE CHASSIS HARN
LSAX2RO
A GND-DCON-BR
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR 6 WAY ENGINE HARN TO TILT SENSOR 4 WAY ENGINE HARN-AC GENERATOR PCON MANIFOLD/TILT SENSOR
LSAX1RO
J30 J31 J32 J33
LF STEER LEFT
P30 P31 P32 P33 9 WAY DEUTSCH TETHER CONNECTOR 8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN 4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN 2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
LF STEER RIGHT
12 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN 8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
RF STEER LEFT
J20 J21 J23 J24 J25 J26 J27 J28 J29
RF STEER RIGHT
P20 P21 P23 P24 P25 P26 P27 P28 P29
LR STEER LEFT
PCON PCB TO MEMBRANE SWITCH PCON PCB TO MEMBRANE SWITCH
LR STEER RIGHT
J1 J2
RR STEER LEFT
P1 P2
LF STEER LEFT
TCON PCB TO MEMBRANE SWITCH TCON PCB TO MEMBRANE SWITCH
RR STEER RIGHT
J10 J11
LF STEER RIGHT
P10 P11
P2-23
3 WAY DEUTSCH CAN CONNECTOR BOOM HARN TO SLIP RING 6 WAY DEUTSCH DCON SAFETY SW LIMIT SW TO SLIP RING 2 WAY DEUTSCH DCON ECU PWR LIMIT SW HARN TO SLIP RING 3 WAY DEUTSCH CAN CONNECTOR SLIP RING TO DCON HARN 6 WAY DEUTSCH DCON SLIP RING TO DCON HARN 2 WAY DEUTSCH SLIP RING TO DCON HARNESS
V37LFS-BL/BK
J6 J7 J8 J16 J17 J18
RF STEER LEFT
P6 P7 P8 P16 P17 P18
P2-22
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN 2 WAY DEUTSCH LOAD SENSE LIMIT SWITCH TO BOOM HARN
V36LFS-BL
STEER SNSR PWR
J2 J157
P2-21
STEER SNSR GND
RF STEER RIGHT
LR STEER LEFT
LR STEER RIGHT
BRAKE
VALVE RTN2
LR STEER SNSR
RF STEER SNSR
LR STEER SNSR
RR STEER SNSR
RR STEER LEFT
RR STEER RIGHT
J1
V37RFS-BL/BK
P2-20
P2-19
P2-18
P2-17
P2-16
P2-15
P2-14
P2-13
P2-12
P2-11
P2-10
P2-09
P2-08
P2-07
MOTOR SPEED
P_6R2
P1 P2 P157
BK
C P109ANG-GR/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BR
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
P2-06
P2-05
AXLE EXTEND
AXLE RETRACT
VALVE RTN1
OUT PWR ENABLE
J1 J2
BL
RD
B
LF STEER RIGHT
A
BK
C
BL
RD
B
BK
A
BL
RD
C
RF STEER RIGHT
LR STEER RIGHT
B
BK
A
BL
RD
P2-04
P2-03
P2-02
P2-01 J144
V29MS-RD/WH
V60AXEX-GR/WH
V61AXRT-GR
VLVRET-BR
8
BRAKE
MOTOR SPEED
4
AXLE EXTEND
RR STEER RIGHT
13 AXLE RETRACT
3 CONNECTOR DESCRIPTION AND/OR LOCATION BLACK 23 PIN AMP CONNECTOR TCON TO BOOM HARN BLACK 35 PIN AMP CONNECTOR TCON TO LIMIT SWITCH WHITE 23 PIN AMP CONNECTOR TCON TO ENGINE HARN WHITE 35 PIN AMP CONNECTOR TCON TO FUNCTION MANIFOLD BLACK 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
PLATFORM PLATFORM ROTATE LEVEL
E
-
PCON ALARM
D
-
2 P1 P2
C
+
PLUG NO JACK NO J1 P1 J2 P2 J3 P3 J4 P4 J5 P5
B
+
A Z
PWR TO TCON ESTOP U95
TCON MEMBRANE PANEL
TO MICRO
TO HORN BUTTON
TO MICRO
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL
P10 P_22R P7R
30
K7
30
DETAIL E - TCON RELAY PARKING
LIMIT SWITCH HARNESS
J2 BLACK 35 PIN
OPTIONAL HYDRAULIC PRESSURE SENSOR
24
24
S2PLD1-BL/RD
S7PLE1-BL/BK
