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5 - 10

Genie S-100 & S-105 & S-120 & S-125

Part No. 62401

First Edition • First Printing

Section 5 • Troubleshooting Flow Charts

Diagnostic code displayed   

Condition

Possible Causes

Solution

FAULT CODE CHART

SAFETY SWITCH P12 FAULT

Axle retract inoperative.

Open in stowed safety circuit or limit 
switch LSB7DS or LSB3RS have 
failed or operational limit switches 
LSB1DO or LSB3RO have failed.

Refer to chart 18 or 19 and chart 20 
or 21 to troubleshoot.

SAFETY SWITCH P14 FAULT

Axle retract inoperative.

Open in stowed safety circuit or limit 
switch LSB7DS has failed or limit 
switch LSB1DO has failed.

Refer to chart 18 or 19 and chart 20 
or 21 to troubleshoot.

SAFETY SWITCH P18 FAULT

Boom extend inoperative.

Open in axle safety switch circuit or 
limit switch LSB3RS,LSAX1ES, or 
LSAX2ES have failed or operational 
limit switch LSB3RO has failed.

Refer to chart 18 or 19 and chart 20 
or 21 to troubleshoot.

SAFETY SWITCH P22 FAULT

Platform level inoperative. Fault 
creates a safety switch P22R fault.

Platform out of level >10degrees out 
of stowed position or platform level 
sensor is bad or there is an open in 
the platform level sensor circuit or 
limit switches LSB1DO or LSB3RO 
are bad.

Refer to chart 27 to troubleshoot.

SAFETY SWITCH P22R FAULT

Platform level and Boom up/down 
inoperative. 

Platform out of level >10degrees out 
of stowed position or platform level 
sensor is bad or there is an open in 
the platform level sensor circuit or 
limit switches LSB1DO or LSB3RO 
are bad.

Refer to chart 27 to troubleshoot.

DCON SAFETY SWITCH P7R 
FAULT

Steering and axle functions 
inoperative.

Open in Red S56PRV wire circuit that 
runs from the turntable control box to 
the DCON control box.

Repair damage in circuit wiring. Refer 
to electrical schematic to 
troubleshoot or consult Genie 
Industries Service Department.

PROX. KILL SW. FAULT

All functions inoperative unless spare 
membrane on platform control box is 
activated.

Proximity Kill Bumper under platform 
has run into an obstruction or is out of 
adjustment.

Activate spare membrane and 
carefully move away from obstruction 
or readjust proximity kill limit switch.

PLTFRM OVERLOAD SEN. FAULT

All functions inoperative red LED 
above spare membrane flashing.

Load in platform is above rated load 
or load sensor is out of adjustment.

Unload excessive weight out of 
platform or readjust load sensor.

BOOM UP OVERLOAD FAULT

All functions except Boom retract 
inoperative.

Load in platform is above rated load 
or boom has run into an obstruction 
or boom up overload switch is out of 
adjustment.

Unload excessive weight out of 
platform or readjust limit switch or 
move away from obstruction.

BOOM DOWN OVERLOAD FAULT

All functions except Boom up and 
retract inoperative.

Boom has been lowered into an 
obstruction with boom extended or 
boom down overload switch is out of 
adjustment or there is an open in 
boom down overload circuit.

Refer to chart 14 to troubleshoot.

PRESS PLATFORM ESTOP

Code displayed whenever engine is 
running and controller is waiting for 
engine to be shut off to save 
calibrations or any parameter 
changes made with the display to 
memory.

Just finished a speed calibration for 
boom up/dwn, ext.ret, or turntable 
rotate or Joysticks were calibrated 
with engine running or a function 
parameter was changed with the 
display while the engine was running.

Turn key switch to platform control 
position and depress platform 
Emergency stop.

Содержание S-100

Страница 1: ......

Страница 2: ...ent and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries 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 Read...

Страница 3: ...del S120 Serial number S12006 12345 Electrical schematic number ES0427 Machine unladen weight Rated work load including occupants 500 lb 227 kg Maximum allowable inclination of the chassis 0 deg Gradeability N A Maximum allowable side force 150 lb 670 N Maximum number of platfrm occupants 2 Model year Manufacture date 01 05 06 2006 Maximum wind speed 28 mph 12 5 m s Maximum platform height 126 ft ...

Страница 4: ...Genie S 100 S 105 S 120 S 125 Part No 62401 First Edition First Printing iv This page intentionally left blank ...

Страница 5: ...e 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 ap...

Страница 6: ...cking 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 Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the conti...

Страница 7: ... 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 Perkins Engine 1004 42 Specifications 2 7 Cummins Engine B3 9L Specifications 2 8 Deutz Engine F4L 913 Specifications 2 9 Hydraulic Hose and Fitting Torque Specifications 2 10 Section Three Theo...

Страница 8: ...intenance Deutz Models 4 10 A 7 Check the Hydraulic Filter Condition Indicators 4 10 A 8 Test the Auxiliary Power Operation 4 12 A 9 Test the Tilt Sensor and Alarm 4 12 A 10 Test the Operating Envelope 4 13 A 11 Perform 30 Day Service 4 14 A 12 Perform Engine Maintenance Perkins Models 4 14 A 13 Perform Engine Maintenance Deutz Models 4 13 A 14 Grease the Turntable Rotation Bearing and Rotate Gear...

Страница 9: ...t the Engine RPM 4 27 B 13 Test the Key Switches 4 30 B 14 Test the Ground Control Override 4 31 B 15 Test the Platform Self leveling 4 32 B 16 Test the Safety Envelope and Circuits 4 33 B 17 Inspect the Fuel Tank Cap Venting System 4 39 B 18 Test the Engine Idle Select Operation 4 40 B 19 Test the Drive Brakes 4 41 B 20 Test the Drive Speed Stowed Position 4 41 B 21 Test the Drive Speed Raised or...

Страница 10: ...e Bearing Wear 4 58 D 9 Perform Engine Maintenance Deutz Models 4 59 D 10 Perform Engine Maintenance Perkins Models 4 60 D 11 Perform Engine Maintenance Cummins Models 4 60 D 12 Replace the Hydraulic Filter Elements 4 61 E 1 Test or Replace the Hydraulic Oil 4 63 E 2 Perform Engine Maintenance Cummins Models 4 65 E 3 Perform Engine Maintenance Perkins Models 4 65 E 4 Perform Engine Maintenance Per...

Страница 11: ...tive Drive Steer and Axle Extend Retract Functions Operational 5 32 9 All Platform Steering and Axle Functions Inoperative All Other Functions Operational 5 33 10 Ground Controls Inoperative Platform Controls Operate Normally 5 38 11 Platform Controls Inoperative Ground Controls Operate Normally 5 40 12 Boom Angle Switch Fault 5 42 13 Boom Up Function Inoperative 5 45 14 Boom Down Function Inopera...

Страница 12: ...rative 5 151 29 Platform Rotate Counter Clockwise Function Inoperative 5 154 30 Jib Up Function Inoperative 5 157 31 Jib Down Function Inoperative 5 160 32 Auxiliariy Functions Inoperative 5 163 33 Axle Extend Function Inoperative 5 168 34 Axle Retract Function Inoperative 5 174 35 Blue End Blue Side Steering Function Inoperative 5 178 36 Blue End Yellow Side Steering Function Inoperative 5 181 37...

Страница 13: ...ve Chassis DCON and Platform Controls PCON 6 14 Electrical Schematic Legend Ground Controls TCON 6 15 Electric Symbols Legend 6 16 Electrical Schematic Drive Chassis and Platform Controls Sheet 1 of 2 located at end of manual Electrical Schematic Ground Controls Sheet 2 of 2 located at end of manual Limit Switch Harness Schematic S 100 S 105 Models 6 17 Limit Switch Harness Schematic S 120 S 125 M...

Страница 14: ...dels with 2 Wheel Steer 6 29 Hydraulic Schematic S 105 Models with 4 Wheel Steer 6 31 Hydraulic Schematic S 120 Models 6 33 Hydraulic Schematic S 125 Models 6 35 Section Seven Repair Procedures Introduction 7 1 Display Module 7 2 Platform Controls 1 1 Circuit Boards 7 5 1 2 Membrane Decal 7 6 1 3 Joystick Controllers 7 7 1 4 Foot Switch 7 14 1 5 Toggle Switches 7 15 Platform Components 2 1 Platfor...

Страница 15: ...Cable Track 7 29 4 2 Boom 7 32 4 3 Boom Lift Cylinder 7 43 4 4 Extension Cylinders 7 45 4 5 Boom Extend Retract Cables 7 49 Turntable Covers 5 1 Turntable Covers 7 53 Engines 6 1 RPM Adjustment 7 55 6 2 Flex Plate 7 55 6 3 Oil Pressure and Coolant Temperature Sending Units Cummins and Perkins Models 7 57 6 4 Oil Pressure and Temperature Sending Units Deutz Models 7 57 Ground Controls 7 1 Circuit B...

Страница 16: ...5 Models 7 86 10 6 Proportional Valves Function Manifold 7 87 10 7 Distribution Manifold Components 7 88 10 8 Valve Adjustments Distribution Manifold 7 90 10 9 Platform Manifold Components S 100 and S 120 Models 7 92 10 10 Platform Manifold Components S 105 and S 125 Models 7 94 10 11 Proportional Valves Platform Manifolds 7 96 10 12 Platform Rotate Counterbalance Valve Manifold 7 96 10 13 Turntab...

Страница 17: ... Tank 7 116 Turntable Rotation Components 12 1 Turntable Rotation Hydraulic Motor and Drive Hub 7 118 Axle Components 13 1 Steer Sensors 7 122 13 2 Yoke and Hub 7 124 13 3 Drive Motor 7 126 13 4 Drive Hub 7 127 13 5 Steering Cylinders 7 128 13 6 Extendable Axles 7 129 Appendix Electrical Schematic Genie part number 62304 Drive Chassis and Platform Control Sheet 1 of 2 Ground Controls Sheet 2 of 2 ...

Страница 18: ...Genie S 100 S 105 S 120 S 125 Part No 62401 First Edition First Printing This page intentionally left blank xviii ...

Страница 19: ... lb 340 kg 227 kg Turntable tailswing 66 in 66 in axles retracted 168 cm 168 cm Turntable tailswing 48 in 48 in axles extended 122 cm 122 cm Wheelbase 12 ft 12 ft 366 cm 366 cm Turning radius outside 24 ft 4 in 24 ft 4 in axles retracted 7 4 m 7 4 m Turning radius inside 16 ft 4 in 16 ft 4 in axles retracted 4 9 m 4 9 m Turning radius outside 20 ft 8 in 20 ft 8 in axles extended 6 3 m 6 3 m Turnin...

Страница 20: ... 50 to 55 seconds time between 53 envelope limit and a fully raised position Boom extended to 100 ft 30 5 m 24 to 28 seconds time between 68 envelope limit and a fully raised position Boom down Boom fully retracted 80 to 88 seconds Boom extended to 4 ft 1 2 m 100 to 110 seconds time between fully raised and a fully lowered position Boom extended to 80 ft 24 4 m 50 to 55 seconds time between fully ...

Страница 21: ...ngth transport position 39 ft 11 in 39 ft 11 in 12 17 m 12 17 m Length stowed 42 ft 8 in 46 ft 13 m 14 m Width axles retracted 8 ft 6 in 8 ft 6 in 259 cm 259 cm Width axles extended 11 ft 6 in 11 ft 6 in 351 cm 351 cm Height stowed maximum 10 ft 1 in 10 ft 1 in 308 cm 308 cm Weight 39 700 lbs 40 000 lbs 18 007 kg 18 143 kg Ground clearance 151 2 in 151 2 in 39 cm 39 cm Operational dimensions Platf...

Страница 22: ...m Width 36 in 91 cm Tires and wheels Tire size 15 x 22 5 18 pr FF Tire ply rating 18 Overall tire diameter 43 1 in 109 5 cm Wheel diameter 22 5 in 57 cm Wheel width 11 75 in 30 cm Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 433 9 Nm Fluid capacities Hydraulic tank capacity 55 gallons 208 liters Hydraulic system capacity 80 gallons including tank...

Страница 23: ...me between fully lowered and a fully raised position Boom extended to 80 ft 24 4 m 50 to 55 seconds time between 53 envelope limit and a fully raised position Boom down Boom fully retracted 80 to 88 seconds Boom extended to 4 ft 1 2 m 100 to 110 seconds time between fully raised and a fully lowered position Boom extended to 80 ft 24 4 m 50 to 55 seconds time between fully raised and the 50 envelop...

Страница 24: ...t 0 73 to 2 75 cu in per revolution variable 12 cc to 45 cc Function pump Type two section gear pump Displacement Pump 1 1 75 cu in 28 7 cc Displacement 2350 rpm Pump 1 17 8 gpm 67 4 L min Displacement Pump 2 1 cu in 16 4 cc Displacement 2350 rpm Pump 2 10 2 gpm 38 5 L min Auxiliary pump Type two section gear pump Displacement Section 1 0 159 cu in 2 61 cc Displacement 2687 rpm Section 1 1 85 gpm ...

Страница 25: ... 0W 13 F to 68 F 25 C to 20 C 5W 20 10 F to 104 F 12 C to 40 C 10W 30 14 F to 122 F 10 C to 50 C 15W 40 above 23 F 5 C 20W 50 Engine oil should have properties of API classification CF4 grade OR ACEA classification E3 Injection system Injection pump make Zexel Injector opening pressure 2204 psi 152 bar Fuel requirement Summer grade diesel number 2 D Winter grade At operating temperatures below 32 ...

Страница 26: ...Engine capacity 8 8 quarts 8 3 liters System capacity 20 quarts 18 9 liters Cummins Engine B3 9L Displacement 238 cu in 3 9 liters Number of cylinders 4 Bore and stroke 4 02 x 4 72 inches 102 x 120 mm Horsepower 75 2200 rpm Firing order 1 3 4 2 Compression ratio 16 5 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle no load 1300 ...

Страница 27: ...to 12 mm Deutz Engine F4L 913 Displacement 249 3 cu in 4 086 liters Number of cylinders 4 Bore and stroke 4 02 x 4 92 inches 102 x 125 mm Horsepower 77 2200 rpm Firing order 1 3 4 2 Compression ratio 18 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle no load 1300 rpm High idle no load 2350 rpm Valve clearance cold Intake 0 006 ...

Страница 28: ...e seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Torque Procedure 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 The O rings used in the Parker S...

Страница 29: ...ated at 28 gpm 106 L min 2350 rpm Two internal 4250 psi 293 bar relief valves are used to prevent over pressurization of the closed loop drive system The boom lift cylinder boom extend cylinders platform leveling slave cylinder platform rotator and jib boom cylinder S 105 and S 125 models incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure A regeneration ...

Страница 30: ...re sent to DCON via the high speed data bus using multiplexed signals A series of proximity switches and mechanical limit switches provide information to the controllers These proximity and mechanical switches maintain and define the safe operating parameters of the machine In addition there is a back up safety system using mechanical limit switches which will cut power to selected portions of the...

Страница 31: ...made to level the platform For safety machine drive speed is reduced relative to the steer angle of the wheels and boom length Steering is accomplished using hydraulic cylinders at each wheel Correct steering geometry is maintained through the use of four steering sensors one at each wheel Steering angles are sent from the primary steering sensor to DCON and the appropriate adjustments are made to...

Страница 32: ...3 4 Genie S 100 S 105 S 120 S 125 Part No 62401 Section 3 Theory of Operation First Edition First Printing This page intentionally left blank ...

Страница 33: ...ved Wheelschocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduledmaintenanceinspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personneltopotentialpersonal injury hazards Obey all safety messages that follow this sym...

Страница 34: ...ed inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms asrequired MaintenanceSchedule 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 s...

Страница 35: ...in the appropriate box after each part is completed Follow the instructions in the operator s manual 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 Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre deliveryPreparation The Pre deli...

Страница 36: ...Section 4 Scheduled Maintenance Procedures 4 4 S 100 S 105 S 120 S 125 Part No 62401 January2010 This page intentionally left blank ...

Страница 37: ... filter condition indicator A 8 Auxiliary Power A 9 Tilt Sensor A 10 Operating Envelope Perform after 40 hours A 11 30 Day Service Perform every 50 hours A 12 Engine Maintenance Perkins models Perform after 50 hours A 13 Engine Maintenance Deutz models Perform every 100 hours A 14 Grease rotation bearing A 15 Extendable axle lubrication system Perform after 150 hours A 16 Replace drive hub oil Ins...

Страница 38: ...els 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 Y N R 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 Grease the turntable rotation bearing and rotate gear D...

Страница 39: ...ions 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 goodcondition Result The operator s manual is not appropriate for the machine or all...

Страница 40: ...ppropriate operator s manual Refer to the Operator s Manual on your machine A 2 Perform Pre operation Inspection 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...

Страница 41: ...the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury CHECKLIST A PROCEDURES A 5 Perform Engine Maintenance Cummins Models Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good...

Страница 42: ...um 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 hight idle A 6 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed daily or every 10 hours whichever comes first Requiredmaintenanceproceduresandadditional engine information are available in the DeutzF4L913O...

Страница 43: ...eing bypassed and the filter needs to be replaced See D 12 Replace the Hydraulic Filter Elements a b c Medium and high pressure filters The medium and high pressure filters are mounted to the engine sidebulkhead 4 Inspect the filter condition indicators a high pressure filters b filter condition indicators c medium pressure filter Result The filter condition indicators should be operating with the...

Страница 44: ...e performed daily Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operating the machine on engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term use only and excessive use wi...

Страница 45: ...is critical to safe machine operation If the boom is allowed to operate outside of the operating envelope the machine stability is compromised and may tip over 1 Turn the key switch to ground controls and pull out the Emergency Stop buttons out to the ON position at both the groundandplatform controls 2 Simultaneously push the LCD screen buttons shown to activate status mode 3 Push one of the LCD ...

Страница 46: ...uire that this procedure be performed every 50 hours or weekly whichever come first Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poorengineperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional engine information are available in the...

Страница 47: ...ard 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 14 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 ...

Страница 48: ... lubrication system on existing products that were produced without this lubrication system It is available as Genie part number 102771 through our Service Parts department A 15 Extendable Axle Lubrication System Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent lubrication to the front an...

Страница 49: ... 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 Section 2 Specifications a CHECKLIST A PROCEDURES TurntableRotateDriveHub 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 duringinstallation Ref...

Страница 50: ...ve clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight 4 Be sure that the battery separator wire connections are tight 5 Fully charge the batteries and allow the b...

Страница 51: ... 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 B 2 Inspect the Electrical Wiring 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 mach...

Страница 52: ...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 4 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 i...

Страница 53: ... Clean the oil cooler of debris and foreign 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 foreignmaterial 8 If needed clean the cylinder head cooling passages and fins of debris and foreign material 9 Install the engi...

Страница 54: ...ng beacon should be on and flashing 4 Press down the foot switch Move the boom control handle to the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 5 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite directi...

Страница 55: ... 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 6 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 250hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance...

Страница 56: ...he engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 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 th...

Страница 57: ...ting fasteners Refer to Section 2 Specifications 6 Repeat this procedure for each drive hub a CHECKLIST B PROCEDURES B 9 Inspect the Tires Wheels and Lug Nut Torque 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 perfor...

Страница 58: ... 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 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 B 11 Confirm the Proper Brake Configuration Genie requir...

Страница 59: ... 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 Deutzmodels 1 Start the engine from the groundcontrols 2 Push one of the LCD screen buttons shown until engi...

Страница 60: ...t plate out away from the machine a engine pivot plate anchor hole b 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 co...

Страница 61: ...oid 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 Be sure the solenoid fully retracts when activating high idle 9 Remove the engine pivot plate retaining fastener from the engine pivot plate ...

Страница 62: ...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 Perform this procedure with the axles retracted and t...

Страница 63: ...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 CHECKLIST B PROCEDURES 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 co...

Страница 64: ...nly work in the direction that will level the platform Level the platform until the indicator light turns off 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...

Страница 65: ...te 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 RepairSection Bodily injury hazard If the boom extends to mo...

Страница 66: ...ep 9 and connect the deutsch connector to LSB14AO 50 Angle Safety Switch LSB8AS 14 Raise the boom to approximately 60 15 Extend the boom to approximately 95 feet 28 96 m 16 Disconnect the 53 proximity switch LSB13AO and install a wire jumper between pin 3 and pin 4 of the deutsch connector 17 Activate the function enable high RPM button and lower the boom to 50 Result The engine should stop and th...

Страница 67: ...d result in death or serious injury 23 Using auxiliary power retract the boom until the boom is extended to less than 75 feet 22 9 m 24 Remove the wire jumper installed in step 21 and connect the harness plug to LSB3EO CableBreakSafetySwitch LSB6S 25 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 26 Remove...

Страница 68: ...m could result in death or serious injury 31 Activate the function enable high RPM button and attempt to retract the boom Result The boom retract function should be disabled Result If the boom retracts the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired See Repair Section 32 Rotate the head of the switch 45 degrees clockwise and install the arm onto LSB6S Axle Ext...

Страница 69: ...rcuit 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 40 Remove the wire jumper installed in step 36 and connect the deutsch connector to LSAX1ES 41 Disconnect the circ...

Страница 70: ...r the boom onto the boom rest pad and continue to hold the boom lower function button for 5 seconds 47 Activate the function enable high RPM button and extend the boom until 0 is present on the display screen at the ground controls Result The alarm should sound and REVERSE LOAD MOMENT FAULT should be present on the display screen at the ground controls Result If the alarm does not sound or if REVE...

Страница 71: ...her within easy reach 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 When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash th...

Страница 72: ...he 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 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 eng...

Страница 73: ...e 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications CHECKLIST B PROCEDURES B 19 Test the Drive Brakes 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...

Страница 74: ...ming when your reference point on the machine crosses the start line 17 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications B 21 Test the Drive Speed Raised or Extended Position Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential...

Страница 75: ... 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 CHECKLIST B PROCEDURES B 23 Inspect the Boom Extend Retract Cables Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first The boom extend retract cables are responsible for the extension and retr...

Страница 76: ...ct the above items A pulley groove gauge should be used to check the condition of the pulleys 4 Replace the cables if any damage is found 5 At the pivot end of the boom visually inspect for thefollowing 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 7 Start the engine ...

Страница 77: ...all the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury C 2 Perform Engine Maintenance Cummins Models Engine specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine perfor...

Страница 78: ...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 C 4 Replace the Engine Air Filter Element Engine specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Maintaining the engine air ...

Страница 79: ...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 Failure to remove all weight tools and accessories from the platform will result in an inaccurate test C 5 Grease the Platform Overload Mechanism if equipped Geniespecificationsrequire that this procedure be performed every 500 hours or 6 months...

Страница 80: ... 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 Section 4 5 Calibrate the Platform Overload System if equipped 5 Carefully move the test weight to each remaininglocat...

Страница 81: ...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 operatenormally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls Result All platform control functions should operate If the platform overload system is not operating...

Страница 82: ...procedure be performed every 1000 hours or annually whichever comes first 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 conditi...

Страница 83: ...onditions 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 7 16 inch Minimum thickness 11 1 mm 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 zero clearance and ...

Страница 84: ...pport 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 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 6 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each w...

Страница 85: ...lift cylinder extension rod Carefully lower the boom onto the lift cylinder safety chock Crushinghazard Keephands away from the cylinder and all moving parts when lowering the boom The lift cylinder safety chock is availablethroughGenie Geniepart number75097 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 remo...

Страница 86: ...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 m...

Страница 87: ...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 Fasten a straight edge on the side of the rotator using tape so one end is just above the tape measure CHECKLIST D PROCEDURES 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 ta...

Страница 88: ...en 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 Section 2 Specifications TurntableRotateDriveHub 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 duringinstallation Refer to Section 2 Specifi...

Страница 89: ...drain the oil from the drive hub into a suitable container 7 Fill the drive hub with oil until the oil is level with the bottom of the threads Apply pipe thread sealant to the plug Install the plug and tighten 8 Fill the drive brake with oil until the oil is level with the bottom of the threads Apply pipe thread sealant to the plug Install the plug and tighten 9 Install the drive hub onto the mach...

Страница 90: ...t with the turntable rotation gear could result in serious injury Do not operate the machine if the turntable rotation gear cover is not installed D 8 Inspect for Turntable Bearing Wear Genie requires 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 s...

Страница 91: ... 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 turntable b dial indicator c drive chassis d turntable rotation bearing 5 At the dial indicator adjust it to zero the indicator 6 Fully extend the boom and lower to a h...

Страница 92: ... 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 D 10 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 1000hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to go...

Страница 93: ...e filter is for the charge pump and the high pressure filters are for the drive circuit Perform this procedure with the engine off 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 f...

Страница 94: ...lement from the housing 5 Inspect the housing seal and replace it if necessary 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 installationprocedure CHECKLIST D PROCEDURES a b 9 Use a permanent ink marker to write ...

Страница 95: ...iary 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 open closed E 1 Test or Replace the Hydraulic Oil 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 p...

Страница 96: ...ulic 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 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 hos...

Страница 97: ...stall the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury E 2 Perform Engine Maintenance Cummins Models Engine specifications require that this procedure be performed every 2000 hours or 2 years whichever comes first Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine perf...

Страница 98: ...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 CHECKLIST E PROCEDURES E 5 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 2 years Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine perfor...

Страница 99: ...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 E 7 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 3000hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service lif...

Страница 100: ... the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury CHECKLIST E PROCEDURES E 9 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 6000 hours or 3 years whichever come first Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to...

Страница 101: ...ble 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 E 11 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 12000 hours or 6 years whichever comes first Properenginemaintenance followingtheengine manufacturer s maintenance schedu...

Страница 102: ...gine 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 E 13 Replace the Boom Extend Retract Cables Genie specifications require that ...

Страница 103: ... 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Troubleshooting Flow Charts Observe and Obey Troubleshooting and repair procedures s...

Страница 104: ...tmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working conditi...

Страница 105: ...ATED Up down function speeds to fast or to slow Up down speed calibration set from display or Reset Boom up down flow valve defaults set from display Refer to Display module section Calibrate Boom up down speed refer to repair section BOOM UP DOWN FLOW VALVE NOT CALIBRATED No movement on up down functions until joystick is moved past half stroke Reset Boom up down flow valve defaults set from disp...

Страница 106: ... itself is bad Refer to chart 17 to troubleshoot LOCK OUT VALVE P1 FAULT Retract function inoperative when boom length is 100 Boom retract lockout valve coil circuit open or shorted to ground or the coil itself is bad Refer to chart 16 to troubleshoot LOCK OUT VALVE P2 FAULT Extend function inoperative when boom length or 100 Boom extend lockout valve coil circuit open or shorted to ground or the ...

Страница 107: ...pen circuit between platform control card and steering joystick Refer to charts 35 36 37 and 38 to troubleshoot STEERING JOYSTICK SHORTED TO 5V Steering functions inoperative from platform Shorted circuit between platform control card and steering joystick Refer to charts 35 36 37 and 38 to troubleshoot STEERING JOYSTICK VALUE TOO HIGH steering functions inoperative from platform Damaged circuit b...

Страница 108: ...w side steering functions inoperative Shorted circuit between yellow end yellow side steering sensor and DCON box Refer to chart 38 to troubleshoot YELLOW END YELLOW SIDE STEER SENSOR VALUE TOO HIGH Yellow end yellow side steering functions inoperative Damaged circuit between yellow end yellow side steering sensor and DCON box or steering sensor may need to be replaced Refer to chart 38 to trouble...

Страница 109: ...atform control box or shorted platform level up or down membrane switch on the turntable membrane panel Refer to charts 25 and 26 to troubleshoot PLATFORM LEVEL SENSOR DEGREES SHORTED TO 0V Platform level and boom up down functions inoperative Open circuit between platform level sensor and platform control box Refer to chart 24 to troubleshoot PLATFORM LEVEL SENSOR DEGREES SHORTED TO 5V Platform l...

Страница 110: ...TURE SENSOR SHORTED TO 5V Engine runs then dies Engine temperature sensor circuit open Refer to chart 4 to troubleshoot ENGINE TEMPERATURE SENSOR VALUE TOO HIGH Engine runs then dies Engine temperature sensor circuit damaged or sensor may need to be replaced Refer to chart 4 to troubleshoot ENGINE TEMPERATURE SENSOR VALUE TOO LOW Engine runs then dies Engine temperature sensor circuit damaged or s...

Страница 111: ...AULT All functions inoperative Open circuit in tether Emergency stop wiring Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department SAFETY SWITCH P6R1 FAULT Boom extend and boom down functions inoperative This fault creates Safety switch P9A P10 P11 and P18 fault Bad K4 relay inside turntable control box Replace K4 relay or consu...

Страница 112: ...PRV wire circuit that runs from the turntable control box to the DCON control box Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department PROX KILL SW FAULT All functions inoperative unless spare membrane on platform control box is activated Proximity Kill Bumper under platform has run into an obstruction or is out of adjustment ...

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Страница 262: ... YZGXZ ZNK KTMOTK Z ZNK MXU TJ IUTZXURY GIZO GZK ZNK L TIZOUT KTGHRK NOMN 863 H ZZUT GTJ ZNK POH HUUS JU T SKSHXGTK H ZZUT GTJ INKIQ ZNK VXKYY XK RKYY ZNGT VYO 69 UX SUXK XK ZNKXK SKINGTOIGR XKYZXOIZOUTY QKKVOTM ZNK POH HUUS JU T L TIZOUT LXUS UVKXGZOTM 8KVGOX UX XKVRGIK ZNK POH HUUS JU T GR K OZKS 2 58 XKVGOX UX XKVRGIK ZNK I_ROTJKX IU TZKXHGRGTIK GR KY 58 XKVGOX UX XKVRGIK ZNK I_ROTJKX 58 ZNK VR...

Страница 263: ...OXK NGXTKYY MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK POH HUUS V SKSHXGTK H ZZUT GZ ZNK MXU TJ IUTZXURY HKZ KKT VOT UL ZNK 0 SKSHXGTK JKIGR IUTTKIZUX GZ ZNK IOXI OZ HUGXJ GTJ VOT UL ZNK 0 SKSHXGTK JKIGR IUTTKIZUX GZ ZNK IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR HU SKSHXGTK JKIGR 58 IUTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ MUUJ TU UTZOT KJ UT ZNK TK Z VGMK TU UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZS...

Страница 264: ...UX GZ ZNK POH HUUS JU T GR K IUOR OZKS 2 HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 8 1 0 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK VRGZLUXS IUTZXUR HU ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK POH HUUS JU T GR K IUOR OZKS 2 8KVGOX UX XKVRGIK ZNK 8 2 8 OXK MUUJ NKIQ ZNK XKYOYZGTIK UL POH HUUS JU T GR K IUOR OZKS 2 L GT_ UZNKX IUJKY GXK UT ZNK JOYVRG_ YIXKKT XKLKX ZU ZNK LG RZ I...

Страница 265: ...other functions operate normally Be sure the batteries are fully charged and properly connected TU UTZOT KJ UT ZNK TK Z VGMK OZN ZNK QK_ Y OZIN Z XTKJ ZU MXU TJ IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK L TIZOUT KTGHRK H ZZUT GTJ G HUUS L TIZOUT H ZZUT K M HUUS K ZKTJ XKZXGIZ UX HUUS V JU T UKY ZNK SUZUX UVKXGZK UTZOT KJ ZU VGMK _KY ...

Страница 266: ... OXK IGHRK IOXI OZ LXUS ZNK G OROGX_ V SV SUZUX SU TZOTM HURZ ZU MXU TJ MUUJ HGJ 8KVRGIK ZNK TKMGZO K MXU TJ OXK IGHRK LXUS G OROGX_ V SV SUZUX SU TZOTM HURZ ZU MXU TJ 8KVRGIK ZNK G OROGX_ V SV SUZUX UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 2UUYKT H Z JU TUZ XKSU K ZNK XKJ YKIUTJGX_ RUIQ GTJ XK OTYKXZ ZNK ZKXSOTGR TZOR OZ RUIQY OTZU VRGIK 6 YN OT ZNK YKIUTJGX_ RUIQ ZU RUIQ ZNK ZKXSOTGR OTZU VRG...

Страница 267: ...V JU T H ZZUT GTJ TUZK ZNK VXKYY XK NK HGZZKX_ IGHRK ZKXSOTGR IUTTKIZOUTY SG_ HK JOXZ_ 58 XKVGOX UX XKVRGIK ZNK HGZZKX_ IGHRKY 8KVRGIK ZNK G OROGX_ V SV RKYY ZNGT VYO UTZOT KJ UT ZNK TK Z VGMK JP YZ ZNK G OROGX_ V SV VYO XKROKL GR K GRR ZNK G_ OT IRUIQ OYK IU TZOTM ZNK T SHKX UL Z XTY 6XKYY GTJ NURJ ZNK G OROGX_ VU KX H ZZUT GTJ VXKYY ZNK VRGZLUXS RK KR V JU T H ZZUT GTJ TUZK ZNK VXKYY XK VYO UX S...

Страница 268: ...TUZK ZNK VXKYY XK VYO UX SUXK NK HGZZKX_ IGHRK ZKXSOTGR IUTTKIZOUTY SG_ HK JOXZ_ 58 XKVGOX UX XKVRGIK ZNK HGZZKX_ IGHRKY RKYY ZNGT VYO UTZOT KJ UT ZNK TK Z VGMK UTZOT KJ ZNK VXK OU Y VGMK JP YZ ZNK G OROGX_ V SV VYO XKROKL GR K GRR ZNK G_ OT IRUIQ OYK IU TZOTM ZNK T SHKX UL Z XTY 6XKYY GTJ NURJ ZNK G OROGX_ VU KX H ZZUT GTJ VXKYY ZNK VRGZLUXS XUZGZK H ZZUT GTJ TUZK ZNK VXKYY XK VYO UX SUXK 6XKYY G...

Страница 269: ...UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ XT ZNK QK_ Y OZIN ZU VRGZLUXS IUTZXURY 6XKYY JU T ZNK LUUZ Y OZIN GTJ VXKYY GTJ NURJ ZNK G OROGX_ VU KX H ZZUT GTJ SU K ZNK YZKKX PU_YZOIQ ZU ZNK XOMNZ UX RKLZ NKIQ URZGMK UL ZNK 58 8 3 OXK IOXI OZ UL ZNK S RZOL TIZOUT GR K OZKS GZ ZNK JOYZXOH ZOUT SGTOLURJ OYIUTTKIZ ZNK 0 NOZK VOT IUTTKIZUX LXUS ZNK MXU TJ IUTZXURY GTJ INKIQ ZU SGQK Y XK ZNGZ VOT OY VXU...

Страница 270: ...TKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT YZGXZ ZNK KTMOTK 6XKYY JU T ZNK LUUZ Y OZIN GTJ GIZO GZK ZNK G RK K ZKTJ L TIZOUT XK ZNKXK GT_ JOGMTUYZOI IUJKY VXKYKTZ UT ZNK JOYVRG_ YIXKKT GZ ZNK MXU TJ IUTZXURY TU _KY 6XKYY JU T ZNK LUUZ Y OZIN GTJ GIZO GZK ZNK G RK K ZKTJ H ZZUT Y ZNKXK GT G JOHRK HKKV UTZOT KJ ZU VGMK _KY UTZOT KJ UT ZNK TK Z VGMK UTY RZ Z...

Страница 271: ...ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK 4 IUTTKIZUX GZ ZNK G RK K ZKTJ XKZXGIZ GR K IUORY OZKS 9 8KVGOX UX XKVRGIK ZNK 8 OXK HGJ MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK 4 IUTTKIZUX GZ ZNK G RK K ZKTJ XKZXGIZ GR K IUORY OZKS 9 UX OZKS 9 8KVGOX UX XKVRGIK ZNK 8 2 8 OXK HGJ MUUJ NKIQ ZNK XKYOYZGTIK...

Страница 272: ...T UNS _KY TU JP YZ ZNK VXU OSOZ_ Y OZIN Y ZU ZNK VXUVKX JOYZGTIK LXUS ZNK ZGXMKZ 9KK 8KVGOX 9KIZOUT _KY TU _KY 8KVRGIK GTJ GJP YZ 29 5 9KK 8KVGOX 9KIZOUT OYIUTTKIZ 29 5 LXUS ZNK OXK NGXTKYY GTJ INKIQ ZNK XKYOYZGTIK GIXUYY VOT GTJ UL 29 5 Y ZNK XKYOYZGTIK RKYY ZNGT UNS TU _KY 8KVRGIK GTJ GJP YZ 29 5 9KK 8KVGOX 9KIZOUT OYIUTTKIZ ZNK 0 HRGIQ VOT IUTTKIZUX LXUS ZNK JXO K INGYYOY IUTZXURRKX GTJ INKIQ Z...

Страница 273: ... LXUS VOT UL ZNK JK ZYIN IUTTKIZUX GZ 29 5 ZU VOT UL ZNK JK ZYIN IUTTKIZUX GZ 29 5 TU _KY NKIQ LUX IUTZOT OZ_ OT ZNK 8 6 29 OXK LXUS VOT UL ZNK 0 IUTTKIZUX ZU VOT UL ZNK JK ZYIN IUTTKIZUX GZ 29 5 Y ZNKXK IUTZOT OZ_ TU _KY 8KVGOX ZNK 8 6 29 OXK LXUS VOT UL ZNK 0 IUTTKIZUX ZU VOT UL ZNK JK ZYIN IUTTKIZUX GZ 29 5 UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ ZNK 8 29 OXK LUX IUTZOT OZ_ LXUS VOT UL...

Страница 274: ...OK TJ YZXOKY 9KX OIK KVGXZSKTZ RKYY ZNGT 69 JP YZ ZNK G RK K ZKTJ XKROKL GR K OZKS 77 OT ZNK YZKKX G RK SGTOLURJ GRR ZNK G_ OT IRUIQ OYK IU TZOTM ZNK T SHKX UL Z XTY IZO GZK ZNK G RK K ZKTJ L TIZOUT GTJ INKIQ ZNK VXKYY XK JP YZ ZNK G RK K ZKTJ XKROKL GR K OZKS 77 9KK 8KVGOX 9KIZOUT 69 UX SUXK RKYY ZNGT 69 69 UX SUXK 9ZUV ZNK KTMOTK OYIUTTKIZ ZNK N_JXG ROI NUYK LXUS ZNK 6 VUXZ UL ZNK YZKKX G RK SGT...

Страница 275: ... N_JXG ROI Y O KR 6R M ZNK VUXZ GTJ IUTTKIZ ZNK N_JXG ROI NUYK OTZU G ZU 69 HGX MG MK U 45 YZGXZ ZNK KTMOTK JGSGMK IU RJ XKY RZ IZO GZK ZNK G OROGX_ N_JXG ROI V SV GTJ ZNK G RK K ZKTJ L TIZOUT GTJ INKIQ ZNK VXKYY XK 8KVGOX UX XKVRGIK ZNK N_JXG ROI Y O KR 58 IUTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 69 UX SUXK RKYY ZNGT 69 UTZOT KJ LXUS ZNK VXK OU Y VGMK UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSK...

Страница 276: ...ZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK G RK K ZKTJ GR K OZKS 9 UX OZKS 9 8KVGOX UX XKVRGIK 8 2 8 OXK MUUJ NKIQ ZNK XKYOYZGTIK UL ZNK G RK K ZKTJ GR K IUOR OZKS 9 UTZOT KJ UT ZNK TK Z VGMK OZN ZNK QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ YZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT YZGXZ ZNK KTMOTK 6XKYY JU T ZNK LUUZ Y OZIN GTJ GIZO GZK ZNK G RK XKZXGIZ...

Страница 277: ...J MUUJ 8KVRGIK GTJ GJP YZ 29 9 9KK 8KVGOX 9KIZOUT NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 9 68 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY ZU VOT UL ZNK JK ZYIN IUTTKIZUX ZU 29 9 HGJ 8KVGOX UX XKVRGIK ZNK 8 9 68 OXK MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK 58 9 9 5 OXK LXUS VOT UL ZNK JK ZYIN IUTTKIZUX ZU 29 9 ZU VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY ZU VOT UL ZNK JK ZYIN IUTTKIZUX ZU 2...

Страница 278: ...K RU KX 0 NGXTKYY HGJ 8KVGOX UX XKVRGIK 8 8 OXK MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 8 OXK LXUS VOT UL ZNK VOT JK ZYIN IUTTKIZUX UT ZNK Z XTZGHRK ZU ZNK RU KX 0 NGXTKYY ZU ZNK VVKX 0 NGXTKYY ZU VOT UL ZNK VOT JK ZYIN IUTTKIZUX GZ ZNK KRKIZXOI Y O KR HGJ 8KVGOX UX XKVRGIK ZNK 8 8 OXK MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 OXK LXUS LXUS VOT UL ZNK VOT JK ZYIN IUTTKIZUX UT ZNK Z XTZGHRK YOJK UL K...

Страница 279: ... YNUXZ OT ZNK 58 9 9 5 OXK LXUS VOT UL ZNK JK ZYIN IUTTKIZUX ZU 29 89 ZU VOT UL ZNK VOT JK ZYIN IUTTKIZUX GZ ZNK MXU TJ IUTZXURY ZU ZNK VVKX 0 NGXTKYY ZU ZNK RU KX 0 NGXTKYY HGJ 8KVGOX UX XKVRGIK ZNK 58 9 9 5 OXK MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK 58 9 9 5 OXK LXUS VOT UL ZNK VOT JK ZYIN IUTTKIZUX UT ZNK Z XTZGHRK ZNGZ IUTTKIZY ZU ZNK RU KX 0 NGXTKYY ZU ZNK VVKX 0 NGXTKYY ZU VOT PUL ZNK 0 IUTTK...

Страница 280: ... XKVRGIK ZNK YZKKX PU_YZOIQ UTZOT KJ UT ZNK TK Z VGMK 9ZUV ZNK KTMOTK TYZGRR G ZU 69 HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VRKX UT ZNK YZKKX G RK SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK YZKKX L TIZOUT OT HUZN JOXKIZOUTY Y ZNK VXKYY XK RKYY ZNGT VYO HGX TU _KY NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM ZNK YZKKX L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK ZNK YZKKX I_ROTJKX 58 XKVGOX UX X...

Страница 281: ... MUUJ HGJ 8KVGOX UX XKVRGIK ZNK 58 2 9 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 6 4 OXK LXUS VOT UL ZNK YW GXK KTJ HR K YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGYYOY IUTZXURRKX 54 MUUJ HGJ 8KVGOX UX XKVRGIK ZNK 8 6 4 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 1 6 8 OXK LXUS VOT UL ZNK YW GXK KTJ HR K YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGYYOY IU...

Страница 282: ...TKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX 54 ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK YW GXK KTJ HR K YOJK YZKKX GR K IUOR OZKS UX OZKS 7 HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 2 1 2 9 OXK UTZOT KJ LXUS ZNK VXK OU Y VGMK Y 2 4 2 9 9 8 2 2 VXKYKTZ UT ZNK JOYVRG_ YIXKKT _KY L GT_ UZNKX IUJKY GXK VXKYKTZ UT ZNK JOYVRG_ YIXKKT XKLKX ZU ZNK LG RZ IUJK INGXZ LUX SUXK OTLUXSGZOUT TU NKIQ LUX GT UVKT UX YNUXZ OT ZNK 2 2 9 ...

Страница 283: ...PU_YZOIQ YKK 8KVGOX 9KIZOUT 58 XKVRGIK ZNK YZKKX PU_YZOIQ UTZOT KJ UT ZNK TK Z VGMK 9ZUV ZNK KTMOTK TYZGRR G ZU 69 HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VRKX UT ZNK YZKKX G RK SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK YZKKX L TIZOUTY OT HUZN JOXKIZOUTY Y ZNK VXKYY XK RKYY ZNGT VYO HGX TU _KY NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM ZNK YZKKX L TIZOUT LXUS SU OTM 58 XKVGOX UX XKVRGIK ZNK Y...

Страница 284: ...X 54 MUUJ HGJ 8KVGOX UX XKVRGIK ZNK 58 8 9 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 6 4 OXK LXUS VOT UL ZNK YW GXK KTJ _KRRU YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGYYOY IUTZXURRKX 54 MUUJ HGJ 8KVGOX UX XKVRGIK ZNK 8 6 4 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 1 6 8 OXK LXUS VOT UL ZNK YW GXK KTJ _KRRU YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGY...

Страница 285: ...L ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK YW GXK KTJ _KRRU YOJK YZKKX GR K IUOR OZKS HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 2 1 8 9 OXK UTZOT KJ LXUS ZNK VXK OU Y VGMK Y 2 4 225 9 9 8 2 2 VXKYKTZ UT ZNK JOYVRG_ YIXKKT _KY L GT_ UZNKX IUJKY GXK VXKYKTZ UT ZNK JOYVRG_ YIXKKT XKLKX ZU ZNK LG RZ IUJK INGXZ LUX SUXK OTLUXSGZOUT TU NKIQ LUX GT UVKT UX YNUXZ OT ZNK 2 8 9...

Страница 286: ...X 9KIZOUT 58 XKVRGIK ZNK YZKKX PU_YZOIQ UTZOT KJ UT ZNK TK Z VGMK 9ZUV ZNK KTMOTK TYZGRR G ZU 69 HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK YZKKX G RK SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK YZKKX L TIZOUTY OT HUZN JOXKIZOUTY Y ZNK VXKYY XK RKYY ZNGT VYO HGX TU _KY NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM ZNK YZKKX L TIZOUT LXUS SU OTM 58 XKVGOX UX XKVRGIK ZNK YZKKX I_ROTJKX 58 ...

Страница 287: ...KX 54 MUUJ HGJ 8KVGOX UX XKVRGIK ZNK 58 289 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 6 4 OXK LXUS VOT UL ZNK IOXIRK KTJ HR K YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGYYOY IUTZXURRKX 54 MUUJ HGJ 8KVGOX UX XKVRGIK ZNK 8 6 4 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 1 6 8 OXK LXUS VOT UL ZNK IOXIRK KTJ HR K YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGYY...

Страница 288: ...ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX 54 ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK IOXIRK KTJ HR K YOJK YZKKX GR K IUOR OZKS HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 2 1 289 OXK UTZOT KJ LXUS ZNK VXK OU Y VGMK Y 225 4 2 9 9 8 2 2 VXKYKTZ UT ZNK JOYVRG_ YIXKKT _KY L GT_ UZNKX IUJKY GXK VXKYKTZ UT ZNK JOYVRG_ YIXKKT XKLKX ZU ZNK LG RZ IUJK INGXZ LUX SUXK OTLUXSGZOUT TU NKIQ LUX GT UVKT UX YNUXZ OT ZNK 2 289...

Страница 289: ...TU 8KIGROHXGZK ZNK YZKKX PU_YZOIQ YKK 8KVGOX 9KIZOUT 58 XKVRGIK ZNK YZKKX PU_YZOIQ UTZOT KJ UT ZNK TK Z VGMK 9ZUV ZNK KTMOTK TYZGRR G ZU 69 HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VRKX UT ZNK YZKKX G RK SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK YZKKX L TIZOUT OT HUZN JOXKIZOUTY Y ZNK VXKYY XK RKYY ZNGT VYO HGX TU _KY 8KVGOX UX XKVRGIK ZNK I_ROTJKX UX VORUZ UVKXGZKJ INKIQ GR KY OZKSY UX 58 I...

Страница 290: ... NKIQ IOXIRK KTJ _KRRU KTJ _KRRU YOJK YZKKX YKTYUX LUX VXUVKX OTYZGRRGZOUT GTJ UVKXGZOUT YKK 8KVGOX 9KIZOUT TU HGJ 8KVRGIK ZNK YZKKX YKTYUX 9KK 8KVGOX 9KIZOUT MUUJ NKIQ LUX GT UVKT UX YNUXZ OT ZNK 58 889 OXK LXUS VOT UL ZNK IOXIRK KTJ _KRRU YOJK YZKKX YKTYUX IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX UT ZNK JXO K INGYYOY IUTZXURRKX MUUJ 8KVGOX UX XKVRGIK ZNK 58 889 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 ...

Страница 291: ...OJK YZKKX GR K IUOR OZKS HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 2 889 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK IOXIRK KTJ _KRRU YOJK YZKKX GR K IUOR OZKS 8KVGOX UX XKVRGIK ZNK 8 2 8 OXK MUUJ NKIQ ZNK XKYOYZGTIK UL ZNK IOXIRK KTJ _KRRU YOJK YZKKX GR K IUOR OZKS NKIQ LUX GT UVKT UX YNUXZ OT ZNK 2 1 889 OXK LX...

Страница 292: ... YZGXZ ZNK KTMOTK 6XKYY JU T ZNK LUUZ Y OZIN GTJ GIZO GZK ZNK JXO K LUX GXJ L TIZOUT XK ZNKXK GT_ JOGMTUYZOI IUJKY VXKYKTZ UT ZNK JOYVRG_ GZ MXU TJ IUTZXURY _KY _KY Y 8 05 9 1 45 2 8 UT ZNK JOYVRG_ YIXKKT GROHXGZK ZNK JXO K PU_YZOIQ 9KK 8KVGOX 9KIZOUT TU Y 8 05 9 1 9 58 5 52 9 UX 8 05 9 1 9 58 5 52 9 UX 8 05 9 1 2 5 UX 8 05 9 1 2 5 25 VXKYKTZ UT ZNK JOYVRG_ YIXKKT _KY NKIQ LUX JGSGMKJ OXKY OT OTZK...

Страница 293: ...Q LUX G YNUXZ UX UVKT OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY ZU VOT UL ZNK OT IUTTKIZUX UT ZNK KRKIZXUTOI VXUVUXZOUTGR IUTZXUR 6 GZ ZNK JXO K V SV HGJ 8KVGOX UX XKVRGIK 8 2 8 OXK UTZOT KJ UT ZNK TK Z VGMK UTZOT KJ LXUS ZNK VXK OU Y VGMK MUUJ NKIQ ZNK XKYOYZGTIK UL ZNK KRKIZXUTOI VXUVUXZOUTGR IUTZXUR 6 UT ZNK JXO K V SV ZU UNSY 8KVRGIK ZNK 6 UTY RZ ZNK KTOK TJ YZXOKY 9K...

Страница 294: ...YOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK HXGQK GR K IUOR OZKS 5 HGJ UQ 8KVGOX UX XKVRGIK ZNK 8 81 OXK NKIQ LUX G YNUXZ UX UVKT OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK HXGQK GR K IUOR OZKS 5 HGJ 8KVGOX UX XKVRGIK ZNK 8 2 8 OXK UQ NKIQ ZNK XKYOYZGTIK UL ZNK HXGQK GR K IUOR OZKS 5 UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKT...

Страница 295: ...K KTMOTK TYZGRR Z U ZU 69 HGX VXKYY XK MG MKY UT ZNK W OIQ JOYIUTTKIZY ZU ZNK VUXZY UL ZNK JXO K V SV 9ZGXZ ZNK KTMOTK Y ZNK VXKYY XK VYO HGX UX SUXK TU UTZOT KJ UT ZNK TK Z VGMK _KY UTZOT KJ ZU VGMK _KY 9ZUV ZNK KTMOTK OYIUTTKIZ ZNK NUYKY LXUS VUXZY UT JXO K V SV GTJ VR M ZNK VUXZY 9ZGXZ ZNK KTMOTK Y ZNK VXKYY XK VYO HGX UX SUXK TU 8KVGOX UX XKVRGIK ZNK JXO K V SV 6XKYY JU T ZNK LUUZ Y OZIN GTJ G...

Страница 296: ... K LUX GXJ L TIZOUT Y ZNK VXKYY XK VYO HGX UX SUXK TU 8KVGOX UX XKVRGIK N_JXG ROI Y O KR _KY 9ZUV ZNK KTMOTK GTJ IUTTKIZ ZNK NUYKY ZU ZNK JXO K V SV OYIUTTKIZ ZNK IGYK JXGOT NUYK LXUS UTK JXO K SUZUX 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK XK KXYK L TIZOUT LUX UTK SOT ZK SKGY XOTM ZNK UR SK UL UOR Y ZNK UOR UR SK MXKGZKX ZNGT MGRRUT ROZKXY 8KVKGZ LUX KGIN SUZUX 8KVGOX UX XKVRGIK ZNK HGJ JXO K SUZUX TU _...

Страница 297: ...GZ ZNK JXO K SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK JXO K LUX GXJ L TIZOUT Y ZNK VXKYY XK VYO HGX UX SUXK TU 8KVGOX UX XKVRGIK N_JXG ROI Y O KR _KY 9ZUV ZNK KTMOTK GTJ IUTTKIZ ZNK NUYKY ZU ZNK JXO K V SV OYIUTTKIZ ZNK IGYK JXGOT LXUS UTK JXO K SUZUX 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK JXO K LUX GXJ L TIZOUT LUX UTK SOT ZK SKGY XOTM ZNK UR SK UL UOR Y ZNK UOR UR SK MXKGZKX ZNGT MGRRUT ROZKXY 8KVK...

Страница 298: ... ZU ZNK 54 VUYOZOUT YZGXZ ZNK KTMOTK 6XKYY JU T ZNK LUUZ Y OZIN GTJ GIZO GZK ZNK JXO K XK KXYK L TIZOUT XK ZNKXK GT_ JOGMTUYZOI IUJKY VXKYKTZ UT ZNK JOYVRG_ GZ MXU TJ IUTZXURY _KY _KY Y 8 05 9 1 45 2 8 UT ZNK JOYVRG_ YIXKKT GROHXGZK ZNK JXO K PU_YZOIQ 9KK 8KVGOX 9KIZOUT TU Y 8 05 9 1 9 58 5 52 9 UX 8 05 9 1 9 58 5 52 9 UX 8 05 9 1 2 5 UX 8 05 9 1 2 5 25 UT ZNK JOYVRG_ YIXKKT _KY NKIQ LUX JGSGMKJ O...

Страница 299: ...Z OT ZNK 1 8 OXK IOXI OZ LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY ZU VOT UL ZNK OT IUTTKIZUX UT KRKIZXUTOI VXUVUXZOUTGR IUTZXUR 6 UT ZNK JXO K V SV HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 1 8 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 2 8 OXK IOXI OZ LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK KRKIZXUTOI VXUVUXZOUTGR IUTZXUR 6 HGJ 8KVGOX UX XKVRGIK ZNK 8 2 8 O...

Страница 300: ... VOT UL ZNK OT IUTTKIZUX GZ ZNK HXGQK GR K IUOR HGJ 8KVGOX UX XKVRGIK ZNK 8 2 8 OXK UQ NKIQ ZNK XKYOYZGTIK UL ZNK HXGQK GR K IUOR OZKS 5 ZU UNSY 8KVRGIK ZNK IUOR UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UX OTLOTOZK UNSY UTZOT KJ LXUS ZNK VXK OU Y VGMK NKIQ LUX G YNUXZ UX UVKT OT ZNK 8 81 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK HXGQK GR K...

Страница 301: ...V ZNK KTMOTK TYZGRR Z U ZU 69 HGX VXKYY XK MG MKY UT ZNK W OIQ JOYIUTTKIZY ZU ZNK VUXZY UL JXO K V SV 9ZGXZ ZNK KTMOTK Y ZNK VXKYY XK VYO HGX UX SUXK TU UTZOT KJ UT ZNK TK Z VGMK _KY UTZOT KJ UT VGMK _KY 9ZUV ZNK KTMOTK OYIUTTKIZ ZNK NUYKY LXUS VUXZY UT JXO K V SV GTJ VR M ZNK VUXZY 9ZGXZ ZNK KTMOTK Y ZNK VXKYY XK VYO HGX UX SUXK TU 8KVGOX UX XKVRGIK ZNK JXO K V SV 6XKYY JU T ZNK LUUZ Y OZIN GTJ G...

Страница 302: ...KXYK L TIZOUT Y ZNK VXKYY XK VYO HGX UX SUXK TU 8KVGOX UX XKVRGIK ZNK N_JXG ROI Y O KR _KY 9ZUV ZNK KTMOTK GTJ XKIUTTKIZ NUYKY ZU ZNK JXO K V SV OYIUTTKIZ ZNK SUZUX IGYK JXGOT LXUS UTK JXO K SUZUX 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK XK KXYK L TIZOUT LUX UTK SOT ZK SKGY XOTM ZNK UR SK UL UOR Y ZNK UOR UR SK MXKGZKX ZNGT MGRRUT ROZKXY 8KVKGZ LUX KGIN SUZUX 8KVGOX UX XKVRGIK ZNK LG RZ_ JXO K SUZUX Y TU...

Страница 303: ... ZNK JXO K SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK JXO K LUX GXJ L TIZOUT Y ZNK VXKYY XK VYO HGX UX SUXK TU 8KVGOX UX XKVRGIK ZNK N_JXG ROI Y O KR _KY 9ZUV ZNK KTMOTK GTJ XKIUTTKIZ NUYKY ZU ZNK JXO K V SV OYIUTTKIZ ZNK SUZUX IGYK JXGOT LXUS UTK JXO K SUZUX 9ZGXZ ZNK KTMOTK GTJ GIZO GZK ZNK JXO K LUX GXJ L TIZOUT LUX UTK SOT ZK SKGY XOTM ZNK UR SK UL UOR Y ZNK UOR UR SK MXKGZKX ZNGT MGRRUT ROZKX...

Страница 304: ...GHRK 2 Z XT UT _KY NKIQ 29 5 LUX VXUVKX UVKXGZOUT GTJ OTYZGRRGZOUT 9KK 8KVGOX 9KIZOUT 8KVRGIK GTJ GJP YZ 29 5 9KK 8KVGOX 9KIZOUT HGJ NKIQ LUX YNUXZ UT 2 8 4 OXK LXUS VOT UL ZNK JK ZYIN IUTTKIZUX ZU 29 5 ZU VOT UT ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 2 8 4 OXK TU 8UZGZK ZNK HUUS TZOR OZ OY U ZYOJK ZNK IOXIRK KTJ _KRRU KTJ ZOXKY Z ZNK VRGZLUXS IUTZXURY JUKY ZNK JXO K...

Страница 305: ...T UL ZNK JK ZYIN IUTTKIZUX GZ 29 5 ZU VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY 8KVGOX UX XKVRGIK ZNK 2 8 4 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 58 1 29 OXK LXUS VOT UL ZNK JK ZYIN IUTTKIZUX GZ 29 5 ZU VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY 8KVGOX UX XKVRGIK ZNK 58 1 29 OXK UTZOT KJ LXUS ZNK VXK OU Y VGMK UQ HGJ UQ UTZGIZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ ...

Страница 306: ...54 VUYOZOUT GIZO GZK JXO K SUJK YKRKIZ H ZZUT Y ZNKXK GT G JOHRK HKKV _KY UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 6RGZLUXS SKSHXGTK JKIGR SG_ TKKJ ZU HK XKVRGIKJ IZO GZK ZNK JXO K SUJK YKRKIZ H ZZUT UKY ZNK NOMN JXO K SUJK 2 Z XT UT TU UTZOT KJ UT ZNK TK Z VGMK TU UTZOT KJ ZU VGMK _KY TU NKIQ ZNK JOYVRG_ YIXKKT GZ ZNK MXU TJ IUTZXURY XK ZNKXK IUJKY VXKYKTZ Y 553 2 4 9 9 2 VXKYKTZ UT ZNK JOYVRG...

Страница 307: ...VKX UVKXGZOUT HGJ 8KVRGIK GTJ GJP YZ 29 5 9KK 8KVGOX 9KIZOUT 8KIUTTKIZ 29 5 OYIUTTKIZ ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY GTJ INKIQ LUX IUTZOT OZ_ HKZ KKT VOT GTJ VOT UL ZNK 0 IUTTKIZUX JP YZ 29 5 9KK 8KVGOX 9KIZOUT 58 XKVGOX UX XKVRGIK ZNK 8 6 OXK LXUS VOT UL ZNK JK ZYIN IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY 58 XKVGOX UX XKVRGIK ZNK 58 1 29 OXK GZ VOT UL ZNK JK ZYIN IUTTKI...

Страница 308: ...UTTKIZ ZNK 0 VOT IUTTKIZUX GTJ INKIQ LUX IUTZOT OZ_ HKZ KKT VOT GTJ VOT UL ZNK 0 IUTTKIZUX UT ZNK VVKX 0 NGXTKYY IUTZOT OZ_ 8KVGOX UX XKVRGIK ZNK 2 6 OXK LXUS VOT UL ZNK J KZYIN IUTTKIZUX GZ 29 85 ZU VOT UL ZNK 0 IUTTKIZUX 58 INKIQ LUX GT UVKT OT ZNK 58 1 29 OXK IOXI OZ 8KVGOX UX XKVRGIK ZNK 2 6 OXK LXUS VOT UL ZNK 0 IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY NKIQ LUX VXUVKX OTYZGR...

Страница 309: ... K IUOR TU Y 35 58 5 2 2 VXKYKTZ UT ZNK JOYVRG_ YIXKKT _KY NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 39 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK YVKKJ GR K IUOR OZKS NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK YVKKJ GR K IUOR OZKS HGJ MUUJ UTY RZ ZNK KTOK T...

Страница 310: ...GJ 8KVRGIK GTJ GJP YZ 29 85 9KK 8KVGOX 9KIZOUT MUUJ OZN 29 85 JOYIUTTKIZKJ H Z YZORR OTYZGRRKJ UT SGINOTK INKIQ LUX IUTZOT OZ_ HKZ KKT VOT VOT UL ZNK J KZYIN IUTTKIZUX ZU 29 85 UTTKIZ 29 85 OYIUTTKIZ ZNK 0 VOT IUTTKIZUX GTJ INKIQ LUX IUTZOT OZ_ HKZ KKT VOT GTJ VOT UL ZNK 0 IUTTKIZUX IUTZOT OZ_ 8KVGOX UX XKVRGIK 2 6 OXK LXUS VOT UL ZNK J KZYIN IUTTKIZUX GZ 29 85 ZU VOT UL ZNK 0 IUTTKIZUX 58 INKIQ L...

Страница 311: ...VXUVKX UVKXGZOUT 8KVRGIK GTJ GJP YZ 29 5 9KK 8KVGOX 9KIZOUT MUUJ 8KIUTTKIZ 29 5 GTJ JOYIUTTKIZ ZNK 0 IUTTKIZUX GZ MXU TJ IUTZXURY NKIQ LUX IUTZOT OZ_ HKZ KKT VOT UL ZNK 0 IUTTKIZUX GTJ VOT UL ZNK 0 IUTTKIZUX NKIQ LUX VXUVKX GJP YZSKTZ UL 29 5 58 XKVGOX UX XKVRGIK ZNK 8 6 OXK LXUS VOT UL ZNK 0 IUTTKIZUX ZU VOT UL ZNK 0 IUTTKIZUX GZ ZNK MXU TJ IUTZXURY 58 XKVGOX UX XKVRGIK ZNK 58 1 29 OXK GZ VOT UL ...

Страница 312: ... YZXOKY 9KX OIK KVGXZSKTZ XT ZNK QK_ Y OZIN ZU VRGZLUXS IUTZXURY 6XKYY ZNK KTMOTK YZGXZ GYYOYZ H ZZUT Y ZNKXK GT G JOHRK HKKV NKT SKSHXGTK OY GIZO GZKJ TU _KY 8KVRGIK ZNK VRGZLUXS IUTZXUR HU SKSHXGTK JKIGR 58 IUTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ XT ZNK QK_ Y OZIN ZU MXU TJ IUTZXURY 6XKYY ZNK KTMOTK YZGXZ GYYOYZ H ZZUT GTJ INKIQ ZNK URZGMK GZ ZNK 1 8 9 OXK GZ ZNK KTMOTK YZGXZ GYYOYZ IUSVUTK...

Страница 313: ...K ZKXSOTGRY LUX ZKYZOTM GTJ INKIQ ZNK URZGMK GZ ZKXSOTGR U TUZ IUSVRKZKR_ XKSU K ZNK XKRG_ UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ ZNK URZGMK GZ ZKXSOTGR UL ZNK 1 XKRG_ NKIQ LUX URZGMK UL ZNK 1 XKRG_ OZN ZNK HRGIQ RKGJ UL ZNK URZ SKZKX UT ZKXSOTGR GTJ ZNK XKJ RKGJ UT ZKXSOTGR 8KVRGIK ZNK 1 XKRG_ 58 IUTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UT...

Страница 314: ... VGMK NKIQ LUX IUTZOT OZ_ HKZ KKT ZKXSOTGR UL ZNK KTMOTK YZGXZ GYYOYZ XKRG_ GTJ VOT UL ZNK 0 NOZK VOT IUTTKIZUX GZ ZNK MXU TJ IUTZXURY Y ZNKXK IUTZOT OZ_ TU 8KVGOX UX XKVRGIK ZNK 8 2 8 OXK LXUS ZKXSOTGR UL ZNK KTMOTK YZGXZ GYYOYZ XKRG_ ZU VOT UL ZNK 0 IUTTKIZUX _KY 8KVRGIK ZNK KTMOTK YZGXZ GYYOYZ XKRG_ 58 IUTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ ...

Страница 315: ...YVRG_ YIXKKT TU L GT_ UZNKX IUJKY GXK UT ZNK JOYVRG_ YIXKKT XKLKX ZU ZNK LG RZ IUJK INGXZ LUX SUXK OTLUXSGZOUT _KY NKIQ LUX GT UVKT UX YNUXZ OT ZNK 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K INGYYOY IUTZXURRKX ZU VOT UL ZNK OT IUTTKIZUX GZ ZNK LUX GXJ GR K IUOR OZKS 0 HGJ MUUJ 8KVGOX UX XKVRGIK ZNK 2 8 OXK NKIQ LUX GT UVKT UX YNUXZ OT ZNK 8 2 8 OXK LXUS VOT UL ZNK 0 IUTTKIZUX GZ ZNK JXO K IN...

Страница 316: ...X_ SGTOLURJ SG_ NG K GT OTZKXTGR LG RZ UTY RZ ZNK KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ INGTMK ZNK LUX GXJ GR K OZKS 0 OZN ZNK XK KXYK GR K OZKS 0 6XKYY JU T ZNK LUUZ Y OZIN GTJ GIZO GZK ZNK G OROGX_ VU KX IZO GZK ZNK LUX GXJ GTJ XK KXYK L TIZOUT GTJ INKIQ ZNK VXKYY XK UKY ZNK L TIZOUT UVKXGZK TU 8KVRGIK ZNK LG RZ_ GR K _KY IZO GZK ZNK G OROGX_ V SV GTJ GT G OROGX_ JXO K L TIZOUT UKY ZNK G OROGX_ V SV ...

Страница 317: ... and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying hyd...

Страница 318: ...7 20 I 1 CR6 CR7 CR10 through CR17 Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 CO5 10 F1 Fuse 20A Maxi Deutz models 75433 Bussman MAX 20 1 F2 Fuse 70A Maxi 61116 Bussman MAX 70 1 FB Flashing beacon 20189 ECCO Electronic Controls 6400A GEN 2 FS1 Foot switch 13482 Linemaster Switch Corp 632 S 1 H1 H2 Alarm Audio 62379 Sauer Danfoss K27631 2 H3 Horn 12V DC 112 dB 54506 Wolo Industries 300LJ 12...

Страница 319: ...nts FP 2000 10 Relay Relay SPDT 12V DC Deutz models 60521 Potter Brumfield VF4 65F11 S01 4 Cummins and Perkins models 60521 Potter Brumfield VF4 65F11 S01 3 Relay Relay SPDT 12V DC Deutz models 61225 Potter Brumfield VF7 41F11 C05 2 Cummins and Perkins models 61225 Potter Brumfield VF7 41F11 C05 1 SS1 through SS4 Steer sensor 50159 Power Components HP NRPS 4 TS1 TS2 TS3 Toggle switch DPDT 3 positi...

Страница 320: ...the circuit for boom stowed and BSTO 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 V 61 AXRT V stands for valve power 61 stands for axle retracted circuit and AXRT is the mnemonic for Axle Retracted C...

Страница 321: ...act Lockout Valve PBL Primary Boom Extend PBE Primary Boom Extend Retract Flow Control PERF Primary Boom Retract PBR Primary Boom Up PBU Primary Boom Up Down Flow Control PBF Primary Lockout 1 P1L Primary Lockout 2 P2L Proportional Valve PRV Proximity Sensor PXS Receptacle REC Reverse REV Right Front RF Right Front Steer Sensor RFS Right Rear RR Right Rear Steer Sensor RRS RPM RPM Sec Boom Down SB...

Страница 322: ...ht 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 down FC proportional valve drive BL RD 13 Drive enable OR 14 Platform level up valve OR BK 15 Platform level down...

Страница 323: ...i 1 Lockout RD WH 75 Pri 2 Lockout BL 76 Pri boom 3 extended Section 6 Schematics First Edition First Printing WIRE CIRCUIT LEGEND WH 77 Lower Angle 1 operational WH BK 78 Upper Angle 2 operational BK 79 power from TCON ESTOP 80Can 2 0 J1939 Shield GR 81 Can 2 0 J1939 Low YL 82 Can 2 0 J1939 High GR WH 83 Tilt signal x axis GR BK 84 Tilt signal y axis GR 85 Tilt sensor power OR 86 Hydraulic Filter...

Страница 324: ...dicated 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 t...

Страница 325: ...PartNo 62401 Genie S 100 S 105 S 120 S 125 6 9 Section 6 Schematics First Edition First Printing LIMIT SWITCHES S 100 S 105 Models S 100 shown S 120 S 125 Models S 120 shown ...

Страница 326: ... Engine cold start i 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 j CR14 relay K2 powers P7R or S56PRV circuit including the auxiliary valve boom extend retract and turntable rotate valve coils k CR10 relay K6 powers C21IGN and C107AF circuits Fuel on off solenoid and alternator field l CR1...

Страница 327: ...PartNo 62401 Genie S 100 S 105 S 120 S 125 6 11 Section 6 Schematics First Edition First Printing Drive Chassis Controller Pin Legend ...

Страница 328: ...6 12 Genie S 100 S 105 S 120 S 125 PartNo 62401 First Edition First Printing Section 6 Schematics Platform Controller Pin Legend ...

Страница 329: ...PartNo 62401 Genie S 100 S 105 S 120 S 125 6 13 Section 6 Schematics First Edition First Printing Turntable Controller Pin Legend ...

Страница 330: ...6 14 Genie S 100 S 105 S 120 S 125 PartNo 62401 Electrical Schematic Legend Drive Chassis DCON and Platform Controls PCON First Edition First Printing Section 6 Schematics ...

Страница 331: ...PartNo 62401 Genie S 100 S 105 S 120 S 125 6 15 Section 6 Schematics First Edition First Printing Electrical Schematic Legend Ground Controls TCON ...

Страница 332: ...6 16 Genie S 100 S 105 S 120 S 125 PartNo 62401 Electrical Symbols Legend First Edition First Printing Section 6 Schematics ...

Страница 333: ...First Edition First Printing Section 6 Schematics Limit Switch Harness Schematic S 100 S 105 Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 17 ...

Страница 334: ...Limit Switch Harness Schematic S 120 S 125 Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A First Edition First Printing Section 6 Schematics Part No 62401 Genie S 100 S 105 S 120 S 125 6 18 ...

Страница 335: ...Safety Circuit Schematic 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A First Edition First Printing Section 6 Schematics Part No 62401 Genie S 100 S 105 S 120 S 125 6 19 ...

Страница 336: ...Electrical Schematic Generators 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A First Edition First Printing Section 6 Schematics Part No 62401 Genie S 100 S 105 S 120 S 125 6 20 ...

Страница 337: ...Electrical Schematic Deutz Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A First Edition First Printing Section 6 Schematics Part No 62401 Genie S 100 S 105 S 120 S 125 6 21 ...

Страница 338: ...Electrical Schematic Cummins and Perkins Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A First Edition First Printing Section 6 Schematics Part No 62401 Genie S 100 S 105 S 120 S 125 6 22 ...

Страница 339: ...PartNo 62401 Genie S 100 S 105 S 120 S 125 6 17 Section 6 Schematics First Edition First Printing This page intentionally left blank ...

Страница 340: ...6 18 Genie S 100 S 105 S 120 S 125 PartNo 62401 Section 6 Schematics First Edition First Printing Hydraulic Symbols Legend ...

Страница 341: ...First Edition First Printing Section 6 Schematics Hydraulic Schematic S 100 Models with 2 Wheel Steer 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N 6 25 Genie S 100 S 105 S 120 S 125 Part No 62401 ...

Страница 342: ...Hydraulic Schematic S 100 Models with 2 Wheel Steer 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 26 First Edition First Printing Section 6 Schematics ...

Страница 343: ...Hydraulic Schematic S 100 Models with 4 Wheel Steer 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N First Edition First Printing Section 6 Schematics 6 27 Genie S 100 S 105 S 120 S 125 Part No 62401 ...

Страница 344: ...Hydraulic Schematic S 100 Models with 4 Wheel Steer 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 28 First Edition First Printing Section 6 Schematics ...

Страница 345: ...Hydraulic Schematic S 105 Models with 2 Wheel Steer 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N First Edition First Printing Section 6 Schematics 6 29 Genie S 100 S 105 S 120 S 125 Part No 62401 ...

Страница 346: ...Hydraulic Schematic S 105 Models with 2 Wheel Steer 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 30 First Edition First Printing Section 6 Schematics ...

Страница 347: ...Hydraulic Schematic S 105 Models with 4 Wheel Steer 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N First Edition First Printing Section 6 Schematics 6 31 Genie S 100 S 105 S 120 S 125 Part No 62401 ...

Страница 348: ...Hydraulic Schematic S 105 Models with 4 Wheel Steer 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 32 First Edition First Printing Section 6 Schematics ...

Страница 349: ...Hydraulic Schematic S 120 Models 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N First Edition First Printing Section 6 Schematics 6 33 Genie S 100 S 105 S 120 S 125 Part No 62401 ...

Страница 350: ...Hydraulic Schematic S 120 Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 34 First Edition First Printing Section 6 Schematics ...

Страница 351: ...Hydraulic Schematic S 125 Models 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N First Edition First Printing Section 6 Schematics 6 35 Genie S 100 S 105 S 120 S 125 Part No 62401 ...

Страница 352: ...Hydraulic Schematic S 125 Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Part No 62401 Genie S 100 S 105 S 120 S 125 6 36 First Edition First Printing Section 6 Schematics ...

Страница 353: ...azardous situation which if not avoided may result in propertydamage Green usedtoindicateoperation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this m...

Страница 354: ...m length Boom angle Axle status Unit of Measure and Language With the key switch OFF press and hold the button and turn the key switch to the ON position Release the button and press Metric Imperial measurements Language selection Drive Functions With the key switch OFF press and hold the button and turn the key switch to the ON position Release the button and press Drive output max forward Drive ...

Страница 355: ...ve defaults Reset turntable rotate valve defaults Reset platform level valve defaults Allow boom up down speed calibration Allow boom extend retract 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 Options Wi...

Страница 356: ... 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 Joystic...

Страница 357: ...to Remove the Membrane 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 lid retaining fasteners Open the control box lid 1 1 Circuit Boards 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 Circu...

Страница 358: ...d 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 t...

Страница 359: ...he 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 The joystick ...

Страница 360: ...m 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 Drivefunctions If the calibration fault is already displayed at the ground box begin with step 6 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 c...

Страница 361: ...lt 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 Boomup downfunctions If the calibration fault is already displayed at the ground box begin with step 6 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 swi...

Страница 362: ...econds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat the calibration procedure beginning with step 1 How to Reset a Proportional Valve Coil Default Software version 2 0 requires the use of Web GPI to perform this procedure Refer to 5 5 Software This procedure only needs to be...

Страница 363: ... 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 7 While holding the joystick...

Страница 364: ... all the joystick controllers have been calibrated push in the Emergency Stop button at the platform controls to save the settings in memory The 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 ...

Страница 365: ...rol panel while turning the key switch to ground controls Hold the enter button for approximately 5 seconds 3 Press the plus button twice then press the scroll button twice 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 to save the setting in memo...

Страница 366: ...witch mounting fasteners that attach the foot switch to the foot switch guard 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals 5 Do not press down the foot switch Connect the leads from an ohmmeter or continuity tester to the wire combination listed below and check for continuity Test Desired result black to white no continuity C to N O infinite ...

Страница 367: ... to the switch terminals in the following combinations listed below to check for continuity Test Desired result Leftposition terminal 1 to 2 3 4 5 6 no continuity infiniteW terminal 2 to 3 continuity zeroW terminal 2 to 4 5 6 no continuity infiniteW terminal 3 to 4 5 6 no continuity infiniteW terminal 4 to 5 6 no continuity infiniteW terminal 5 to 6 continuity zeroW Center position There are no te...

Страница 368: ...form may become unbalanced and fall when it is removed from the machine if it is not properly supported 2 2 Platform Leveling Cylinder The platform leveling cylinder keeps the platform level through the entire range of boom motion The platform is maintained level to the turntable The ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable ...

Страница 369: ...ner from the platform leveling cylinder rod end pivot pin Do not remove the pin 6 Remove the external snap ring from the barrel end pivot pin Do not remove the pin 7 Support the platform leveling cylinder with a suitable lifting device Protect the cylinder rod from damage 8 Use a soft metal drift to remove the rod end pivot pin Crushing hazard The platform S 100 and S 120 models or jib boom S 105 ...

Страница 370: ... to rotate the platform 160 degrees 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...

Страница 371: ...ous injury Remove all rings watches and other jewelry 6 Remove the power to platform electrical outlet box from the platform and lay it to the side PLATFORM COMPONENTS 7 Remove the weld cable from the platform if equipped Electrocution 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...

Страница 372: ... 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 PLATFORM COMPONENTS How to Bleed the Platform Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure S 105 Be...

Страница 373: ...0 and S 120 S 105 After serial number 250 S 125 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 PLATFORM COMPONENTS 2 4 Platform Overload System How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued u...

Страница 374: ...ustment There may be a 2 second delay before the platform overload indicator light and alarm responds 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to 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 grou...

Страница 375: ...form 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 There may be a 2 second delay before the platform overload indicator light and alarm responds 9 Test all machine functions from the platform controls Result All ...

Страница 376: ...e jib boom with a suitable lifting device 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Support the barrel end of the cylinder with a suitable l...

Страница 377: ... lifting strap from an overhead crane to the jib boom bellcrank 17 Support the rod end of the platform leveling cylinder with a suitable lifting device Protect the cylinder rod from damage 18 Remove the pin retaining fastener from the platform leveling cylinder rod end pivot pin 19 Use a soft metal drift to remove the platform leveling cylinder rod end pivot pin Crushing hazard The platform leveli...

Страница 378: ...an penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the hose and cable cover retaining fasteners from the jib boom leveling arm Remove the hose and cable cover from the machine 4 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 5 Us...

Страница 379: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 27 Section 7 Repair Procedures First Edition First Printing This page intentionally left blank ...

Страница 380: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 28 Section 7 Repair Procedures First Edition First Printing Boom Components a Number 0 b Number 1 c Number 2 d Number 3 a Number 1 b Number 2 c Number 3 ...

Страница 381: ...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 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 4 Tag and disconnect the black electrical connector from the bottom of the con...

Страница 382: ...move and cap the fittings 17 Tag and disconnect the wiring connectors The wiring connectors that need to be disconnected are located next to the hose fittings that were removed in step 16 If not removing the boom from the machine proceed to step 19 18 Tag disconnect and plug the primary extension cylinder hydraulic hoses on the side of the number 2 boom tube at the ground controls side of the mach...

Страница 383: ...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 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 ...

Страница 384: ... the Boom 1 Measure each upper side and lower wear pad Boom wear pad specifications 1 2 inch Minimum thickness 12 7 mm Note If a wear pad is not less than specification performthefollowingprocedure 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 wea...

Страница 385: ...approximately 4 feet 1 2 m 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 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 fast...

Страница 386: ...rift 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 BOOM COMPONENTS 21 Carefully remove the boom assembly from the machine and place it on a structure capable of supportin...

Страница 387: ...er cable track and hoses down and out of the way 9 Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the pivot end of the boom 10 Remove the pulley pivot pins cable guards and pulleys 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 o...

Страница 388: ...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 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 str...

Страница 389: ... 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 BOOM COMPONENTS 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...

Страница 390: ...e 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 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 operat...

Страница 391: ...he platform end of the boom Do not remove the bottom wear pads 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 BOOM COMPONENTS 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 remov...

Страница 392: ...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 When installing the pulleys be sure that the side of the pulley with the taller flange is facing the ...

Страница 393: ...m 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 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...

Страница 394: ... 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 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...

Страница 395: ...the number 1 boom tube if it is not properly supported and attached to the overhead crane During removal the overhead crane strap will need to be adjusted for proper balancing 4 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and too...

Страница 396: ...ning 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 Crushing hazard The boom may fall when the rod end pivot pin is removed if the boom is not properly su...

Страница 397: ...inder 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 even...

Страница 398: ...end of the boom 11 Remove the pulley pivot pins cable guards and pulleys When installing the pulleys be sure that the side of the pulley with the shorter flange is facing the inside of the boom tube 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 When installin...

Страница 399: ... attached to the overhead crane Component damage hazard Cables can be damaged if they are kinked pinched or snagged during removal During removal the overhead crane strap will need to be adjusted for proper balancing BOOM COMPONENTS 14 Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin 15 Remove the cable break actuator mounting plate retaining fast...

Страница 400: ...perly installed Operating the machine with the covers removed could result in death or serious injury 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 squ...

Страница 401: ...he 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 a limit switch b extend cable adjustment bolts c red cable adjustment locking bracket d boom tube distance Illus...

Страница 402: ...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 6 3 4 to6 7 8 inches 17 to 17 5 cm d e boom tube 1 f boom tube 2 g nylock nut h hex jam nut Illustration 3 14 Install the red locking bracket over the cable adjustment bolts A flat edge of each bolt head b m...

Страница 403: ...et 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 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 t...

Страница 404: ...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 14 At the pivot end of the boom care...

Страница 405: ... 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 Turntable Covers 4 Mark the location of the hinges on the bulkhead to ensure proper cover alignment during installation 5 Remove the cover hinge to bulkhead retaining fastener...

Страница 406: ...ve 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 co...

Страница 407: ...d on the drive pump 2 Remove the hose clamp from the air cleaner hose at the air cleaner Carefully disconnect the hose from the air cleaner 3 Remove the air cleaner mounting fasteners Remove the air cleaner from the machine 4 Remove the fuel filter water separator retaining fasteners from the pump mounting plate Do not disconnect the fuel hoses 5 Remove the fuel filter water separator and lay it t...

Страница 408: ...ead sealant to the pump coupler set screw Torque the set screw to 70 ft lbs 95 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 Componentdamagehazard Do not force the drive pump during installation...

Страница 409: ...e 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 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 sta...

Страница 410: ...ay 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 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 ...

Страница 411: ...nic 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 gro...

Страница 412: ...cuit board 9 Close the control box lid and install the retaining fasteners 7 3 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electro...

Страница 413: ...6 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 85 to 95 terminal 87 to 87a 30 no continuity infinite terminal 87a to 30 continuity zero 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 terminal 87a to 30 no continu...

Страница 414: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 62 Section 7 Repair Procedures First Edition First Printing S 100 and S 105 Models S 120 and S 125 Models Limit Switches ...

Страница 415: ... deutsch connector terminals in the combination listed below and check for continuity terminal 1 to 2 continuity zero terminal 3 to 4 no continuity infinite terminal 1 to 3 and 4 no continuity infinite terminal 2 to 3 and 4 no continuity infinite 3 Activate the limit switch Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below an...

Страница 416: ... switch Proximity switch a target area a 3 Place a piece of ferrous metal steel iron etc in front of the target area so it is no more than 1 2 inch 12 7 mm away from the target area of the proximity switch 4 Connect the leads from an ohmmeter or continuity tester to the deutsch connector terminals in the combination listed below and check for continuity terminal 3 to 4 continuity zero 5 Move the p...

Страница 417: ...oom until the switch contacts open Repeat the process until the switch contacts open between 65 and 65 5 degrees 12 Tighten the 65 degree safety switch mounting fasteners 13 Lower the boom to 52 5 degrees All models 14 S 100 and S 105 models Raise the boom to 52 5 degrees 15 Loosen the mounting fasteners from the 53 degree proximity switch LSB13AO 16 Disconnect the deutsch connector from the 53 de...

Страница 418: ...on First Printing Limit Switch and Angle Sensor Legend LIMIT SWITCHES LSB2RO LSB2RS LSB6S LSAX1ES LSAX1EO LST1O LSAX2EO LSAX2RO LSAX2ES PLATFORM LEVEL SENSOR LSB19LO TURNTABLE LEVEL SENSOR LSAX1RO LSB3RO LSB4ES LSB4EO LSB3RS LSB3EO LSB1DO LSB13AO LSB8AS LSB9AS LSB7DS LSB14AO LSB19LO REV B ...

Страница 419: ...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 an...

Страница 420: ...engine fuel solenoid when it is mechanically activated at 75 5 feet if boom angle is less than 50O 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...

Страница 421: ...e 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 Over load This switch disables all functions except boom retract and boom up and activat...

Страница 422: ...ulic 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 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 connection...

Страница 423: ...nd or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the function pumps See How to Remove the Function Pumps 2 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump 3 Close the two hydraulic tank valves located at the hydraulic tank ...

Страница 424: ...ng the pump The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to one of the test ports located under the drive pump Cummins and Perkins models 2 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine to access the fuel inject...

Страница 425: ... 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 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 sh...

Страница 426: ...essure gauge to the high pressure port on pump number 1 3 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position 4 Activate any function using auxiliary power Result If the pressure gauge reads 2500 psi 172 bar immediately stop The pump is good Result If pressure fails to reach 2500 psi 172 bar the internal relief valve setting is incorrect or the pump is b...

Страница 427: ...watches and other jewelry How to Test the Power Relay Electrocution hazard Disconnect the ground cable from the battery before performing this procedure 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result small post to relay case 12 to 18 2 large posts no continuity infinite small post to no continuity any large post infinite 2 Connect 12V...

Страница 428: ...8 L min FE Bleeds off differential sensing valves to tank 18 20 ft lbs 24 27 Nm 6 Proportional solenoid valve FF Boom up down proportional speed control 33 37 ft lbs 44 9 50 3 Nm 7 Proportional solenoid valve FG Turntable rotate proportional speed 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 ...

Страница 429: ...t No 62401 Genie S 100 S 105 S 120 S 125 7 77 Section 7 Repair Procedures First Edition First Printing MANIFOLDS FQ FR FA FD FE FB FC FF FG FH FI FJ FK FL FM TP FP 14 2 3 1 15 16 17 9 10 11 12 13 5 7 8 6 4 ...

Страница 430: ...o the ground controls Index Schematic No Description Item Function Torque 11 Orifice plug 0 040 inch 1 02 mm FK Differential sensing dampening 12 Check valve FL Load sensing circuit turntable rotate 12 14 ft lbs 16 19 Nm 13 Diagnostic Nipple Testing 14 Check valve FM Load sensing circuit boom extend retract 12 14 ft lbs 16 19 Nm 15 Differential sensing valve FP Directs flow to functions 25 27 ft l...

Страница 431: ...t No 62401 Genie S 100 S 105 S 120 S 125 7 79 Section 7 Repair Procedures First Edition First Printing MANIFOLDS FQ FR FA FD FE FB FC FF FG FH FI FJ FK FL FM TP FP 14 2 3 1 15 16 17 9 10 11 12 13 5 7 8 6 4 ...

Страница 432: ...se the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 to confirm the relief valve pressure How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the test port on the function manifold 2 Start the engine from...

Страница 433: ...n First Printing 10 3 Proportional Valves Function Manifold When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity the proportional valve cartridge or coil will need to be calibrated See 1 3 How to Calibrate a Joystick Controller MANIFOLDS ...

Страница 434: ...20 ft lbs 24 27 Nm 6 Proportional solenoid valve BF Boom up down proportional speed control 33 37 ft lbs 45 50 Nm 7 Proportional solenoid valve BG Turntable rotate proportional speed control 18 20 ft lbs 24 27 Nm 8 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 ...

Страница 435: ...2401 Genie S 100 S 105 S 120 S 125 7 83 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 15 4 3 2 1 17 19 18 16 9 10 11 13 5 7 8 6 14 12 BQ BR BA BD BE BB BC BF BG BH BI BJ TP BK BL BM BN BO BP ...

Страница 436: ...he ground controls Index Schematic No Description Item Function Torque 12 Diagnostic nipple Testing 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 cont...

Страница 437: ...2401 Genie S 100 S 105 S 120 S 125 7 85 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 15 4 3 2 1 17 19 18 16 9 10 11 13 5 7 8 6 14 12 BQ BR BA BD BE BB BC BF BG BH BI BJ TP BK BL BM BN BO BP ...

Страница 438: ...se the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 to confirm the relief valve pressure How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the test port on the function manifold 2 Start the engine from...

Страница 439: ...n First Printing 10 6 Proportional Valves Function Manifold When a proportional valve cartridge or coil is replaced or moved to a different valve cartridge or cavity the proportional valve cartridge or coil will need to be calibrated See 1 3 How to Calibrate a Joystick Controller MANIFOLDS ...

Страница 440: ... and 2 to auxiliary pump 20 25 ft lbs 27 34 Nm 3 Relief valve 3000 psi 206 8 bar JC Platform manifold relief 20 25 ft lbs 27 34 Nm 4 Diagnostic Nipple TP Testing 5 Flow regulator 3 gpm 11 34 L Min JD Priority flow to platform manifold 30 35 ft lbs 41 47 Nm 6 Check valve JE Blocks flow from pump 2 to auxiliary pump 8 10 ft lbs 11 14 Nm 7 Check valve 50 psi 3 45 bar JF Blocks flow from auxiliary pum...

Страница 441: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 89 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 4 7 5 6 8 2 1 3 AG AF AA AB AC AD AE TP ...

Страница 442: ...3 Simultaneously push and hold the function enable high speed button and the platform level up button with the platform fully leveled in the UP direction Observe the pressure reading on the pressure gauge Refer to Section 2 Hydraulic Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AC 5 Adjust the internal hex socket Turn it clockwise to increase t...

Страница 443: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 91 Section 7 Repair Procedures First Edition First Printing MANIFOLDS This page intentionally left blank ...

Страница 444: ...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...

Страница 445: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 93 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 10 9 8 4 1 11 12 5 6 3 7 2 GQ GI GE GB GG GA GO GD GH GC GF GJ ...

Страница 446: ...erential 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 cir...

Страница 447: ...t No 62401 Genie S 100 S 105 S 120 S 125 7 95 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 12 11 14 15 6 4 1 16 17 7 8 9 10 5 3 2 13 CD CO CH CL CF CJ CN CQ CM CP CI CE CB CC CK CG CA ...

Страница 448: ...ve cartridge or cavity the proportional valve cartridge or coil will need to be calibrated See 1 3 How to Calibrate a Joystick Controller 10 12 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 2 1 B A 12...

Страница 449: ...on 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 2 1 3 MANIFOLDS A B C B A C 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 123456 123456 12...

Страница 450: ... Left rear steer circuit 18 20 ft lbs 24 27 Nm 5 Flow regulator valve 2 gpm 7 6 L min EE Controls the left rear steer cylinder extend speed 18 20 ft lbs 24 27 Nm 6 Check valve EF Left rear steer cylinder retract circuit 18 20 ft lbs 24 27 Nm 7 Check valve pilot operated EG Left rear steer cylinder extend retract circuit 18 20 ft lbs 24 27 Nm 8 Check valve pilot operated EH Right rear steer cylinde...

Страница 451: ...2401 Genie S 100 S 105 S 120 S 125 7 99 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 7 9 10 5 6 8 11 2 1 3 13 19 18 17 16 15 14 12 4 EO EB EC ED EE EF EG EH EI EJ EK EL EM EN EA ES EP EQ ER ...

Страница 452: ...teer cylinder extend circuit 18 20 ft lbs 24 27 Nm 14 Check valve EN Front right steer cylinder retract circuit 18 20 ft lbs 24 27 Nm 15 Flow regulator valve 0 1 gpm 0 38 L min EO Pressurizes pilot lines to check valves 18 20 ft lbs 24 27 Nm 16 Differential sensing valve EP Differential sensing circuit 25 27 ft lbs 34 37 Nm 17 Flow regulator valve 1 4 gpm 5 3 L min EQ Controls the left front steer...

Страница 453: ...401 Genie S 100 S 105 S 120 S 125 7 101 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 7 9 10 5 6 8 11 2 1 3 13 19 18 17 16 15 14 12 4 EO EB EC ED EE EF EG EH EI EJ EK EL EM EN EA ES EP EQ ER ...

Страница 454: ... cylinder extend speed 18 20 ft lbs 24 27 Nm 4 Flow regulator valve 1 4 gpm 5 3 L min EW Controls the right front steer cylinder retract speed 18 20 ft lbs 24 27 Nm 5 Check valve EX Load sense circuit for front and rear axle extend 12 14 ft lbs 16 19 Nm 6 Check valve EY Load sense circuit for front and rear axle retract 12 14 ft lbs 16 19 Nm 7 Relief valve 2200 psi 152 bar EQQ Axle extend circuit ...

Страница 455: ... 120 S 125 7 103 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 22 20 19 18 17 16 21 4 5 6 3 2 1 24 13 15 11 8 7 9 10 12 14 23 EV EW EX EY EDD EHH EII EJJ EKK ELL EOO EMM EPP ENN ET EU EZ EQQ EAA EBB ECC EEE EFF EGG ...

Страница 456: ...o the left rear steer cylinder 18 20 ft lbs 24 27 Nm 16 Check valve pilot operated EHH Left rear steer cylinder extend lock 18 20 ft lbs 24 27 Nm 17 Check valve EII Right front steer cylinder retract load sense circuit 12 14 ft lbs 16 19 Nm 18 Check valve EJJ Left front steer cylinder extend load sense circuit 12 14 ft lbs 16 19 Nm 19 Check valve EKK Right front steer cylinder extend load sense ci...

Страница 457: ... 120 S 125 7 105 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 22 20 19 18 17 16 21 4 5 6 3 2 1 24 13 15 11 8 7 9 10 12 14 23 EV EW EX EY EDD EHH EII EJJ EKK ELL EOO EMM EPP ENN ET EU EZ EQQ EAA EBB ECC EEE EFF EGG ...

Страница 458: ...et 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 relief valve pressure How to Adjust the Axle Extend Relief Valve Perform this procedure with the axles retracted the boom in the stowed position and the machine on a paved s...

Страница 459: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 107 Section 7 Repair Procedures First Edition First Printing MANIFOLDS This page intentionally left blank ...

Страница 460: ... 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 ...

Страница 461: ... No 62401 Genie S 100 S 105 S 120 S 125 7 109 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 9 11 10 1 2 3 17 16 15 12 14 13 5 6 7 8 4 DA DO DB DC DD DE DF DG DH DI DJ DK DL TP DM DP DN ...

Страница 462: ...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 D...

Страница 463: ... No 62401 Genie S 100 S 105 S 120 S 125 7 111 Section 7 Repair Procedures First Edition First Printing MANIFOLDS 9 11 10 1 2 3 17 16 15 12 14 13 5 6 7 8 4 DA DO DB DC DD DE DF DG DH DI DJ DK DL TP DM DP DN ...

Страница 464: ...ve cap 6 Repeat steps 2 through 5 to confirm the relief valve pressure MANIFOLDS 10 19 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field Electrocution hazard Contact with electrically charged circuits could result in death or serious i...

Страница 465: ...y 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 hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and otherje...

Страница 466: ...llic 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 ...

Страница 467: ...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 Be sure to only use a hand operated pump suitable for use with diesel fuel 5 Remove the fuel tank hold down str...

Страница 468: ...nd or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the ground controls side turntable cover See 5 1 How to Remove a Hinged Turntable Cover 2 Close the two hydraulic shutoff valves located at the hydraulic tank Component damage hazard Be sure that the hydraulic tank shutoff valves are i...

Страница 469: ...or 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 overhe...

Страница 470: ...from the brake a motor b motor brake mounting bolts c brake d drive hub mounting bolts e drive hub 12 1 Turntable Rotation Hydraulic Motor and Drive Hub How to Remove the Turntable Rotation Hydraulic Motor 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 Section Two Hydraulic Hose and ...

Страница 471: ... and the machine could tip over when the drive hub is removed from the machine which could result in death or serious injury Crushing hazard The drive hub may become unbalanced and fall if it is not properly supported by the overhead crane or lifting device 6 Remove the plug from the side of the drive hub Drain the oil from the hub Installing the Drive Hub 7 Install the drive hub Use blue thread l...

Страница 472: ... Do not remove them It may be necessary to raise the boom slightly to access all the turntable rotate drive hub mounting bolts a adjustment bolt with lock nut b pivot plate mounting bolts 4 Loosen the lock nut on the turntable drive hub adjustment bolt 5 Tighten the turntable drive hub adjustment bolt until the turntable drive hub gear is fully engaged and tight into the turntable rotate gear 6 Tu...

Страница 473: ...Part No 62401 Genie S 100 S 105 S 120 S 125 7 121 Section 7 Repair Procedures First Edition First Printing TURNTABLE ROTATION COMPONENTS This page intentionally left blank ...

Страница 474: ... 13 1 Steer Sensors 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 If the square end steering fu...

Страница 475: ... will need to be adjusted See How to Adjust a Steer Sensor 8 Repeat step 4 for the other square end tire How to Adjust a Steer Sensor Square end steer sensors 1 At the platform controls press the circle end steer mode button 2 Locate the steer sensor on top of the yoke pivot pin 3 Loosen the steer sensor cover retaining fasteners Do not remove them 4 Rotate the steer sensor cover either clockwise ...

Страница 476: ... 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 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 Section Two Hydraulic Hose and Fit...

Страница 477: ...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 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 I...

Страница 478: ...the axle Refer to Section 2 Machine TorqueSpecifications 13 3 Drive Motor How to Remove a Drive Motor Component damage hazard Repairs to the motor should only be performed by an authorized Rexroth dealer Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damag...

Страница 479: ...il 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 ...

Страница 480: ...ve 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 fa...

Страница 481: ...retract the axle through an entire cycle Check for tight spots that could cause binding or scraping of the axle tubes Always maintain squareness between the inner and outer axle tubes Top and bottom wear pads 3 Center a lifting jack of ample capacity under the axle that needs to be shimmed Do not raise the machine 4 Block the wheels at the opposite end of the machine 5 Raise the machine just until...

Страница 482: ... above the axle Remove the chassis cover from the machine 5 Remove the upper wear pad retainer plate retaining fasteners Remove the plate from the machine 6 Attach a lifting strap from an overhead crane of ample capacity to the inner axle for support Do not lift it 7 Remove the retaining fasteners from the upper and lower wear pads at the outer axle Do not remove the side wear pads Pay careful att...

Страница 483: ...he 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 How to Remove 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 remaini...

Страница 484: ... pin on the remaining inner axle 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 e...

Страница 485: ...functioning machine Repair any machine damage or malfunction before operating the machine BeforeTroubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 120 and Genie S 125 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use About This Section This section explains various parts of the machine soft...

Страница 486: ...Extend Retract Speed Not calibrated Boom Extend Retract Flow Valve Not calibrated and fault check Boom Up Down Flow Valve Not calibrated and fault check Boom Extend Valve Fault check Boom Retract Valve Fault check Boom Up Valve Fault check Boom Down Valve Fault check Lock Out Valve P1 Fault check Lock Out Valve P2 Fault check Engine Module Engine Speed Range check Oil Pressure Range check Water Oi...

Страница 487: ...table Rotate Flow Valve Not calibrated and fault check Turntable Rotate Clockwise Valve Fault check Turntable Rotate CounterClockwise Valve Fault check Turntable Level Module Turntable Level Sensor X Direction Fault check Turntable Level Sensor Y Direction Fault check Platform Rotate Module Platform Rotate Switches Fault check Platform Rotate Valve Fault check Propel Module Propel Joystick Not cal...

Страница 488: ...afety Switch P18 Safety Switch P22 Safety Switch P22R Platform Overload Sensor IF active Boom Up Overload IF active Boom Down Overload IF active Shut Down Mode IF active Steering Module Steering Joystick Not calibrated and fault check Left Front Steer Angle Sensor Fault check Right Front Steer Angle Sensor Fault check Left Rear Steer Angle Sensor Fault check Right Rear Steer Angle Sensor Fault che...

Страница 489: ... Language Press on power on Metric English display language then press measurement units Drive Functions Press on power on then Drive output max forward press Drive output max reverse Elevated drive 80 feet 24 4 m Elevated drive 80 feet 24 4 m Stowed drive Drive acceleration Drive deceleration Speed limit on steer angle Boom function Press on power on Boom up down speed stowed speeds then press Bo...

Страница 490: ... speed calibration Allow boom extend retract 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 Options Press on power on then Limit boom height to 100 feet 30 5 m press Limit boom height to 80 feet 24 4 m AC g...

Страница 491: ...the primary number 1 lock out valve PRLO stands for Primary Lockout S 62 BSTO This is the circuit that tells the computer on the machine that the boom is fully stowed S stands for safety number 62 is the circuit for boom stowed BSTO stands for Boom Stowed P 48 LP P stands for power Number 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 t...

Страница 492: ...D 16 Platform level up down proportional valve GR RD 17 Platform rotate left valve GR BK 18 Platform rotate right valve GR WH 19 Jib boom select valve circuit RD 20 12V DC battery supply WH 21 12V DC ignition supply Wire Circuit Color Number Function BK 22 Key switch power to platform Emergency Stop button WH 23 Power to platform WH 24 Power to warning senders WH BK 25 Power to oil pressure sender...

Страница 493: ...ve cut off BK WH 54 Power to safety interlock switches engine GR BK 55 Axle oscillation RD 56 Foot switch Ground controls Emergency Stop power RD WH 57 Boom down safety interlock RD BK 58 Safety interlock to engine GR WH 59 Cable break circuit GR WH 60 Axle extend GR 61 Axle retract OR 62 Boom stowed safety OR RD 63 Power to boom envelope safety switch OR BL 64 Power to operational switches WIRE C...

Страница 494: ...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 ...

Страница 495: ... STEER SENSOR SS4 C C B A B A YEL GRN 3 1 4 2 PROXIMITY KILL SWITCH OPTIONAL JIB BOOM BOOM UP DOWN AND TURNTABLE ROTATE JOYSTICK H1 JC1 JC2 JC3 P2 TS3 TS2 TS1 H3 H2 H3 H4 DRIVE AND STEERING JOYSTICK BOOM EXTEND RETRACT JOYSTICK PLATFORM EMERGENCY STOP PLATFORM ALARM PLATFORM ROTATE PLATFORM LEVEL D81CAN GR D80SHLD N A D82CAN YL P63LS OR RD P53LS WH BK C60AXEX GR WH P57PBD RD WH P21DCON RD GNDDCON ...

Страница 496: ... 9B P 7 P 6R2 5 5 5 K4 K5 86 30 85 87 87a 86 30 85 87 87a 86 30 85 87 87a K3 87a 87 86 85 30 To Limit Switch Harness Schematic To Limit Switch Harness Schematic Go to A on Drive Chassis and Platfom Controls Schematic Go to B on Drive Chassis and Platfom Controls Schematic Go to C on Drive Chassis and Platfom Controls Schematic CURRENT LIMITING DEVICE CURRENT LIMITING DEVICE SERVICE BYPASS RUN A A ...

Страница 497: ...7 11 974 6838 27 11 974 6797 55 11 4055 2499 55 11 713 1661 Genie Holland Genie Denmark Genie France Genie Spain Genie Germany Genie U K Genie Mexico City Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax 31 70 51 78836 31 70 51 13993 45 6612 5544 45 6612 5530 33 2 37 26 09 99 33 2 37 31 11 95 34 93 579 5042 34 93 579 5059 49 4202 8852 0 49 4202 8852 20 44 1636 614700 44 1636 6...

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