Genie S-100 Manuale utente

Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

First Edition • First Printing

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie S-100 and

Genie S-105 Operator's Manual

or the

Genie S-

120 and Genie S-125 Operator's Manual

before

attempting any maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes and repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

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.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

http://www.genieindustries.com

e-mail: [email protected]

62401 Rev A January 2001

First Edition, First Printing

"Genie" and "S" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

Part No. 62401 Genie S-100 & S-105 & S-120 & S-125

First Edition • First Printing

iii

Serial Number Legend

INTRODUCTION

S120 06 - 12345

Model

Model year

Sequence

number

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5

CAN B.354.4

Model:

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:

Model year: Manufacture date:

01/05/06

2006

Maximum wind speed :

28 mph/ 12.5 m/s

Maximum platform height :

126 ft/ 38.6 m

Maximum platform reach :

75ft/ 22.9 m

Serial number

(stamped on chassis)

Serial label

(located under cover)

Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

First Edition • First Printing

This page intentionally left blank.

Part No. 62401 Genie S-100 & S-105 & S-120 & S-125

First Edition • First Printing

Danger

Failure to obey the instructions and safety rules in

this manual, and the

Genie S-100 & Genie S-105

Operator's Manual

or the

Genie S-120 & Genie

S-125 Operator's Manual

will result in death or

serious injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules

Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

First Edition • First Printing

SAFETY RULES

Section 1 - Safety Rules

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable

and combustible materials like battery

gases and engine fuels. Always have an approved

fire extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

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

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This manual and

the decals on the machine, use signal words to

identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used to

indicate the presence of a

potentially hazardous situation

which, if not avoided, may cause

minor or moderate injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

property damage.

Part No. 62401 Genie S-100 & S-105 & S-120 & S-125

First Edition • First Printing

Table of Contents

vii

Introduction

Important Information......................................................................................................

Section One Safety Rules

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

iii

Section Two Specifications

Machine Specifications, S120 and S-125 Models ..................................................... 2 - 1

Performance Specifications, S120 and S-125 Models .............................................. 2 - 2

Machine Specifications, S100 and S-105 Models ..................................................... 2 - 3

Performance Specifications, S100 and S-105 Models .............................................. 2 - 5

Hydraulic Specifications............................................................................................ 2 - 6

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 Theory of Operation

Theory of Operation .................................................................................................. 3 - 1

Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

First Edition • First Printing

TABLE OF CONTENTS

viii

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

Pre-Delivery Preparation .......................................................................................... 4 - 3

Maintenance Inspection Report ................................................................................ 4 - 5

A-1 Inspect the Manuals and Decals ..................................................................... 4 - 7

A-2 Perform Pre-operation Inspection ................................................................... 4 - 8

A-3 Perform Function Tests ................................................................................... 4 - 8

A-4 Perform Engine Maintenance - Perkins Models .............................................. 4 - 9

A-5 Perform Engine Maintenance - Cummins Models ........................................... 4 - 9

A-6 Perform Engine Maintenance - 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.............................. 4 - 15

A-15 Extendable Axle Lubrication System ............................................................ 4 - 16

A-16 Replace the Drive Hub Oil ............................................................................. 4 - 17

B-1 Inspect the Batteries ..................................................................................... 4 - 18

B-2 Inspect the Electrical Wiring .......................................................................... 4 - 19

B-3 Check the Oil Cooler and Cooling Fins - Deutz Models ................................ 4 - 21

B-4 Inspect the Engine Air Filter .......................................................................... 4 - 21

Part No. 62401 Genie S-100 & S-105 & S-120 & S-125

First Edition • First Printing

TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued

B-5 Test the Alarm Package (if equipped) ........................................................... 4 - 22

B-6 Perform Engine Maintenance - Deutz Models ............................................... 4 - 23

B-7 Perform Engine Maintenance - Cummins Models ......................................... 4 - 23

B-8 Check the Exhaust System ........................................................................... 4 - 24

B-9 Inspect the Tires, Wheels and Lug Nut Torque ............................................. 4 - 25

B-10 Check the Drive Hub Oil Level and Fastener Torque .................................... 4 - 25

B-11 Confirm the Proper Brake Configuration ....................................................... 4 - 26

B-12 Check and Adjust 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 Extended Position .................................... 4 - 42

B-22 Perform Hydraulic Oil Analysis ...................................................................... 4 - 43

B-23 Inspect the Boom Extend/Retract Cables ..................................................... 4 - 43

C-1 Perform Engine Maintenance - Deutz Models ............................................... 4 - 45

C-2 Perform Engine Maintenance - Cummins Models ......................................... 4 - 45

C-3 Perform Engine Maintenance - Perkins Models ............................................ 4 - 46

C-4 Replace the Engine Air Filter Element........................................................... 4 - 46

Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

First Edition • First Printing

TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued

C-5 Grease the Platform Overload Mechanism (if equipped) ............................... 4 - 47

C-6 Test the Platform Overload System (if equipped) .......................................... 4 - 47

D-1 Check the Boom Wear Pads ......................................................................... 4 - 50

D-2 Check the Extendable Axle Wear Pads ........................................................ 4 - 51

D-3 Check the Free-wheel Configuration ............................................................. 4 - 52

D-4 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 53

D-5 Check the Turntable Rotation Gear Backlash ............................................... 4 - 54

D-6 Replace the Drive Hub Oil ............................................................................. 4 - 56

D-7 Grease the Turntable Rotatiion Bearing and Rotate Gear ............................. 4 - 58

D-8 inspect for Turntable 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 - Perkins Models ............................................ 4 - 66

E-5 Perform Engine Maintenance - Deutz Models ............................................... 4 - 66

E-6 Perform Engine Maintenance - Perkins Models ............................................ 4 - 67

E-7 Perform Engine Maintenance - Deutz Models ............................................... 4 - 67

E-8 Perform Engine Maintenance - Perkins Models ............................................ 4 - 68

E-9 Perform Engine Maintenance - Deutz Models ............................................... 4 - 69

E-9 Perform Engine Maintenance - Perkins Models ............................................ 4 - 69

E-10 Perform Engine Maintenance - Deutz Models ............................................... 4 - 70

E-11 Replace the Boom Extend/Retract Cables .................................................... 4 - 70

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