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Genie S-105 Service Manual

Genie S-105
317 pages
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Table of Contents

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Genie S-105 Specifications

General IconGeneral
Lift Capacity227 kg
Power SourceDiesel
Swing360° Continuous
Gradeability45%
Drive Speed - Stowed4.4 km/h
Drive Speed4.8 km/h
Turning Radius2.1 m

Summary

Introduction

Important

Read, understand, and obey safety rules and operating instructions before maintenance or repair.

Safety Rules

Danger

Warning about severe injury or death from not following instructions.

Do Not Perform Maintenance Unless:

Lists prerequisites: trained personnel, understanding manuals, proper tools.

Personal Safety

General safety advice for personnel working on or around machines.

Workplace Safety

Safety guidelines for maintaining a safe work environment and practices.

Section 2 Specifications

Performance Specifications, S-120 and S-125 Models

Lists performance data including drive speeds, boom speeds, and braking distance.

Performance Specifications, S-100 and S-105 Models

Lists performance data including drive speeds, boom speeds, and braking distance.

Section 3 Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Details procedures for scheduled maintenance inspections.

Pre-Delivery Preparation

Fundamentals and instructions for dealer pre-delivery preparation.

A-1 Inspect the Manuals and Decals

Daily procedure to check manual and decal condition for safety.

A-2 Perform Pre-operation Inspection

Daily visual inspection to identify machine issues before use.

A-3 Perform Function Tests

Daily tests to discover any malfunctions before machine use.

A-4 Perform Engine Maintenance - Perkins Models

Daily or 8-hour engine maintenance for Perkins models.

A-5 Perform Engine Maintenance - Cummins Models

Daily or 8-hour engine maintenance for Cummins models.

A-6 Check the Hydraulic Filter Condition Indicators

Daily check of hydraulic filter condition indicators for bypass.

A-8 Perform Engine Maintenance - Perkins Models

Every 50 hours or weekly engine maintenance for Perkins models.

A-9 Perform Engine Maintenance - Deutz Models

One-time engine maintenance for Deutz models after the first 50 hours.

B-1 Inspect the Batteries

Every 250 hours or quarterly inspection of battery condition and specific gravity.

B-2 Inspect the Electrical Wiring

Every 250 hours or quarterly inspection of electrical wiring for damage.

B-4 Inspect the Engine Air Filter

Every 250 hours or quarterly inspection of the engine air filter.

B-6 Perform Engine Maintenance - Deutz Models

Every 250 hours engine maintenance procedure for Deutz models.

B-7 Perform Engine Maintenance - Cummins Models

Every 250 hours engine maintenance procedure for Cummins models.

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

Every 250 hours or quarterly inspection of tires, wheels, and lug nut torque.

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

Every 250 hours or quarterly check of drive hub oil level and fastener torque.

B-11 Confirm the Proper Brake Configuration

Every 250 hours or quarterly check to ensure proper brake configuration.

B-12 Check and Adjust the Engine RPM

Every 250 hours or quarterly check and adjustment of engine RPM.

B-13 Test the Key Switches

Every 250 hours or quarterly test of main and service bypass key switches.

B-14 Test the Ground Control Override

Every 250 hours or quarterly test of the ground control override function.

B-15 Test the Platform Self-leveling

Every 250 hours or quarterly test of the automatic platform self-leveling system.

B-16 Test the Safety Envelope and Circuits

Every 250 hours or quarterly test of safety envelope and circuits.

B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems

Every 250 hours or quarterly inspection of fuel and hydraulic tank cap venting.

B-18 Test the Engine Idle Select Operation

Every 250 hours or quarterly test of engine idle select operation.

B-19 Test the Drive Brakes

Every 250 hours or quarterly test of drive brake action.

B-20 Test the Drive Speed - Stowed Position

Every 250 hours or quarterly test of drive speed with boom stowed.

B-21 Test the Drive Speed - Raised or Extended Position

Every 250 hours or quarterly test of drive speed with boom raised or extended.

B-22 Inspect the Boom Extend/Retract Cables

Every 250 hours or quarterly inspection of boom extend/retract cables.

C-1 Perform Engine Maintenance - Deutz Models

Every 500 hours engine maintenance for Deutz models.

C-2 Perform Engine Maintenance - Cummins Models

Every 500 hours or 6 months engine maintenance for Cummins models.

C-3 Perform Engine Maintenance - Perkins Models

Every 500 hours or 12 months engine maintenance for Perkins models.

C-4 Replace the Engine Air Filter Element

Every 500 hours or 6 months replacement of engine air filter element.

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

Every 500 hours or 6 months test of the platform overload system.

D-1 Check the Boom Wear Pads

Every 1000 hours or annually check of boom wear pads for condition.

D-2 Check the Extendable Axle Wear Pads

Every 1000 hours or annually check of extendable axle wear pads for condition.

D-3 Check the Free-wheel Configuration

Every 1000 hours or annually check of the free-wheel configuration.

D-4 Check the Turntable Rotation Bearing Bolts

Every 1000 hours or annually check of turntable bearing bolt torque.

D-5 Check the Turntable Rotation Gear Backlash

Every 1000 hours or annually check of turntable rotation gear backlash.

D-6 Replace the Drive Hub Oil

Every 1000 hours or annually replacement of drive hub oil.

D-7 Inspect for Turntable Bearing Wear

Every 1000 hours or annually inspection of turntable bearing wear.

D-8 Perform Engine Maintenance - Deutz Models

Every 1000 hours engine maintenance for Deutz models.

D-9 Perform Engine Maintenance - Perkins Models

Every 1000 hours engine maintenance for Perkins models.

D-10 Perform Engine Maintenance - Cummins Models

Every 1000 hours or annually engine maintenance for Cummins models.

D-11 Replace the Hydraulic Filter Elements

Every 1000 hours or annually replacement of hydraulic filter elements.

E-1 Test or Replace the Hydraulic Oil

Every 2000 hours or 2 years test or replace hydraulic oil.

E-2 Perform Engine Maintenance - Cummins Models

Every 2000 hours or 2 years engine maintenance for Cummins models.

E-3 Perform Engine Maintenance - Perkins Models

Every 2000 hours engine maintenance for Perkins models.

E-13 Replace the Boom Extend/Retract Cables

Every 10 years replacement of boom extend/retract cables.

Section 4 Repair Procedures

Repair Procedures

Details procedures for repair by trained service professionals.

Before Repairs Start

Prerequisites for starting repairs, including safety and tool readiness.

Platform Controls

Overview of platform controls, circuit boards, and joysticks.

1-3 Joysticks

Information on joystick calibration for proportional control.

2-4 Platform Level Sensor

Description and procedure for calibrating the platform level sensor.

2-5 Platform Overload System

Description and calibration procedure for the platform overload system.

How to Remove the Boom

Procedure for removing the boom assembly from the machine.

4-5 Boom Extend/Retract Cables

Procedure for adjusting boom extend/retract cables.

How to Replace the Boom Extend/Retract Cables

Procedure for replacing boom extend/retract cables and pulleys.

Section 5 Diagnostic Codes

Diagnostic Codes

Overview of diagnostic codes and troubleshooting.

Before Troubleshooting

Prerequisites for troubleshooting, including safety and tool availability.

Control System Fault Codes

Methods for clearing boom safety switch faults using Web GPI or TCON LCD.

Section 6 Schematics

Schematics

Contains electrical and hydraulic schematics for machine systems.

Observe and Obey

General safety rules for working with schematics.

Safety Circuit Schematic

Schematic diagram of the safety circuit.

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