Terex Genie S-100, S-105, S-120, S-125 Telescopic Boom Lift Service Manual
497 pages · Publication 62401
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- Models
- Genie S-100, S-105, S-120, S-125
- Serial coverage
- See Cover
- Manual type
- Service Manual
- Pages
- 497
- Publication
- 62401
- Condition
- Brand new
What's inside
From the manual's own table of contents: 194 topics. See sample pages (PDF, 617 KB)
- Important Information
- General Safety Rules
- Machine Specifications, S120 and S-125 Models
- Performance Specifications, S120 and S-125 Models
- Machine Specifications, S100 and S-105 Models
- Performance Specifications, S100 and S-105 Models
- Hydraulic Specifications
- Perkins Engine 1004-42 Specifications
- Cummins Engine B3.9L Specifications
- Deutz Engine F4L 913 Specifications
- Hydraulic Hose and Fitting Torque Specifications
- Theory of Operation
- Introduction
- Pre-Delivery Preparation
- Maintenance Inspection Report
- Inspect the Manuals and Decals
- Perform Pre-operation Inspection
- Perform Function Tests
- Perform Engine Maintenance - Perkins Models
- Perform Engine Maintenance - Cummins Models
- Perform Engine Maintenance - Deutz Models
- Check the Hydraulic Filter Condition Indicators
- Test the Auxiliary Power Operation
- Test the Tilt Sensor and Alarm
Show all 194 topics
- A-10 Test the Operating Envelope
- A-11 Perform 30 Day Service
- A-12 Perform Engine Maintenance - Perkins Models
- A-13 Perform Engine Maintenance - Deutz Models
- A-14 Grease the Turntable Rotation Bearing and Rotate Gear
- A-15 Extendable Axle Lubrication System
- A-16 Replace the Drive Hub Oil
- Inspect the Batteries
- Inspect the Electrical Wiring
- Check the Oil Cooler and Cooling Fins - Deutz Models
- Inspect the Engine Air Filter
- Test the Alarm Package (if equipped)
- Check the Exhaust System
- Inspect the Tires, Wheels and Lug Nut Torque
- B-10 Check the Drive Hub Oil Level and Fastener Torque
- B-11 Confirm the Proper Brake Configuration
- B-12 Check and Adjust the Engine RPM
- B-13 Test the Key Switches
- B-14 Test the Ground Control Override
- B-15 Test the Platform Self-leveling
- B-16 Test the Safety Envelope and Circuits
- B-17 Inspect the Fuel Tank Cap Venting System
- B-18 Test the Engine Idle Select Operation
- B-19 Test the Drive Brakes
- B-20 Test the Drive Speed - Stowed Position
- B-21 Test the Drive Speed - Raised or Extended Position
- B-22 Perform Hydraulic Oil Analysis
- B-23 Inspect the Boom Extend/Retract Cables
- Replace the Engine Air Filter Element
- Grease the Platform Overload Mechanism (if equipped)
- Test the Platform Overload System (if equipped)
- Check the Boom Wear Pads
- Check the Extendable Axle Wear Pads
- Check the Free-wheel Configuration
- Check the Turntable Rotation Bearing Bolts
- Check the Turntable Rotation Gear Backlash
- Replace the Drive Hub Oil
- Grease the Turntable Rotatiion Bearing and Rotate Gear
- inspect for Turntable Bearing Wear
- D-10 Perform Engine Maintenance - Perkins Models
- D-11 Perform Engine Maintenance - Cummins Models
- D-12 Replace the Hydraulic Filter Elements
- Test or Replace the Hydraulic Oil
- E-10 Perform Engine Maintenance - Deutz Models
- E-11 Replace the Boom Extend/Retract Cables
- Fault Code Chart
- Display Not Active
- Engine Will Not Crank Over
- Engine Cranks Over But Will Not Start
- Engine Starts and Runs for 3 Seconds and Dies
- Engine High Idle Inoperative
- Engine Low Idle Inoperative
- All Functions Inoperative, Engine Starts and Runs
- Drive, Steer and Axle Extend/Retract Functions Operational
- All Other Functions Operational
- Ground Controls Inoperative, Platform Controls Operate Normally
- Platform Controls Inoperative, Ground Controls Operate Normally
- Boom Angle Switch Fault
- Boom Up Function Inoperative
- Boom Down Function Inoperative
- Boom Length Switch Fault
- Boom Extend Function Inoperative
- Boom Retract Function Inoperative
- Boom Envelope Operational Switch Failure, S-100 and S-105 Models
- Boom Envelope Operational Switch Failure, S-120 and S-125 Models
- Boom Envelope Safety Switch Failure, S-100 and S-105 Models
- Boom Envelope Safety Switch Failure, S-120 and S-125 Models
- Turntable Rotate Clockwise Function Inoperative
- Turntable Rotate Counter Clockwise Function Inoperative
- Platform Level Function Inoperative
- Platform Level Up Function Inoperative
- Platform Level Down Function Inoperative
- Platform Level Safety Fault
- Platform Rotate Clockwise Function Inoperative
- Platform Rotate Counter Clockwise Function Inoperative
- Jib Up Function Inoperative
- Jib Down Function Inoperative
- Auxiliariy Functions Inoperative
- Axle Extend Function Inoperative
- Axle Retract Function Inoperative
- Blue End Blue Side Steering Function Inoperative
- Blue End Yellow Side Steering Function Inoperative
- Yellow End Blue Side Steering Function Inoperative
- Yellow End Yellow Side Steering Function Inoperative
- Drive Forward Function Inoperative
- Drive Reverse Function Inoperative
- Drive Enable Fault
- Drive Mode Select Inoperative
- Engine Start Assist Inoperative
- Auxiliary Drive Function Inoperative
- Electrical Components
- Wire Circuit Legend
- Limit Switches
- Relay Layout
- Drive Chassis Controller Pin Legend
- Platform Controller Pin Legend
- Turntable Controller Pin Legend
- Drive Chassis (DCON) and Platform Controls (PCON)
- Electrical Schematic Legend - Ground Controls (TCON)
- Electric Symbols Legend
- Limit Switch Harness Schematic, S-100 & S-105 Models
- Limit Switch Harness Schematic, S-120 & S-125 Models
- Safety Circuit Schematic
- Electrical Schematic - Generators
- Electrical Schematic - Deutz Models
- Electrical Schematic - Cummins and Perkins Models
- Hydraulic Symbols Legend
- Hydraulic Schematic, S-100 Models with 2 Wheel Steer
- Hydraulic Schematic, S-100 Models with 4 Wheel Steer
- Hydraulic Schematic, S-105 Models with 2 Wheel Steer
- Hydraulic Schematic, S-105 Models with 4 Wheel Steer
- Hydraulic Schematic, S-120 Models
- Hydraulic Schematic, S-125 Models
- Display Module
- Circuit Boards
- Membrane Decal
- Joystick Controllers
- Foot Switch
- Toggle Switches
- Platform
- Platform Leveling Cylinder
- Platform Rotator
- Platform Overload System
- Jib Boom, S-105 and S-125 Models
- Jib Boom Lift Cylinder, S-105 and S-125 Models
- Cable Track
- Boom
- Boom Lift Cylinder
- Extension Cylinders
- Boom Extend/Retract Cables
- Turntable Covers
- RPM Adjustment
- Flex Plate
- Cummins and Perkins Models
- Oil Pressure and Temperature Sending Units, Deutz Models
- Control Relays
- Function Pumps
- Drive Pump
- Auxiliary Pump
- Power Relay
- 10-1 Function Manifold Components, S-100 and S-105 Models
- 10-2 Valve Adjustments - Function Manifold, S-100 and S-105 Models
- 10-3 Proportional Valves - Function Manifold
- 10-4 Function Manifold Components, S-120 and S-125 Models
- 10-5 Valve Adjustments - Function Manifold, S-120 and S-125 Models
- 10-6 Proportional Valves - Function Manifold
- 10-7 Distribution Manifold Components
- 10-8 Valve Adjustments - Distribution Manifold
- 10-9 Platform Manifold Components, S-100 and S-120 Models
- 10-10 Platform Manifold Components, S-105 and S-125 Models
- 10-11 Proportional Valves - Platform Manifolds
- 10-12 Platform Rotate Counterbalance Valve Manifold
- 10-13 Turntable Rotation Manifold Components
- 10-14 Steer and Axle Extend/Retract Manifold Components - View 1
- 10-15 Steer and Axle Extend/Retract Manifold Components - View 2
- 10-16 Valve Adjustments - Steer and Axle Extend/Retract Manifold
- 10-17 Drive Manifold Components
- 10-18 Valve Adjustments - Drive Manifold
- 10-19 Valve Coils
- 11-1 Fuel Tank
- 11-2 Hydraulic Tank
- 12-1 Turntable Rotation Hydraulic Motor and Drive Hub
- 13-1 Steer Sensors
- 13-2 Yoke and Hub
- 13-3 Drive Motor
- 13-4 Drive Hub
- 13-5 Steering Cylinders
- 13-6 Extendable Axles
- Drive Chassis and Platform Control
- Ground Controls
Inside this manual
Real pages from this service manual (497 pages). Open the sample pages (PDF, 616 KB)
- Specifications, page 22: Section 2 • Specifications
- Troubleshooting, page 106: Diagnostic code displayed
- Diagram, page 351: Hydraulic Schematic,
- Foldout diagram, page 337: Electrical Schematic -
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 497 pages
Quantity one is the manual described above.
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Binder not included
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).