s125

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S-100 • S-105 • S-120 • S-125 Part No. 102916ii

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie S-100 andGenie S-105 Operator's Manual or the Genie S-120 and Genie S-125 Operator's Manual beforeattempting any maintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However,several procedures require specialized skills, tools,lifting equipment and a suitable workshop. In theseinstances, we strongly recommend thatmaintenance and repair be performed at anauthorized Genie dealer service center.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specifications aresubject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

http://www.genieindustries.come-mail: [email protected]

Copyright © 2001 by Genie Industries

102916 Rev E June 2011Second Edition, Fifth Printing

"Genie" and "S" are registered trademarks ofGenie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

Introduction

Serial Number Information

Genie Industries offers the followingService Manuals for these models:

Title Part No.

Genie S-100, S-105, S-120 and S-125Service Manual(from serial number 100 to 135)(from serial number 100 to 403) ..........62401

June 2011

Part No. 102916 S-100 • S-105 • S-120 • S-125 iii

Serial Number Legend

INTRODUCTION

S120 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5CAN 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: 2

Model year: Manufacture date: 01/05/062006

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)

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June 2011

Part No. 102916 S-100 • S-105 • S-120 • S-125

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-100 & Genie S-105Operator's Manual or the Genie S-120 & GenieS-125 Operator's Manual will result in death orserious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules

v

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S-100 • S-105 • S-120 • S-125 Part No. 102916vi

SAFETY RULES

Section 1 - Safety Rules

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammableand combustible materials like battery

gases and engine fuels. Always have an approvedfire extinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. This manual andthe decals on the machine, use signal words toidentify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

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Part No. 102916 S-100 • S-105 • S-120 • S-125

Table of Contents

Introduction

Important Information ................................................................................................... ii

Serial Number Information............................................................................................ ii

Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

E 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 Oil Specifications ................................................................................... 2 - 6

Hydraulic Component Specifications ...................................................................... 2 - 7

Deutz Engine F4L 913 Specifications .................................................................... 2 - 9

Deutz Engine BF4L 2011 Specifications .............................................................. 2 - 10

Deutz Engine TD2011L04i Specifications............................................................. 2 - 11

Perkins Engine 1004-42 Specifications ................................................................ 2 - 13

Perkins Engine 1104C-44 Specifications .............................................................. 2 - 14

Perkins Engine 804D-33T Specifications ............................................................. 2 - 16

Cummins Engine B3.3T Specifications ................................................................ 2 - 18

Cummins Engine B3.9L Specifications ................................................................ 2 - 19

Cummins Engine B4.5L Specifications ................................................................ 2 - 20

Machine Torque Specifications ............................................................................ 2 - 21

Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 21

Manifold Plug Torque Specifications .................................................................... 2 - 22

SAE and Metric Fasteners Torque Charts ............................................................ 2 - 23

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TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-delivery Preparation ......................................................................................... 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

B Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................. 3 - 8

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

A-4 Perform Engine Maintenance - Perkins Models ............................................ 3 - 9

A-5 Perform Engine Maintenance - Cummins Models ......................................... 3 - 9

A-6 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 10

A-7 Perform 30 Day Service ............................................................................. 3 - 11

A-8 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12

A-9 Perform Engine Maintenance - Deutz Models ............................................. 3 - 12

A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13

A-11 Grease the Extendable Axles ..................................................................... 3 - 13

A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14

E Checklist B Procedures

B-1 Inspect the Batteries .................................................................................. 3 - 16

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17

B-3 Check the Engine Oil Cooler and Cooling Fins - Deutz Models ................... 3 - 19

B-4 Inspect the Engine Air Filter ....................................................................... 3 - 19

B-5 Perform Hydaulic Oil Analysis .................................................................... 3 - 20

B-6 Perform Engine Maintenance - Deutz Models ............................................. 3 - 21

B-7 Perform Engine Maintenance - Cummins Models ....................................... 3 - 21

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Section 3 Rev Scheduled Maintenance Procedures, continued

E Checklist B Procedures

B-8 Check the Exhaust System ....................................................................... 3 - 22

B-9 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 23

B-10 Check the Dirve Hub Oil Level and Fastener Torque .................................. 3 - 23

B-11 Confirm the Proper Brake Configuration...................................................... 3 - 24

B-12 Check and Adjust the Engine RPM ............................................................ 3 - 25

B-13 Test the Key Switches ............................................................................... 3 - 28

B-14 Test the Ground Control Override ............................................................... 3 - 29

B-15 Test the Platform Self-leveling ................................................................... 3 - 30

B-16 Test the Safety Envelope and Circuits ....................................................... 3 - 31

B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38

B-18 Test the Engine Idle Select Operation ........................................................ 3 - 39

B-19 Test the Drive Brakes ................................................................................ 3 - 40

B-20 Test the Drive Speed - Stowed Position ..................................................... 3 - 40

B-21 Test the Drive Speed - Raised or Extended Position .................................. 3 - 41

B-22 Inspect the Boom Extend/Retract Cables ................................................... 3 - 42

B Checklist C Procedures

C-1 Perform Engine Maintenance - Deutz Models ............................................. 3 - 44

C-2 Perform Engine Maintenance - Cummins Models ....................................... 3 - 44

C-3 Perform Engine Maintenance - Perkins Models .......................................... 3 - 45

C-4 Replace the Engine Air Filter ...................................................................... 3 - 45

C-5 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 46

C-6 Test the Platform Overload System (if equipped) ....................................... 3 - 47

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x

Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist D Procedures

D-1 Check the Boom Wear Pads ...................................................................... 3 - 49

D-2 Check the Extendable Axle Wear Pads ...................................................... 3 - 50

D-3 Check the Free-wheel Configuration ........................................................... 3 - 51

D-4 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 52

D-5 Check the Turntable Rotation Gear Backlash ............................................. 3 - 53

D-6 Replace the Drive Hub Oil .......................................................................... 3 - 54

D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 57

D-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 58

D-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 58

D-10 Perform Engine Maintenance - Cummins Models ....................................... 3 - 59

D-11 Replace the Hydraulic Filter Elements ........................................................ 3 - 59

C Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 62

E-2 Perform Engine Maintenance - Cummins Models ....................................... 3 - 64

E-3 Perform Engine Maintenance - Perkins Models .......................................... 3 - 64


E-5 Perform Engine Maintenance - Deutz Models ............................................. 3 - 65








E-13 Replace the Boom Extend/Retract Cables .................................................. 3 - 69

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Section 4 Rev Repair Procedures

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

E Display Module ...................................................................................................... 4 - 2

C Platform Controls

1-1 Circuit Boards .............................................................................................. 4 - 7

1-2 Membrane Decal .......................................................................................... 4 - 8

1-3 Joystick Controllers ...................................................................................... 4 - 9

B Platform Components

2-1 Platform ..................................................................................................... 4 - 16

2-2 Platform Leveling Cylinder .......................................................................... 4 - 16

2-3 Platform Rotator ......................................................................................... 4 - 18

2-4 Platform Level Sensor ................................................................................ 4 - 21

2-5 Platform Overload System ......................................................................... 4 - 22

A Jib Boom Components, S-105 and S-125 Models

3-1 Jib Boom, S-105 and S-125 Models ........................................................... 4 - 24

3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models ........................................ 4 - 26

A Boom Components

4-1 Cable Track ................................................................................................ 4 - 29

4-2 Boom ......................................................................................................... 4 - 32

4-3 Boom Lift Cylinder ...................................................................................... 4 - 43

4-4 Extension Cylinders ................................................................................... 4 - 45

4-5 Boom Extend/Retract Cables ..................................................................... 4 - 49

TABLE OF CONTENTS

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xii

Section 4 Rev Repair Procedures, continued

A Turntable Covers

5-1 Turntable Covers ........................................................................................ 4 - 53

B Engines

6-1 RPM Adjustment ........................................................................................ 4 - 55

6-2 Flex Plate................................................................................................... 4 - 55

6-3 Oil Pressure and Coolant Temperature Sending Units,Cummins and Perkins Models .................................................................... 4 - 57

6-4 Oil Pressure and Temperature Sending Units, Deutz Models ..................... 4 - 57

A Ground Controls

7-1 Circuit Boards ............................................................................................ 4 - 58

7-2 Membrane Decal ........................................................................................ 4 - 59

7-3 Control Relays ............................................................................................ 4 - 60

A Limit Switches

8-1 Limit Switches ............................................................................................ 4 - 63

8-2 Limit Switch and Level Sensor Locations ................................................... 4 - 66

8-3 Limit Switch Functions ............................................................................... 4 - 67

A Hydraulic Pumps

9-1 Function Pumps ......................................................................................... 4 - 70

9-2 Drive Pump ................................................................................................ 4 - 71

9-3 Auxiliary Pump ........................................................................................... 4 - 74

A Manifolds

10-1 Function Manifold Components, S-100 and S-105 Models(serial number 136) ..................................................................................... 4 - 76

10-2 Function Manifold Components, S-100 and S-105 Models(after serial number 136) ............................................................................. 4 - 80

10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models .............. 4 - 84

10-4 Proportional Valves - Function Manifold ..................................................... 4 - 85

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10-5 Function Manifold Components, S-120 and S-125 Models(before serial number 431) .......................................................................... 4 - 86

10-6 Function Manifold Components, S-120 and S-125 Models(from serial number 431 to 574) .................................................................. 4 - 90

10-7 Function Manifold Components, S-120 and S-125 Models(after serial number 574) ............................................................................. 4 - 94

10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models .............. 4 - 98

10-9 Proportional Valves - Function Manifold ..................................................... 4 - 99

10-10 Platform Manifold Components, S-100 and S-120 Models .........................4 - 100

10-11 Platform Manifold Components, S-105 and S-125 Models .........................4 - 102

10-12 Proportional Valves - Platform Manifolds ...................................................4 - 104

10-13 Platform Rotate Counterbalance Valve Manifold Components ...................4 - 104

10-14 Turntable Rotation Manifold Components ..................................................4 - 105

10-15 Steer and Axle Extend/Retract Manifold Components - View 1 .................4 - 106

10-16 Steer and Axle Extend/Retract Manifold Components - View 2 .................4 - 108

10-17 Valve Adjustments - Steer and Axle Extend/Retract Manifold ...................4 - 112

10-18 Traction Manifold Components(S-100/105 before serial number 291)(S-120/125 before serial number 1195) ......................................................4 - 114

10-19 Traction Manifold Components(S-100/105 after serial number 290)(S-120/125 after serial number 1194) .........................................................4 - 118

10-20 Valve Adjustments - Traction Manifold ......................................................4 - 122

10-21 Valve Coils ................................................................................................4 - 122

TABLE OF CONTENTS

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xiv


A Fuel and Hydraulic Tanks

11-1 Fuel Tank ..................................................................................................4 - 125

11-2 Hydraulic Tank ..........................................................................................4 - 126

A Turntable Rotation Components

12-1 Turntable Rotation Hydraulic Motor and Drive Hub ....................................4 - 128

A Axle Components

13-1 Steer Sensors ...........................................................................................4 - 132

13-2 Yoke and Hub ...........................................................................................4 - 134

13-3 Drive Motor ...............................................................................................4 - 136

13-4 Drive Hub ..................................................................................................4 - 137

13-5 Steering Cylinders .....................................................................................4 - 138

13-6 Extendable Axles ......................................................................................4 - 139

Section 5 Rev Diagnostic Codes

Introduction ............................................................................................................ 5 - 1

Diagnostic Code Chart ........................................................................................... 5 - 3

Control System Fault Codes .................................................................................. 5 - 9

Software .............................................................................................................. 5 - 10

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Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1

A Circuit Numbering .................................................................................................. 6 - 2

A Wire Color Legend .................................................................................................. 6 - 4

A Limit Switches ....................................................................................................... 6 - 8

A Relay Layout ........................................................................................................ 6 - 10

A Drive Chassis Controller Pin Legend .................................................................... 6 - 11

A Platform Controller Pin Legend ............................................................................. 6 - 12

A Turntable Controller Pin Legend ........................................................................... 6 - 13

A Electrical Symbols Legend .................................................................................. 6 - 14

A Hydraulic Symbols Legend .................................................................................. 6 - 15

A Safety Circuit Schematic ..................................................................................... 6 - 17

A Engine Options- Perkins and Cummins(S-100/105 before serial number 219)(S-120/125 before serial number 933) ......................................................... 6 - 19

A Engine Options- Perkins(S-100/105 from serial number 219 to 247)(S-120/125 from serial number 933 to 984) ................................................. 6 - 21

A Engine Options- Perkins(S-100/105 from serial number 248)(S-120/125 from serial number 985) ............................................................ 6 - 24

A Engine Options- Cummins(S-100/105 from serial number 219 to 247)(S-120/125 from serial number 933 to 984) ................................................. 6 - 25

A Engine Options- Cummins(S-100/105 from serial number 248)(S-120/125 from serial number 985) ............................................................ 6 - 28

A Electrical Schematic - Generator Options ............................................................ 6 - 30

A Electrical Schematic - 12 kW Generator (welder option) ....................................... 6 - 31

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S-100 • S-105 • S-120 • S-125 Part No. 102916xvi

TABLE OF CONTENTS

Section 6 Rev Schematics, continued

A Electrical Schematic (ES105C, ES125G)(S-100/105 before serial number 231)(S-120/125 before serial number 921) ............................ located at end of manual

A Electrical Schematic (ES0427)(S-100/105 from serial number 231 to 809)(S-120/125 from serial number 921 to 2709) .................. located at end of manual

A Electrical Schematic (ES0509)(S100/105 from serial number 810)(S120/125 from serial number 2710) .............................. located at end of manual

A Hydraulic Schematic - 12 kW Generator (welder option) ...................................... 6 - 33

A Hydraulic Schematic, S-100 • S-105(serial number 136) ..................................................................................... 6 - 36

A Hydraulic Schematic, S-100 • S-105(from serial number 137 to 290) .................................................................. 6 - 37

A Hydraulic Schematic, S-100 • S-105from serial number 291 to serial number 738) ............................................. 6 - 40

A Hydraulic Schematic, S-100 • S-105from serial number 739) .............................................................................. 6 - 41

A Hydraulic Schematic, S-120 • S-125(from serial number 404 to serial number 430) ............................................ 6 - 44

A Hydraulic Schematic, S-120 • S-125(from serial number 431 to serial number 1194) .......................................... 6 - 45

A Hydraulic Schematic, S-120 • S-125(from serial number 1195 to serial number 2634) ........................................ 6 - 48

A Hydraulic Schematic, S-120 • S-125(from serial number 2635) ........................................................................... 6 - 49

Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 1

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Section 2 • Specifications

Specifications

Machine Specifications,S-120 and S-125 Models

Stowed dimensions S-120 S-125

Length, transport position 39 ft 11 in 39 ft 11 in12.17 m 12.17 m

Length, stowed 42 ft 8 in 46 ft 9 in13 m 14.25 m

Width, axles retracted 8 ft 2 in 8 ft 2 in249 cm 249 cm

Width, axles extended 11 ft 11 ft335 cm 335 cm

Height, stowed maximum 10 ft 1 in 10 ft 1 in308 cm 308 cm

Weight 44,340 lbs 44,640 lbs20,112 kg 20,248 kg

Ground clearance 15 3/4 in 15 3/4 in40 cm 40 cm

Operational dimensions

Platform height, maximum 120 ft 125 ft36.6 m 38.1 m

Working height, maximum 126 ft 131 ft38.4 m 39.9 m

Horizontal reach maximum 75 ft 80 ft22.9 m 24.4 m

Maximum load capacity 750 lb 500 lb340 kg 227 kg

Turntable tailswing, 66 in 66 inaxles retracted 168 cm 168 cm

Turntable tailswing 48 in 48 inaxles extended 122 cm 122 cm

Wheelbase 12 ft 12 ft366 cm 366 cm

Turning radius, outside, 22 ft 2 in 22 ft 2 inaxles retracted 6.75 m 6.75 m

Turning radius, inside, 13 ft 2 in 13 ft 2 inaxles retracted 4.01 m 4.01 m

Turning radius, outside, 18 ft 10 in 18 ft 10 inaxles extended 5.74 m 5.74 m

Turning radius, inside, 8 ft 6 in 8 ft 6 inaxles extended 2.59 m 2.59 m

Turntable rotation (degrees) 360° continuous

Platform rotation 160°

Maximum allowable 150 lbsside force (ANSI and CSA) 667 N

Maximum allowable 90 lbsside force (CE) 400 N

Controls 12V DC proportional

Platform dimensions

Length 96 in244 cm

Width 36 in91 cm

Tires and wheels

Tire size 445/65D22.5, FF

Tire ply rating 18

Tire weight, new foam-filled (minimum) 815 lbs370 kg

Overall tire diameter 46.5 in118 cm

Wheel diameter 22.5 in57 cm

Wheel width 13 in33 cm

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs570 Nm

Lug nut torque, lubricated 320 ft-lbs434 Nm

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Performance Specifications,S-120 and S-125 Models

Drive speeds

High drive speed, stowed 8.0 - 8.4 sec 36 ft / 11 m

Low drive speed, stowed 14.4 - 16.4 sec 18 ft / 5.5 m

High drive speed,non-stowed < 80 ft 18 - 20 sec 18 ft / 5.5 m

High drive speed,non-stowed > 80 ft 32.6 - 36.6 sec 18 ft / 5.5 m

Braking distance, maximum

High range on paved surface 4 to 6 ft1.2 to 1.8 m

Gradeability (boom stowed) See Operators Manual

SPECIFICATIONS

Fluid capacities

Hydraulic tank 55 gallons208 liters

Hydraulic system 80 gallons(including tank) 303 liters

Fuel tank 40 gallons151 liters

Coolant capacity 20 quarts18.9 liters

Drive hubs 47 oz1.4 liters

Turntable rotation 93 ozdrive hub 2.8 liters

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

For operational specifications, refer to theOperator's Manual.

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.

Boom function speeds, maximumfrom platform controls

Jib boom up (S-125 models) 28 to 32 seconds

Jib boom down (S-125 models) 28 to 32 seconds

Boom up

Boom fully retracted 80 to 88 seconds

Boom extended to >4 ft / >1.2 m 100 to 110 seconds(time between fully lowered anda fully raised position)

Boom extended to >80 ft / >24.4 m 50 to 55 seconds(time between 53° envelopelimit and a fully raised position)


Boom down


Boom extended to >4 ft / >1.2 m 100 to 110 seconds(time between fully raised anda fully lowered position)

Boom extended to >80 ft / >24.4 m 50 to 55 seconds(time between fully raised andthe 50° envelope limit)


Boom extendvertical, 0 to 120 ft / 0 to 36.6 m 170 to 190 seconds

Boom retractvertical, 120 ft to 0 / 36.6 m to 0 170 to 190 seconds

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SPECIFICATIONS

Turntable rotate, 360°boom horizontal andfully retracted 170 to 190 seconds

Turntable rotate, 360°boom horizontal and 63 to 70 secondsextended >0 ft / >0 m drive enable to drive enable

Turntable rotate, 360°boom fully raised and 109 to 120 secondsextended >80 ft / >24.4 m drive enable to drive enable

Platform rotate, 160° 18 to 22 seconds

Machine Specifications,S-100 and S-105 Models

Stowed dimensions S-100 S-105

Length, transport position 39 ft 11 in 39 ft 11 in12.17 m 12.17 m

Length, stowed 42 ft 8 in 46 ft13 m 14 m

Width, axles retracted 8 ft 2 in 8 ft 2 in249 cm 249 cm

Width, axles extended 11 ft 11 ft335 cm 335 cm

Height, stowed maximum 10 ft 1 in 10 ft 1 in308 cm 308 cm

Weight 39,700 lbs 40,000 lbs18,007 kg 18,143 kg

Ground clearance 151/2 in 151/2 in39 cm 39 cm

Operational dimensions

Platform height, maximum 100 ft 105 ft30.5 m 32 m

Working height, maximum 106 ft 111 ft32.3 m 33.8 m

Horizontal reach maximum 75 ft 80 ft22.9 m 24.4 m

Maximum load capacity 750 lb 500 lb340 kg 227 kg

Turntable tailswing, 66 in 66 inaxles retracted 168 cm 168 cm

Turntable tailswing 48 in 48 inaxles extended 122 cm 122 cm

Wheelbase 12 ft 12 ft366 cm 366 cm

Turning radius, outside, 21 ft 7 in 21 ft 7 inaxles retracted 6.58 m 6.58 m

Turning radius, inside, 13 ft 7 in 13 ft 7 inaxles retracted 4.14 m 4.14 m

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Turning radius, outside, 19 ft 10 in 19 ft 10 inaxles extended 6.05 m 6.05 m

Turning radius, inside, 9 ft 9 ftaxles extended 2.74 m 2.74 m

Turntable rotation (degrees) 360° continuous

Platform rotation 160°

Maximum allowable 150 lbsside force (ANSI and CSA) 667 N

Maximum allowable 90 lbsside force (CE) 400 N

Controls 12V DC proportional

Platform dimensions

Length 96 in244 cm

Width 36 in91 cm

Tires and wheels

Tire size IN385/65D22.5, FF

Tire ply rating 18

Tire weight, new foam-filled (minimum) 622 lbs282 kg

Overall tire diameter 43.1 in109.5 cm

Wheel diameter 22.5 in57 cm

Wheel width 11.75 in30 cm

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs570 Nm

Lug nut torque, lubricated 320 ft-lbs434 Nm

Fluid capacities

Hydraulic tank 55 gallons208 liters

Hydraulic system 80 gallons(including tank) 303 liters

Fuel tank 40 gallons151 liters

Coolant capacity 20 quarts18.9 liters

Drive hubs 47 oz1.4 liters

Turntable rotation 93 ozdrive hub 2.8 liters

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

For operational specifications, refer to theOperator's Manual.

SPECIFICATIONS


Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 5

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Performance Specifications,S-100 and S-105 Models

Drive speeds

High drive speed, stowed 8.0 - 8.4 sec 36 ft / 11 m

Low drive speed, stowed 14.4 - 16.4 sec 18 ft / 5.5 m

High drive speed,non-stowed < 80 ft 18 - 20 sec 18 ft / 5.5 m

High drive speed,non-stowed > 80 ft 32.6 - 36.6 sec 18 ft / 5.5 m

Braking distance, maximum

High range on paved surface 4 to 6 ft1.2 to 1.8 m

Gradeability (boom stowed) See Operator's Manual

Boom function speeds, maximumfrom platform controls

Jib boom up (S-105 models) 28 to 32 seconds

Jib boom down (S-105 models) 28 to 32 seconds

Boom up


Boom extended to >4 ft / >1.2 m 100 to 110 seconds(time between fully lowered anda fully raised position)


Boom down


Boom extended to >4 ft / >1.2 m 100 to 110 seconds(time between fully raised anda fully lowered position)


Boom extend, boom fully raised0 to 100 ft / 0 to 30.5 m 120 to 140 seconds

Boom retract, boom fully raised100 ft to 0 / 30.5 m to 0 120 to 140 seconds

Turntable rotate, 360°boom horizontal andfully retracted 170 to 190 seconds

Turntable rotate, 360°boom horizontal and 63 to 70 secondsextended >0 ft / >0 m drive enable to drive enable

Turntable rotate, 360°boom fully raised and 109 to 120 secondsextended >80 ft / >24.4 m drive enable to drive enable

Platform rotate, 160° 18 to 22 seconds

SPECIFICATIONS

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SPECIFICATIONS

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD PremiumMV Equivalent

Viscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rando HD oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Continued use of Chevron AviationA hydraulic oil when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.

Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistentlybelow 0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.


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SPECIFICATIONS

Hydraulic ComponentSpecifications

Drive pump

Type: bi-directional variable displacement piston pump

Displacement 0 to 2.8 cu in0 to 46 cc

Flow rate @ 2350 rpm, maximum 28.5 gpm108 L/min

Drive pressure, maximum 3625 psi250 bar

Charge pump

Type: gerotor

Displacement 0.85 cu in13.9 cc

Flow rate @ 2350 rpm 9 gpm34 L/min

Charge pressure @ 2350 rpm 315 psiNeutral position 21.7 bar

Function pump

Type: variable displacement piston pump

Front Section


Flow rate @ 2350 rpm, maximum 17.4 gpm65.9 L/min

Rear Section


Flow rate @ 2350 rpm, maximum 11.2 gpm42.4 L/min

Pressure, maximum continuous 3350 psi231 bar

Standby pressure 250 psi17 bar

Auxiliary pumps

Type: fixed displacement gear pump

Displacement 0.15 cu in2.47 cc

Function manifold

Function relief pressure 2600 psi(measured at TEST port) 179.3 bar

Platform relief pressure 3000 psi(measured at TEST port 2) 207 bar

Jib and platform manifolds

Platform rotate and platform level 0.3 gpmflow regulator 1.14 L/min

Jib manifold flow regulator 2 gpm7.6 L/min


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SPECIFICATIONS

Steer/Axle manifold

Axle extend relief pressure 1800 psi124 bar

Drive manifold

Hot oil relief pressure:S-100/105 before serial number 291 250 psiS-120/125 before serial number 1195 17.2 bar

Hot oil relief pressure:S-100/105 after serial number 290 280 psiS-120/125 after serial number 1194 19.3 bar

Brakes

Brake release pressure 174-189 psi12-13 bar

Drive motors

Displacement per revolution, 0.8 cu inhigh speed 13.3 cc

Displacement per revolution, 2.7 cu inlow speed 45 cc

Hydraulic filters

High pressure filter Beta 3 200

High pressure filter 102 psibypass pressure 7 bar

Medium pressure filter Beta 3 200

Medium pressure filter 25 psibypass pressure 1.7 bar

Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass

Drive motor case drain Beta 10 2return filter


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Injection system

Injection pump make IMSA

Injection pump pressure 8702 psi600 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement

For fuel requirements, refer to the engine Operator'sManual on your machine.

Alternator output 55A, 12 VDC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Battery - Engine starting

Type 12V, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 175 minutes

Battery - Control system

Type 12V DC, Group 4DQuantity 1Cold cranking ampere 1020AReserve capacity @ 25A rate 300 minutes

Deutz Engine F4L 913

Displacement 249.3 cu in4.086 liters

Number of cylinders 4

Bore and stroke 4.02 x 4.92 inches102 x 125 mm

Horsepower 77 @ 2200 rpm

Firing order 1 - 3 - 4 - 2

Compression ratio 18:1

Compression pressurepressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Low idle rpm 1300 rpmFrequency 385.7 Hz

High idle rpm 2350 rpmFrequency 570.4 Hz

Valve clearance, cold

Intake 0.006 in0.15 mm

Exhaust 0.006 in0.15 mm

Lubrication system

Oil pressure 40 to 60 psi2.75 to 4.14 bar

Oil capacity 14.3 quarts(including filter) 13.5 liters

Oil viscosity requirements

Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

SPECIFICATIONS

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SPECIFICATIONS

Deutz BF4L 2011 Engine




Horsepower

Continuous @ 2500 rpm 69.1Net intermittent @ 2500 rpm 72.8




Compression ratio 17.5:1

Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Governor centrifugal mechanical




Lubrication system

Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar



Units ship with 15W-40.Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

Oil temperature switch

Torque 8-18 ft-lbs11-24 Nm

Oil temperature switch point 275°F135°C

Oil pressure switch


Oil pressure switch point 7 psi0.48 bar

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum 15,000 psi1034 bar


Fuel requirement


Starter motor

Current draw, normal load 140-200A

Cranking speed 200-250 rpm





Alternator output 80A @ 14V DC


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SPECIFICATIONS

Lubrication system




-22°F to 86°F / -30°C to 30°C 5W-30(synthetic)

-4°F to 104°F / -20°C to 40°C 10W-40

Above 5°F / -15°C 15W-40

Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

Oil temperature switch

Installation torque 8-18 ft-lbs11-24 Nm

Oil temperature switch point 275°F135°C

Oil pressure switch



Deutz TD2011L04i Engine




HorsepowerNet intermittent @ 2400 rpm 74 / 55 kW

Induction system turbocharged


Low idle 1500 rpm383 Hz

High idle 2350 rpm599 Hz








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Injection pump make Motorpal

Injection pump pressure, maximum 15,000 psi1034 bar


Fuel requirement


Starter motor



Battery - Auxiliary power units

Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes

Battery - Engine starting and control system

Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes



SPECIFICATIONS

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Perkins Engine 1004-42

Displacement 258 cu in4.23 liters


Bore & stroke 4.06 x 5 inches103.1 x 127 mm










Lubrication system

Oil pressure 51 psi3.45 bar




Injection system

Injection pump make Zexel


Fuel requirement


Alternator output 55A, 12V DC


Battery - System

Type 12V, Group 27TMQuantity 1AH rating 109AHCold cranking ampere 630AReserve capacity @ 25A rate 160 minutes


Type 12V, Group 4DQuantity 1AH rating 190AHCold cranking ampere 1020AReserve capacity @ 25A rate 325 minutes

Cooling system

Engine capacity 9.5 quarts9 liters

System capacity 20 quarts18.9 liters

SPECIFICATIONS


2 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916

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SPECIFICATIONS

Perkins 1104C-44 Engine



Bore and stroke 4.13 x 5 inches105 x 127 mm

Horsepower

Gross intermittent @ 2400 rpm 86Net intermittent @ 2400 rpm 83



Low Idle with belt-driven generator option 1400 rpmFrequency 340.7 Hz








Lubrication system





Oil pressure sending unit






Fuel requirement



Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 15

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Starter motor



Engine coolant

Capacity 14 quarts13.2 liters

Coolant temperature sending unit


Temperature switch point 230°F 110°C

Alternator output 85A @ 13.8V DC

Fan belt deflection 3/8 inch10 mm

SPECIFICATIONS

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Perkins 804D-33T Engine




Horsepower

Gross intermittent @ 2500 rpm 83 / 62 kW

Induction system turbocharged










Lubrication system


Oil capacity 10.6 quarts(including filter) 10 liters


Below 86°F / 30°C 5W-30

-4°F to 104°F / -20°C to 40°C 10W-30

Above 14°F / -10°C 15W-40


Oil pressure sending unit






Fuel requirement






Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 17

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Starter motor

Current draw, normal load 200A

Cranking speed 250 rpm

Engine coolant

Capacity 12.5 quarts11.8 liters





Fan belt deflection 3/8 to 1/2 in9 to 12 mm

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SPECIFICATIONS

Cummins B3.3T Engine




Horsepower 80 @ 2200 rpm60 kW @ 2200 rpm









Lubrication system

Oil pressure, hot 31 to 72 psi(at 2000 rpm) 2 to 5 bar

Oil capacity 9 quarts(including filter) 8.5 liters


Below 68°F / 20°C 5W-30

-10° to 68°F / -23° to 20°C 10W-30

Above 14°F / -10°C 15W-40



Injection pump make Zexel

Injection pressure 12,000 psi827 bar

Fuel requirement






Starter motor

Current draw, maximum 550A

Engine cranking speed, minimum 130 rpm

Engine coolant

Capacity 9.1 quarts8.6 liters


Fan belt deflection 3/8 to 1/2 inch10 to 12.5 mm

Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 19

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Injection system


Injection pump pressure 5500 psi379.2 bar


Fuel requirement



Battery - System

Type 12V, Group 27TMQuantity 1AH rating 109AHCold cranking ampere 630AReserve capacity @ 25A rate 160 minutes


Type 12V, Group 4DQuantity 1AH rating 190AHCold cranking ampere 1020AReserve capacity @ 25A rate 325 minutes

Cooling system

Engine capacity 8.8 quarts8.3 liters

System capacity 20 quarts18.9 liters

Cummins B3.9L Engine













Lubrication system

Oil pressure 50 psi3.45 bar





SPECIFICATIONS

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SPECIFICATIONS

Cummins B4.5L Engine













Lubrication system

Oil pressure, hot 50 psi(at 2000 rpm) 3.45 bar





Injection pump make Delphi

Injection pump pressure 3480 to 3680 psi240 to 254 bar


Fuel requirement






Starter motor

Current draw, no load 125A

Brush length, minimum 0.72 in18.3 mm

Engine coolant

Capacity 17 quarts16 liters





Fan belt deflection 3/8 to 1/2 inch10 to 12.5 mm

Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 21

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Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 14 ft-lbs / 18.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 48.8 Nm

-10 62 ft-lbs / 84.1 Nm

-12 84 ft-lbs / 113.9 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 250 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Machine Torque Specifications

Platform rotator

1-8 center bolt, GR 5, dry 640 ft-lbs868 Nm

1-8 center bolt, GR 5, lubricated 480 ft-lbs651 Nm

3/8 -16 bolts, GR 8, lubricated 35 ft-lbs**use blue thread-locking compound 47.5 Nm

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Rotate drive hub mounting bolts, dry 380 ft-lbs515 Nm

Rotate drive hub mounting bolts, lubricated 280 ft-lbs**use blue thread-locking compound 380 Nm

Rotate drive motor mounting bolts, dry 110 ft-lbs149 Nm

Rotate drive motor mounting bolts, lubricated 80 ft-lbs108 Nm

Drive motor and hubs

Drive hub mounting bolts, dry 269 ft-lbs365 Nm

Drive hub mounting bolts, lubricated 202 ft-lbs274 Nm

Drive motor mounting bolts, dry 110 ft-lbs149 Nm

Drive motor mounting bolts, lubricated 80 ft-lbs108 Nm

Drive hub oil plug, O-ring seal 13 ft-lbs18 Nm


SPECIFICATIONS

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SPECIFICATIONS

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.

Note: The O-rings used in the Parker Seal Lok®fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

Manifold Plug TorqueSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 14 ft-lbs / 18.9 Nm




SAE No. 12 84 ft-lbs / 113.9 Nm

Part No. 102916 S-100 • S-105 • S-120 • S-125 2 - 23

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SPECIFICATIONS

10.9 12.98.84.6

2 - 24 S-100 • S-105 • S-120 • S-125 Part No. 102916

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SPECIFICATIONS

Section 3 • Scheduled Maintenance Procedures

Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 1

June 2011

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every two years as specified on theMaintenance Inspection Report.

Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

• Machine parked on a firm, level surface• Boom in the stowed position• Turntable rotated with the boom between

the circle-end (yellow arrow) wheels• Turntable secured with the turntable

rotation lock pin• Key switch in the off position with the

key removed• Wheels chocked• All external AC power supply disconnected

from the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.


Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Scheduled Maintenance Procedures


3 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916

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Maintenance Symbols Legend

Note: The following symbols have been used in thismanual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

SCHEDULED MAINTENANCE PROCEDURES

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two years.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine which group(s)of procedures are required to perform a scheduledinspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two years or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and governmental regulationsand requirements.

Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and re-inspect it. After repair, place acheck in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover ifanything is apparently wrong with a machine before it isput into service.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered conditionis discovered, the machine must be tagged and removedfrom service.

Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.

Scheduled maintenance inspections shall be performedby qualified service technicians, according to themanufacturer's specifications and the requirements listedin the responsibilities manual.


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Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 5

June 2011

Maintenance Inspection Report

Checklist B - Rev E Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Oil cooler and fins -Deutz models

B-4 Inspect air filter

B-5 Hydraulic oil analysis

B-6 Engine maintenance -Deutz models

B-7 Engine maintenance -Cummins models

B-8 Exhaust system

B-9 Lug nut torque

B-10 Drive hub oil level

B-11 Drive brakes

B-12 Engine RPM

B-13 Key switches

B-14 Ground controloverride

B-15 Platform self-leveling

B-16 Limit switches

B-17 Fuel and hydraulic tankventing systems

B-18 Engine idle selectoperation

B-19 Test the drive brakes

B-20 Drive speed - stowedposition

B-21 Drive speed - raisedor extended position

B-22 Inspect the BoomExtend/Retract Cables

Checklist A - Rev B Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Perform function tests

A-4 Engine maintenance -Perkins models

A-5Engine maintenance -Cummins models

A-6 Hydraulic filtercondition indicator

Perform after 40 hours:

A-7 30 Day Service

Perform every 50 hours:

A-8 Engine Maintenance-Perkins models


A-9 Engine Maintenance-Deutz models


A-10 Grease rotation bearing

A-11 Grease axles


A-12 Replace drive hub oil

Instructions• Make copies of this report to use

for each inspection.

• Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Semi-annual or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriatebox after each inspectionprocedure is completed.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”,tag and remove the machine fromservice, repair and re-inspect it.After repair, place a check in the“R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Comments


3 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916

June 2011

MAINTENANCE INSPECTION REPORT

Instructions• Make copies of this report to use

for each inspection.

• Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Semi-annual or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriatebox after each inspectionprocedure is completed.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”,tag and remove the machine fromservice, repair and re-inspect it.After repair, place a check in the“R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Checklist C - Rev B Y N R

C-1 Engine maintenance -Deutz models

C-2 Engine maintenance -Cummins models

C-3 Engine maintenance -Perkins models

C-4 Replace air filterelement

C-5 Grease platformoverload (if equipped)

C-6 Test the platformoverload (if equipped)

Checklist D - Rev A

D-1 Boom wear pads

D-2 Extendable axlewear pads

D-3 Free-wheelconfiguration

D-4 Turntable rotationbearing bolts

D-5 Rotation gear backlash

D-6 Drive hub oil

D-7 Turntable bearing wear

D-8 Engine maintenance -Deutz models

D-9 Engine maintenance -Perkins models

D-10 Engine maintenance -Cummins models

D-11 Replace the hydraulicfilter elements

Checklist E - Rev C Y N R

E-1 Replace hydraulic oil

E-2 Engine maintenance -Cummins models

E-3 Engine maintenance -Deutz models

Perform every two years:

E-4 Engine maintenance -Perkins models













Perform every 10 years:

E-13 Replace the BoomExtend/Retract cables

Comments


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 7

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A-1Inspect the Manuals and DecalsGenie requires that this procedure be performeddaily.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with each machineand should be stored in the container provided inthe platform. An illegible or missing manual will notprovide safety and operational informationnecessary for a safe operating condition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and could resultin unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is not appropriatefor the machine or all manuals are not in goodcondition or is illegible. Remove the machinefrom service until the manual is replaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible and ingood condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.

Checklist A Procedures


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A-3Perform Function TestsGenie requires that this procedure be performeddaily.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate operator's manual. Referto the Operator's Manual on your machine.

A-2Perform Pre-operationInspectionGenie requires that this procedure be performeddaily.

Completing a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate operator's manual. Referto the Operator's Manual on your machine.

CHECKLIST A PROCEDURES


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A-4Perform Engine Maintenance -Perkins Models

Engine specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.

Required maintenance procedures and additionalengine information are available in thePerkins 1004 User's Handbook(Perkins part number TPD 1349E) OR thePerkins 1100 Series User's Handbook(Perkins part number TPD 1477).

Perkins 1004 User's HandbookGenie part number 61376

Perkins 1100 Series User's HandbookGenie part number 107526


A-5Perform Engine Maintenance -Cummins Models

Engine specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.


Required maintenance procedures and additionalengine information are available in theCummins B4.5 and B3.9L Operation andMaintenance Manual (Cummins part number4021389-01).

Cummins B4.5 and B3.9L Operation andMaintenance ManualGenie part number 107527


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a

A-6Check the Hydraulic FilterCondition Indicators

Genie requires that this procedure be performeddaily.

Note: Perform this procedure after the machinereaches operating temperature. The amount of timethis takes will vary, depending on ambient airtemperature.

Maintaining the hydraulic filters in good condition isessential to good system performance and safemachine operation. The filter condition indicatorswill show when the hydraulic flow is bypassing aclogged filter. If the filters are not frequentlychecked and replaced, impurities will remain in thehydraulic system and cause component damage.

Note: There are four hydraulic filters on themachine: one tank return filter, one mediumpressure filter and two high pressure filters. All thefilters have condition indicators on them, except themedium pressure filter.

1 Start the engine from the ground controls.

2 Press and release the engine idle select buttonto change the engine rpm to high idle.

Tank return filter

Note: The tank return filter indicator needle mayoperate in the red area when hydraulic oil is below50° F / 10° C.

Note: If the return filter indicator needle is notoperating in the green area after performingprevious daily procedures, continue running engineuntil hydraulic oil temperature is at least50° F / 10° C.

3 Open the ground control side turntable cover andinspect the filter condition indicator gauge.

a filter condition indicator gauge

Result: The needle on the gauge should beoperating in the green area. If the needle is inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter needs tobe replaced. See D-11, Replace the HydraulicFilter Elements.



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REV B CHECKLIST A PROCEDURES

a

b

c

Medium and high pressure filters

Note: The medium and high pressure filters aremounted to the engine side bulkhead.

4 Inspect the filter condition indicators.

a high pressure filtersb filter condition indicatorsc medium pressure filter

Result: The filter condition indicators should beoperating with the plungers in the green area. Ifany of the indicators display the plunger in thered area, this indicates that a hydraulic filter isbeing bypassed and the filter needs to bereplaced. See D-11, Replace the Hydraulic FilterElements.

A-7Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage. After thisinterval, refer to the maintenance checklists forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:

• A-10 Grease the Turntable RotationBearing and Rotate Gear

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

• B-10 Check the Drive Hub Oil Leveland Fastener Torque

• D-4Check the Turntable RotationBearing Bolts

• D-11 Replace the Hydraulic FilterElements


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A-8Perform Engine Maintenance -Perkins Models

Engine specifications require that this procedure beperformed every 50 hours or weekly, whichevercome first.





To access the engine:

1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.

2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.

Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.

A-9Perform Engine Maintenance -Deutz Models

Engine specifications require that this one-timeprocedure be performed after the first 50 hours.


Required maintenance procedures and additionalengine information are available in theDeutz F4L913 Operation Manual(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).

Deutz F4L913 Operation ManualGenie part number 62446

Deutz BF4L2011 Operation ManualGenie part number 84794






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A-10Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Remove the turntable rotation gear coverretaining fasteners and remove the gear coverfrom the machine.

2 Open the ground controls side turntable sidecover.

3 Locate the grease fitting below the groundcontrol box.

4 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches (10 to 13 cm) at a time and repeat thisstep until the entire bearing has been greased.

5 Apply grease to each tooth of the drive gear,located under the turntable.

6 Install the turntable rotation gear cover andretaining fasteners onto the machine.

Bodily injury hazard. Contact withthe turntable rotation gear couldresult in serious injury. Do notoperate the machine if theturntable rotation gear cover is notinstalled.


A-11Grease the Extendable Axles

Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.

Frequent lubrication to the front and rear extendableaxles helps to ensure the smooth operation of theaxles over the lifetime of the product. Two greasefittings are added at each extending axle. One todirect grease to the top sliding wear pad and one todirect grease to the bottom sliding wear pad.

a Top wear pad grease fittingb Side wear pad grease fitting

1 Locate the grease fittings on the extendableaxles covers.

a

b


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2 Thoroughly pump grease into each greasefitting. When grease is pumped into each fitting,a hose directs this lubrication to the top orbottom wear pad.

3 Cycle the extending axles in and out.

Genie recommends that the extending axles becycled in and out at least once a week.

A-12Replace the Drive Hub Oil

Genie specifications require that this one-timeprocedure be performed after the first 150 hours ofoperation.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil after the first 150 hoursmay cause the machine to perform poorly andcontinued use may cause component damage.

Drive Hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container. Refer to capacityspecifications

3 Drive the machine to rotate the hub until theplugs are located one at the side and the otherat the other side.

a drive hub plugs

4 Fill the hub with oil from either plug hole until theoil level is even with the bottom of both plugholes. Install the plugs.

5 Repeat steps 1 through 4 for all the other drivehubs.

a



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5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.

6 Install the drive hub assembly onto the machine.Lubricate and torque the drive hub mountingbolts to specification. Refer to Section 2,Specifications.

7 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug. Refer to Section 2, Specifications.

8 Install the turntable rotate drive motor hoses intothe turntable rotate drive motor and install theturntable rotate drive brake hose into theturntable rotate drive brake.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched.

9 Adjust the turntable rotation gear backlash. SeeD-5, Check the Turntable Rotation GearBacklash.

10 Install the ground control side fixed turntablecover onto the machine and tighten the retainingfasteners

6 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.

Turntable Rotate Drive Hub:

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Specifications.

1 Secure the turntable from rotating with theturntable rotation lock pin.

2 Remove the ground control side fixed turntablecover. Refer to Repair Section 5-1, How toRemove a Fixed Turntable Cover.

3 Tag, disconnect and plug the turntable rotatedrive motor hoses at the turntable rotate drivemotor and the turntable rotate drive brake hosesat the turntable rotate drive brake. Cap thefittings.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.


4 Remove the turntable rotate drive hub mountingbolts and pivot bolt. Remove the turntable rotatedrive hub with a suitable lifting device of amplecapacity.

Crushing hazard. The turntablerotate drive hub may becomeunbalanced and fall when it isremoved from the machine if it isnot properly supported.


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REV EChecklist B Procedures

B-1Inspect the Batteries

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions. There are 2 batteries on the machine.One starts the engine and the other powers thecontrol system. The batteries are charged by thealternator through a battery separator.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Open the engine side cover.

2 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosion onthe battery terminals and cables.

3 Be sure that the battery retainers and cableconnections are tight.

4 Fully charge the batteries. Allow the batteries torest 24 hours before performing this procedureto allow the battery cells to equalize.

5 Put on protective clothing and eye wear.

6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 +/- 0.007. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.269 or below. Proceed tostep 8.

8 Perform an equalizing charge OR fully chargethe batteries and allow the batteries to rest atleast 6 hours.

9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.


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10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specificgravity of 1.277 +/- 0.007. The battery is fullycharged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity from 1.269 to 1.218. The batteryis still useable, but at a lower performance sowill need to be recharged more often. Proceedto step 11.

Result: One or more battery cells display aspecific gravity from 1.217 to 1.173. The batteryis approaching the end of its life. Proceed tostep 11.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is 1.172or less. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled.

B-2Inspect the Electrical Wiring

Genie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

1 Open the engine side turntable cover.

2 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.

a engine pivot plate anchor holeb engine pivot plate retaining fastener

3 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.

CHECKLIST B PROCEDURES


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12 Start the engine from the ground controls andraise the boom above the turntable covers.

Component damage hazard. Besure the hydraulic supply hoses tothe function and drive pumps arenot kinked before starting theengine.

13 Inspect the turntable area for burnt, chafed andpinched cables.

14 Lower the boom to the stowed position and turnthe engine off.

15 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the boom· Cables on the boom, jib boom and jib boom

pivot area· Jib boom/platform rotate manifold· Platform control box· Inside of the platform control box

16 Inspect for a liberal coating of dielectric greasein the following location:

· All wire harness connectors toplatform control box

17 Remove the engine pivot plate retaining fastenerfrom the engine pivot plate anchor hole at thepivot end of the engine pivot plate.

18 Swing the engine pivot plate in towards themachine.

19 Install the bolt that was just removed into theoriginal hole to secure the engine pivot plate.

Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.

4 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.



· Engine wiring harness· Battery area wiring

6 Open the ground controls side turntable cover.


· Inside of the ground control box· Hydraulic manifold wiring· Battery area wiring· Hydraulic oil cooler wiring

8 Inspect for a liberal coating of dielectric greasein the following locations:

· All wire harness connectors toground control box

· Wire harness connectors

9 Open the hydraulic manifold box covers at bothsides of the drive chassis.


· Hydraulic manifold wiring

11 Inspect for a liberal coating of dielectric greasein the following location:

· Wire harness connectors to DCON module


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B-3Check the Engine Oil Cooler andCooling Fins - Deutz Models

Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

1 Open the engine side turntable cover.

Oil cooler

2 Remove the retaining fasteners from the engineside cover. Remove the cover.

3 Inspect the oil cooler for leaks and physicaldamage.

4 Clean the oil cooler of debris and foreignmaterial.


Cooling and blower fins

5 Inspect the fan blower fins for physical damage.

6 Clean the fan blower fins of debris and foreignmaterial.

7 Using a flashlight, inspect the head coolingpassages and fins for physical damage orforeign material.

8 If needed, clean the cylinder head coolingpassages and fins of debris and foreignmaterial.

9 Install the engine side cover and tighten theretaining fasteners.


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B-4Inspect the Engine Air Filter


Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.

Note: Perform this procedure with the engine off.

1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

a clampb cannister end capc dust discharge valve

2 Release the latches from the end cap of the airfilter canister. Remove the end cap.

3 Remove the filter element.

4 Clean the inside of the canister and the canisterend cap with a damp cloth.

5 Inspect the filter element. If needed, blow fromthe inside out using low pressure drycompressed air, or tap out dust, taking care notto damage the element.

6 Install the filter element.

7 Install the end cap onto the canister. Secure theclamps.

Note: Be sure the discharge slot is pointing down.


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B-5Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction straineror hydraulic filters may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.See E-1, Test or Replace the Hydraulic Oil.

B-6Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedure beperformed every 250 hours.











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B-8Check the Exhaust System


Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.

Bodily injury hazard. Beware of hotengine components. Contact withhot engine components may causesevere burns.

Cummins and Perkins models:

1 Be sure that all fasteners are tight.

2 Inspect all welds for cracks.

3 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

Deutz models:


B-7Perform Engine Maintenance -Cummins Models










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4 Be sure that all fasteners are tight.

5 Inspect all welds for cracks.

6 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.





ba


B-9Inspect the Tires, Wheelsand Lug Nut Torque


Maintaining the tires and wheels in goodcondition, including proper wheel fastener torque, isessential to safe operation and good performance.Tire and/or wheel failure could result in a machinetip-over. Component damage may also result ifproblems are not discovered and repaired in atimely fashion.

Note: The tires on these machines are foam filledand do not need air added to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.


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1 Remove the fixed turntable cover at the groundcontrols side of the machine.

2 Remove the power to platform plug panel upperretaining fasteners and loosen the lowerretaining fasteners. Do not disconnect thewiring.

3 Support the cover with a suitable lifting device.Protect the cover from damage.

4 Remove the cover retaining fasteners. Removethe cover from the machine.

Crushing hazard. The turntablecover may become unbalancedand fall when it is removed fromthe machine if it is not properlysupporte

5 Remove the plug located on the top of the drivebrake and check the oil level.

Result: The oil level should be even with thebottom of the plug hole.

B-10Check the Drive Hub Oil Leveland Fastener Torque


Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

Drive hubs:


a drive hub plugs

2 Remove both plugs and check the oil level.

Result: The oil level should be even with thebottom of the plug holes.

3 If necessary, add oil until the oil level is evenwith the bottom of the plug holes.

4 Install the plugs in the drive hub.

5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.

6 Repeat this procedure for each drive hub.

a


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a

b

c

B-11Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to be sureit is in the engaged position.

disengaged position

engaged position


a plugb turntable rotate drive hubc drive brake

6 If necessary, add oil until the oil level is evenwith the bottom of the plug hole.

7 Install the plug into the drive hub.


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2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on the drivepump.

a drive pumpb screwdriverc lift pumpd free-wheel valve

Note: The free-wheel valve should always remainclosed.

B-12Check and Adjust theEngine RPM


Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Deutz models:


2 Push one of the LCDscreen buttons shown untilengine rpm is displayed.

Result: Refer to Section 2, Specifications.

Skip to step 5 if the low idle rpm is correct.

3 Loosen the locknut on the low idle adjustmentscrew.

a low idle adjustment screw

a

a

d

c

b


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b

a

c

4 Adjust the low idle adjustment screw until lowidle is 1500 rpm. Tighten the locknut.

5 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.


If the high idle is correct, disregard adjustmentstep 6.

6 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.








Component damage hazard. Besure the hydraulic supply hoses tothe function and drive pumps arenot kinked before starting theengine.

5 Push one of the LCDscreen buttons shown untilengine rpm is displayed.


Perkins modelsa low idle adjustment screwb solenoid bootc yoke lock nut



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Skip to step 7 if the low idle rpm is correct.

6 Loosen the low idle lock nut. Turn the low idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

7 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.


Cummins modelsa low idle adjustment screwb solenoid cablec rpm solenoid


If the high idle is correct, disregard adjustmentstep 8.

8 Perkins models: Loosen the yoke lock nut.Turn the high idle adjustment nut and solenoidboot counterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.Cummins models: Turn the high idle solenoidboot counterclockwise to increase the rpm orclockwise to decrease the rpm. Recheck therpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.





a b c


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B-13Test the Key SwitchesGenie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

Proper key switch action and response is essentialto safe machine operation. Failure of either keyswitch to function properly could cause ahazardous operating situation.

There are two key switches on the machine - theMain key switch and the Service Bypass/Recoverykey switch.

The Main key switch controls machine operationfrom the ground or platform controls.

When the Service Bypass/Recovery key switch isturned to the service bypass position, the primaryboom can be raised while the axles are retracted.This feature of the machine is especially helpful forstorage purposes or when loading the machine fortransport.

Note: When the boom is raised with the axlesretracted, the boom cannot be rotated past eithercircle-end wheel.

When the Service Bypass/Recovery key switch isturned and held to the recovery position, theauxiliary power units will turn on and fully retract theboom and then lower the boom. This feature of themachine is especially helpful if the operator in theplatform cannot lower the boom, if the platformcontrols become inoperative or for returning themachine to a safe position when the safetyswitches have been tripped.

Note: Perform this procedure with the axlesretracted and the boom in the stowed position.

1 Open the ground controls side turntable sidecover.

2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

3 At the ground controls, turn the servicebypass/recovery key switch to the run position.

4 Turn the main key switch to ground control, startthe engine and then turn the key switch toplatform control.

5 Check any machine function from the groundcontrols.

Result: The machine functions should notoperate.

6 Turn the main key switch to ground control.

7 Check any machine function from the platformcontrols.

Result: The machine functions should notoperate.

8 Turn the main key switch to the off position.

Result: The engine should stop and no functionsshould operate.

9 Turn the main key switch to ground control andstart the engine.

STOP

00000

Run

ServiceBypass

Recovery


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10 Attempt to raise the primary boom.

Result: The boom should not raise.

Note: The primary boom will not raise until theaxles are fully extended.

11 Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.

Note: The main key switch should remain in theground control position.

12 Turn the service bypass/recovery key switch tothe service bypass position.

13 Raise the boom.

Result: The boom should raise.

14 Remove the key from the servicebypass/recovery key switch and insert the keyinto the main key switch.


16 Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.

17 Turn and hold the service bypass/recovery keyswitch to the recovery position.

Result: The boom should return to the stowedposition.

18 Turn the service bypass/recovery key switch tothe run position.

19 Remove the key from the servicebypass/recovery key switch and insert the keyinto the main key switch.


21 Close the turntable side cover.

B-14Test the Ground ControlOverrideGenie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton at the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the red Emergency Stop button at theplatform controls to the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.


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5 Push and hold a function enable/speed selectbutton and fully raise the boom.

Result: The platform should remain level atall times to within ±2 degrees.

Note: If the platform becomes out of level, the tiltalarm will sound and the Platform Not LevelIndicator will flash at the ground controls. Theplatform level up/down buttons will only work in thedirection that will level the platform. Level theplatform until the indicator light turns off.

6 Push and hold a function enable/speed selectbutton and fully lower the boom.

Result: The platform should remain level atall times to within ±2 degrees.

Note: If the platform becomes out of level, the tiltalarm will sound and the Platform Not LevelIndicator will flash at the ground controls. Theplatform level up/down buttons will only work in thedirection that will level the platform. Level theplatform until the indicator light turns off.

B-15Test the Platform Self-levelingGenie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained level by the communicationbetween the platform level sensor and the turntablelevel sensor. If the platform becomes out of level,the computer at the ground controls will open theappropriate solenoid valve(s) at the platformmanifold to maintain a level platform.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.

1 Start the engine from the platform controls andextend the axles.

2 Turn the key switch to ground controls.

3 Push and hold a function enable/speed selectbutton and fully retract the boom.

4 Push and hold a function enable/speed selectbutton and adjust the platform to a level positionusing the platform level up/down buttons.


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B-16Test the Safety Envelope andCircuitsGenie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

Testing the machine safety envelope is critical tosafe machine operation. If the boom is allowed tooperate when a safety switch is not functioningcorrectly, the machine stability is compromised andmay tip over.

Note: Refer to Repair Section 8-2, Limit Switch andLevel Sensor Locations for diagram showing thelocation of switches in this procedure.


2 Raise the boom to approximately 60°.

Note: For S-100 or S-105 models, proceed to step30.

101 feet / 30.8 m Length Safety Switch, LSB2RS:

3 Extend the boom to more than 80 feet / 24.4 m.

Machines before SN 2710:

4 Proceed to step 8.

Machines after SN 2709:

5 Push in the red Emergency Stop button to theoff position.

6 Plug in the LSB2RS test jumper between thelower limit switch and the function manifold (J2and J4 connectors on the ground control box).

7 Pull out the red Emergency Stop button to theon position and restart the engine.

8 Disconnect the 68° proximity switch LSB14AOand install a wire jumper between pin 3 and pin4 of the Deutsch connector.

Result: ">68 DEG" should be present on thedisplay screen at the ground controls.

9 Activate the function enable/high RPM buttonand extend the boom to 101 feet / 30.8 m.

Result: The engine should stop and the boomextend function should be disabled.

Result: If the engine does not stop and theboom continues to extend, the LSB2RS switchis out of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 101 feet /30.8 m without stopping theengine, stop immediately andretract the boom until the boom isextended to less than 100 feet /30.5 m. Failure to retract the boomcould result in death or seriousinjury.

10 Using auxiliary power, retract the boom until theboom is extended to approximately 95 feet/ 29 m.

11 Remove the wire jumper installed in step 8 andconnect the Deutsch connector to LSB14AO.


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S-100/105 models before SN 806:

S-120/125 models before SN 2710:

12 Proceed to step 15.

S-100/105 Models after SN 805:

S-120/125 Models after SN 2709:

13 Push in the red Emergency Stop button to theoff position.

14 Remove the LSB2RS test jumper between thelower limit switch and the function manifold (J2and J4 connectors on the ground control box).

15 Pull out the red Emergency Stop button to theon position and restart the engine.

65° Angle Safety Switch, LSB9AS:

16 Raise the boom to the maximum angle.

17 Fully extend the boom.


19 Activate the function enable/high RPM buttonand lower the boom to 65°.

Result: The engine should stop and the boomdown function should be disabled.

Result: If the engine does not stop and theboom continues to lower to less than 65°, theLSB9AS switch is out of adjustment or thewiring is faulty and will need to be replaced orrepaired. See Repair Section.

Bodily injury hazard. If the boomlowers to less than 65° withoutstopping the engine, stopimmediately and raise the boomuntil the boom is elevated togreater than 68°. Failure to raisethe boom could result in death orserious injury.

20 Measure the angle of the boom.

Result: The angle of the boom should be greaterthan 65°.

21 Using auxiliary power, raise the boom until theboom angle is greater than 68°.


23 With the key switch off, press and hold the button and turn the key switch to the on

position. Release the button after five

seconds and press the buttons.

24 Press the button until CLEAR ALL SAFETY SWITCH

FAULTS appears.

25 Select YES, then press the button.

26 Press the button until EXIT appears.


28 Restart the engine.

50° Angle Safety Switch, LSB8AS:

29 Lower the boom to approximately 60°.

30 Extend the boom to approximately95 feet / 28.96 m.



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32 Activate the function enable/high RPM buttonand lower the boom to 50°.

Result: The engine should stop and the boomdown function should be disabled.

Result: If the engine does not stop and theboom continues to lower to less than 50°, theLSB8AS switch is out of adjustment or thewiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the boomlowers to less than 50° withoutstopping the engine, stopimmediately and raise the boomuntil the boom is elevated togreaterthan 53°. Failure to raise the boomcould result in death or seriousinjury.

33 Measure the angle of the boom.

Result: the angle of the boom should be greaterthan 50°.

34 Using auxiliary power, raise the boom until theboom angle is greater than 53°.






FAULTS appears.




41 Restart the engine, retract the boom so it isextended less than 75 feet / 22.9 m and thenlower the boom sufficient to gain access toLSB3EO.

Note: LSB3EO is located on top of boom tubenumber 2 at the platform end of the machine.

76 feet / 23.2 m Length Safety Switch, LSB4ES:

42 Disconnect the 75 feet / 22.9 m safety switchLSB3EO.

43 Start the engine and activate the functionenable/high RPM button and extend the boom to76 feet / 23.2 m.

Result: The engine should stop and the boomextend function should be disabled.

Result: If the engine does not stop and theboom continues to extend, the LSB4ES switchis out of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 76 feet/ 23.2 m without stopping theengine, stop immediately andretract the boom until the boom isextended to less than 75 feet /22.9 m. Failure to retract the boomcould result in death or seriousinjury.


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44 Using auxiliary power, retract the boom until theboom is extended to less than 75 feet / 22.9 m.

45 Re-connect the harness plug to LSB3EO.





FAULTS appears.




Cable Break Safety Switch, LSB6S:

51 Start the engine and activate the functionenable/high RPM button and retract the boomuntil the boom is extended to less than 2 feet /0.6 m.

52 Remove the boom end cover from the pivot endof the boom.

53 Remove the arm from the cable break limitswitch LSB6S.

Note: LSB6S is located at the end of the boomtubes at the pivot end of the boom.

54 Place the arm removed in step 53 back on theLSB6S switch 180° opposite its originalposition. Rotate the head of the switch 45°clockwise and activate the function enable/highRPM button and attempt to extend the boom.

Result: The boom extend function should bedisabled.

Result: If the boom extends, the LSB6S switchor wiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the boomextends at all, stop immediatelyand retract the boom until theboom is extended to less than 2feet / 0.6 m. Failure to retract theboom could result in death orserious injury.

55 Activate the function enable/high RPM buttonand attempt to retract the boom.

Result: The boom retract function should beenabled.

Result: If the boom does not retract, the LSB6Sswitch or wiring circuit is faulty and will need tobe replaced or repaired. See Repair Section.


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56 Allow the switch to return to its neutral position,then rotate the head of the switch 45° counterclockwise and activate the function enable/highRPM button and attempt to extend the boom.

Result: The boom extend function should bedisabled.

Result: If the boom extends, the LSB6S switchor wiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the boomextends at all, stop immediatelyand retract the boom until theboom is extended to less than 2feet (0.6 m). Failure to retract theboom could result in death orserious injury.

57 Reinstall the arm onto LSB6S in its originalposition.

Axle Extend Safety Switch, LSAX1ES andLSAX2ES and

3 feet / 0.9 m Safety Switch, LSB3RS and

11° Angle Safety Switch, LSB7DS:

58 Fully retract and lower the boom to the stowedposition.

59 Retract both axles approximately 1 foot / 0.3 m.

60 Remove the access cover from each axle.

61 Disconnect the square-end axle extend safetyswitch LSAX1ES and install a wire jumperbetween pin 3 and pin 4 of the deutschconnector.

62 Place a metal washer over the target area of theaxle extend proximity switch LSAX1EO andplace a metal washer over the target area of theaxle extend proximity switch LSAX2EO to closethe contacts.

Result: The axle extend indicator light at theground and platform controls should beilluminated.

Proximity switcha target area

63 Activate the function enable/high RPM buttonand attempt to extend the boom.

Result: The boom should not extend to morethan 3 feet / 0.9 m.

Result: If the boom extends to more than 3 feet/ 0.9 m, the LSAX1ES or LSAX2ES switch areout of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 3 feet/ 0.9 m, stop immediately andretract the boom until the boom isextended to less than 2 feet/ 0.6 m. Failure to retract the boomcould result in death or seriousinjury.

a


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64 Activate the function enable/high RPM buttonand attempt to raise the boom.

Result: The boom should not raise to morethan 11°.

Result: If the boom continues to raise, theLSAX1ES or LSAX2ES switch are out ofadjustment or the wiring circuit is faulty and willneed to be replaced or repaired. See RepairSection.

Bodily injury hazard. If the boomraises to more than 11°, stopimmediately and lower the boomuntil the boom is less than 11°.See Repair Section. Failure toretract the boom could result indeath or serious injury.

65 Remove the wire jumper installed in step 61 andconnect the Deutsch connector to LSAX1ES.

66 Disconnect the circle-end axle extend safetyswitch LSAX2ES and install a wire jumperbetween pin 3 and pin 4 of the Deutschconnector.

67 Activate the function enable/high RPM buttonand attempt to extend the boom.

Result: The boom should not extend to morethan 3 feet / 0.9 m.

Result: If the boom extends to more than 3 feet/ 0.9 m, the LSAX1ES or LSAX2ES switch areout of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 3 feet/ 0.9 m, stop immediately andretract the boom until the boom isextended to less than 2 feet/ 0.6 m. Failure to retract the boomcould result in death or seriousinjury.

68 Activate the function enable/high RPM buttonand attempt to raise the boom.

Result: The boom should not raise to morethan 11°.

Result: If the boom continues to raise, theLSAX1ES or LSAX2ES switch are out ofadjustment or the wiring circuit is faulty and willneed to be replaced or repaired. See RepairSection.

Bodily injury hazard. If the boomraises to more than 11°, stopimmediately and lower the boomuntil the boom is less than 11°.Failure to lower the boom couldresult in death or serious injury.

69 Remove the wire jumper installed in step 66 andconnect the Deutsch connector to LSAX2ES.



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B-17Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.


1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.Procced to step 4.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.

Note: When checking for positive tank cap venting,air should pass freely through the cap.

3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

5 Remove the breather cap from the hydraulictank.

6 Check for proper venting.

Result: Air passes through the hydraulic tankcap. Procced to step 8.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 7.

Note: When checking for positive tank cap venting,air should pass freely through the cap.

7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.


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B-18Test the Engine Idle SelectOperationGenie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

A properly operating engine idle select functionis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously, though at reduced speed. Thissetting maintains a consistent low idle.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.

1 Turn the key switch to ground controls.



4 Push and release the rpm select button untilhigh rpm is selected (rabbit symbol).

Result: The engine should change to high idle.

5 Push and release the rpm select button until lowrpm is selected (turtle symbol).

Result: The engine should return to low idle.

6 Turn the key switch to platform controls.

7 At the platform controls, press the engine idleselect button until high idle (rabbit symbol) isselected.


a foot switch activated high idleindicator light

b low idle indicator lightc high idle indicator lightd engine rpm select button

8 Press the engine idle select button until low idle(turtle symbol) is selected.

Result: The engine should change to low idle.

9 Press the engine idle select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

Result: The engine should not change tohigh idle.

10 Press down the foot switch.


b

d

a c



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B-20Test the Drive Speed -Stowed Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Note: Select a test area that is firm, level and freeof obstructions.

Note: Perform this procedure with the boom in thestowed position.

1 Create start and finish lines by marking two lineson the ground 36 feet / 11 m apart.

2 Start the engine from the platform controls.

3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected. then lower the boom intothe stowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

B-19Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-11, Confirm the ProperBrake Configuration.


1 Mark a test line on the ground for reference.


3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected, then lower the boom intothe stowed position.

4 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.

6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.


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REV E


8 Lower the boom below horizontal.

9 Extend the boom approximately 4 feet (1.2 m).

10 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.



13 Raise the boom to a horizontal position.

14 Extend the boom until the raise boom LED andenvelope alarm are activated.




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


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 36 feet (11 m) apart.


3 Press the engine idle select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

4 Raise the boom until the engine rpm switches tolow speed.





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REV E

B-22Inspect the Boom Extend/Retract Cables

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube on the S-100 and S-105, and the numbers 2and 3 boom tubes on the S-120 and S-125.Inspecting for foreign objects, damage and/orimproper adjustment of the boom extend/retractcables on a regular basis is essential to goodmachine performance and safe machine operation.The boom extend and retract functions shouldoperate smoothly and be free of hesitation, jerkingand unusual noise.

Note: Perform this procedure with the boom in thestowed position and the engine off.

1 Remove the boom end cover from the pivot endof the boom.

a boom end coverb side access coversc cable ends (located

underneath the boom)

2 Remove the retaining fasteners from the accesscovers located on the side of the boom at theplatform end of the machine. Remove thecovers.

3 Visually inspect the cables and componentsthrough both inspection holes for the following:

• Frayed or broken wire strands• Kinks or crushed cables• Corrosion

• Paint or foreign materials on the cables

• Split or cracked cable ends• Cables are on all pulleys

• Cables have equal tension

• Cables at end of adjustment range

• No Broken or damaged pulleys• No Unusual or excessive pulley wear

• All fasteners in place and secure

Note: A flashlight and inspection mirror may benecessary to thoroughly inspect the above items.

Note: A pulley groove gauge should be used tocheck the condition of the pulleys.

4 Replace the cables if any damage is found.

5 At the pivot end of the boom, visually inspect forthe following:

• The red locking bracket is securely installed over the cable adjustment bolts

6 Install the plastic cover at the pivot end of theboom and access panels on the sides of theboom.


8 Extend the boom approximately 2 feet (0.6 m).

9 Retract the boom. While retracting the boom,visually inspect the number 2 and number 3boom tubes.

Result: The number 2 should not move morethan 1/2 inch (13 mm) before the number 3boom tube begins to retract.

Note: If the number 2 boom tube moves more than1/

2 inch (13 mm) before the number 3 boom tube

begins to retract, the boom extend/retract cablesneed to be adjusted. See Repair Procedure 4-5,How to Adjust the Boom Extend/Retract Cables.



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3 - 44 S-100 • S-105 • S-120 • S-125 Part No. 102916

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REV BChecklist C Procedures

C-1Perform Engine Maintenance -Deutz Models










C-2Perform Engine Maintenance -Cummins Models

Engine specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first.


Required maintenance procedures and additionalengine information are available in theCummins B4.5 Operation and Maintenance Manual(Cummins part number 4021389-01).

Cummins B4.5 Operation andMaintenance ManualGenie part number 107527






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REV B CHECKLIST C PROCEDURES

C-3Perform Engine Maintenance -Perkins Models

Engine specifications require that this procedure beperformed every 500 hours or 12 months,whichever comes first.









C-4Replace the Engine Air FilterElement

Engine specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

2 Remove the filter element.

3 Use a damp cloth to wipe the filter sealingsurface and the inside of the outlet tube. Makesure that all contaminant is removed before thefilter is inserted.

4 Check new filter element gasket for damagebefore installing.

5 Install the new filter element.

6 Install the end cap on the canister and secure.

Note: Be sure the discharge slot is pointing down.


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REV B

C-6Test the Platform OverloadSystem (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first.

Testing the platform overload system regularly isessential to safe machine operation. Continued useof an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

Note: Perform this procedure with the machine on afirm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.

C-5Grease the Platform OverloadMechanism (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each grease fittingusing a multipurpose grease.

CHECKLIST C PROCEDURES


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REV B CHECKLIST C PROCEDURES

Illustration 1

7 Carefully move the test weights to eachremaining location in the platform.

Result: The alarm should sound.The platform overload indicator light should beflashing at the platform controls andPLATFORM OVERLOAD should be displayed on theLCD screen at the ground controls.

Result: The alarm is not sounding and theplatform overload indicator light is not flashingand PLATFORM OVERLOAD is not displayed on theLCD screen at the ground controls. Calibrate theplatform overload system. Refer to RepairSection 2-4, Calibrate the Platform OverloadSystem (if equipped).

Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

9 Turn the key switch to ground control.

10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

Note: Machine functions should still operate withauxiliary power at the ground controls.

4 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in one of thelocations shown. Refer to Illustration 1.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairSection 2-4, Calibrate the Platform OverloadSystem (if equipped).

5 Carefully move the test weight to eachremaining location.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairSection 2-4, Calibrate the Platform OverloadSystem (if equipped).

6 Using a suitable lifting device, place anadditional weight onto the platform:S-100 and S-120- 75 lbs / 34 kgS-105 and S-125- 50 lbs / 22.7 kg.

Result: The alarm should sound.The platform overload indicator light should beflashing at the platform controls andPLATFORM OVERLOAD should be displayed on theLCD screen at the ground controls.

Result: The alarm is not sounding and theplatform overload indicator light is not flashingand PLATFORM OVERLOAD is not displayed on theLCD screen at the ground controls. Calibrate theplatform overload system. Refer to RepairSection 2-4, Calibrate the Platform OverloadSystem (if equipped).

Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.


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REV B

11 Lift the test weights off the platform floor using asuitable lifting device.

Result: The platform overload indicator light andalarm should turn off at both the ground andplatform controls.

Note: There may be an approximate 2 second delaybefore the overload indicator light and alarm turnoff.


Result: All ground control functions shouldoperate normally.

13 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

Note: If the platform overload system is notoperating properly, refer to Repair Section 2-4,Calibrate the Platform Overload System (ifequipped).

CHECKLIST C PROCEDURES


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REV A

D-1Check the Boom Wear PadsGenie specifications require that this procedure beperformed every 1000 hours or annually, whichevercomes first.

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result in componentdamage and unsafe operating conditions.


2 Raise the end of the boom to a comfortableworking height (chest high). Stop the engine.

3 Remove the protective covers from the platformend of each boom tube.

4 Measure each wear pad.

Boom wear pad specifications 1/2 inchMinimum thickness 12.7 mm

5 Replace any wear pad if it is less thanspecification. If a wear pad is not less thanspecification, shim as necessary to obtainminimum clearance with zero binding.

Note: The minimum shim clearance for the boomwear pads is .030 in / .76 mm and the maximumallowable shim clearance is .090 in / 2.29 mm.

Note: If the wear pads are still within specification,refer to Repair Section 4-2, How to Shim the Boom.

Checklist D Procedures

6 Remove the boom end cover retaining fastenersat the pivot end of the boom. Remove the boomend cover from the machine.

7 Remove the boom side inspection coverretaining fasteners from the boom at the pivotend of the boom. Remove the boom inspectioncover from the machine to access boom 3 wearpads.

8 Measure each wear pad at the pivot end of theboom.


9 Replace any wear pad if it is less thanspecification. If a wear pad is not less thanspecification, shim as necessary to obtainminimum clearance with zero binding.

10 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding of the boom tubes.

Note: Always maintain squareness between theouter and inner boom tubes.


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REV ACHECKLIST D PROCEDURES

D-2Check the Extendable AxleWear Pads

Genie specifications require that this procedure beperformed every 1000 hours or annually, whichevercomes first.

Maintaining the axle wear pads in good condition isessential to safe machine operation. Wear pads areplaced on axle tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result in componentdamage and unsafe operating conditions.

Note: Be sure that the axles are fully extendedbefore attempting this procedure.

1 Start the engine from the platform controls andextend the axles.

2 Measure each wear pad.

Extendable axle wear pad specifications 7/16 inchMinimum thickness 11.1 mm

3 Replace any wear pad if it is less thanspecification. If a wear pad is not less thanspecification, shim as necessary to obtainminimum clearance and no drag.

Note: If the wear pads are still within specification.Refer to Repair Section 13-6, How to Shim theExtendable Axles.

Note: Keep axle lubricated. See A-11, Grease theExtendable Axles.

4 Extend and retract the axles through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the axletubes.

Note: Always maintain squareness between theouter and inner axle tubes.


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 51

June 2011

REV A CHECKLIST D PROCEDURES

D-3Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily for towing.A machine configured to free-wheel without operatorknowledge may cause death or serious injury andproperty damage.

Collision hazard. Select a work sitethat is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

1 Chock both of the wheels at the circle-end of themachine to prevent the machine from rolling.

2 Place a lifting jack of ample capacity(35,000 lbs / 16000 kg) under each of the steeryokes at the square-end of the machine.

3 Lift the wheels off the ground and place blocksunder the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on each wheel hub atthe square-end of the machine.

disengaged position

engaged position

5 Manually rotate each wheel at the square-end ofthe machine.

Result: Each wheel at the square-end of themachine should rotate with minimum effort.

6 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks. Lower themachine.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

7 Chock both of the wheels at the square-end ofthe machine to prevent the machine from rolling.

8 Place a lifting jack of ample capacity(35,000 lbs / 16000 kg) under each of the steeryokes at the circle-end of the machine.

9 Lift the wheels off the ground and place blocksunder the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each wheel hub atthe circle-end of the machine.

11 Manually rotate each wheel at the circle-end ofthe machine.

Result: Each wheel at the circle-end of themachine should rotate with minimum effort.


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D-4

Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.


2 Install a safety chock onto the hydraulic liftcylinder extension rod. Carefully lower the boomonto the lift cylinder safety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering theboom.

Note: The lift cylinder safety chock is availablethrough Genie (Genie part number 75097).

12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks. Lower themachine.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

All models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on the drivepump, and should always remain closed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

a

d

c

b


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 53

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REV A

3 Be sure that each turntable rotation bearingmounting bolt above the turntable is torqued insequence. Refer to Section 2, Specifications.

Bolt torque sequence


5 Remove the safety chock and lower the boom tothe stowed position.

6 Be sure that each turntable rotation bearingmounting bolt under the drive chassis is torquedin sequence. Refer to Section 2, Specifications.

Note: The turntable rotation bearing bolt torquesequence is the same from above the turntable andbelow the drive chassis.

D-5Check the Turntable RotationGear Backlash


Properly adjusted turntable rotation gear backlashis essential for good machine performance andservice life. Improperly adjusted turntable rotationgear backlash will cause the machine to performpoorly and continued use will cause componentdamage. The turntable rotation drive hub ismounted on the swing chassis behind the fixed sidecover at the ground controls side.

Note: Be sure to check the backlash with themachine fully stowed and the counterweight at thesquare end of the machine.


1 Rotate the turntable until the boom is centeredbetween the circle end wheels.

2 Apply approximately 20 lbs / 89 N of side forceto the platform, moving the platform to one sideas far as it will go.


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REV A

3 Using a feeler guage, measure the gap betweenthe swing hub pinion gear and the turntablerotation bearing at the center tooth. The gapshould be meaured on one side of the piniongear on the center tooth.

Note: The pinion gear can be accessed on theoutside of the chassis under the pinion gear guard.

Result: The gap is between .010 inch / .254 mmand .022 inch / .559 mm. The backlash is withintolerance.

Result: The gap is less than .010 inch / .254mm or more than .022 inch / .559 mm. Thebacklash needs to be adjusted. Refer to RepairSection 12-1, Turntable Rotation HydraulicMotor and Drive Hub.

4. After the backlash has been set, place a tapemeasure approximately two feet long / 0.6 m,perpendicular to the boom, on the ground underthe rotator.

Note: Fasten a straight edge on the side of therotator using tape so one end is just above the tapemeasure.

CHECKLIST D PROCEDURES

5. Apply approximately 20 lbs / 89 N of side forceto the platform, moving the rotator to the left asfar as it will go. Move the tape measure so thestraight edge on the rotator measures0 inches / 0 m.

6. Apply approximately 20 lbs / 89 N of side forceto the platform, moving the rotator to the rightas far as it will go.

7. Note the distance on the tape measure therotator has moved.

Result: The rotator movement does not exceed2 inches / 51 mm. The backlash is in tolerence.

Result: The side-to-side rotator movementexceeds 2 inches / 51 mm. The turntable drivehub may need service. Contact Genie IndustriesService Department.


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 55

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REV A

D-6Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly and continueduse may cause component damage.

Drive Hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container. Refer to capacityspecifications


a drive hub plugs

4 Fill the hub with oil from either plug hole until theoil level is even with the bottom of both plugholes. Install the plugs.

5 Repeat steps 1 through 4 for all the other drivehubs.

6 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.


Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Specifications.


2 Remove the ground control side fixed turntablecover. Refer to Repair Section 5-1, How toRemove a Fixed Turntable Cover.

3 Tag, disconnect and plug the turntable rotatedrive motor hoses at the turntable rotate drivemotor and the turntable rotate drive brake hosesat the turntable rotate drive brake. Cap thefittings.



a



3 - 56 S-100 • S-105 • S-120 • S-125 Part No. 102916

June 2011


a drive motorb brake drain plugc drive hub drain plugd drive hube pivot boltf mounting boltg adjustment bolt with lock nuth drive brake

4 Remove the turntable rotate drive hub mountingbolts and pivot bolt. Remove the turntable rotatedrive hub with a suitable lifting device of amplecapacity.

Crushing hazard. The turntablerotate drive hub may becomeunbalanced and fall when it isremoved from the machine if it isnot properly supported.

5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.

6 Install the drive hub assembly onto the machine.Lubricate and torque the drive hub mountingbolts to specification. Refer to Section 2,Specifications.

bh

a

ef

g f

c

d

7 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug. Refer to Section 2, Specifications.

8 Install the turntable rotate drive motor hoses intothe turntable rotate drive motor and install theturntable rotate drive brake hose into theturntable rotate drive brake.


9 Adjust the turntable rotation gear backlash. SeeD-5, Check the Turntable Rotation GearBacklash.

10 Install the ground control side fixed turntablecover onto the machine and tighten the retainingfasteners.


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REV A

D-7Inspect for Turntable BearingWear

Genie requires that this procedure be performedevery 1000 hours or annually, whichever comesfirst.

Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Note: Perform this procedure with the machine on afirm, level surface and the boom in the stowedposition.

1 Grease the turntable bearing. See A-10, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-5, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no more than1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch / 2.5 cm fromthe turntable rotation bearing.


a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Fully extend the boom and lower to a horizontalposition.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.

Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the boom and raise the boom to fullheight. Visually inspect the dial indicator to besure the needle returns to the "zero" position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the boom to the stowed position and turnthe machine off.

12 Remove the dial indicator from the machine.

a

b

c

d


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REV A

D-9Perform Engine Maintenance -Perkins Models











D-8Perform Engine Maintenance -Deutz Models











Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 59

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REV A

D-10Perform Engine Maintenance -Cummins Models

Engine specifications require that this procedure beperformed every 1000 hours or annually, whichevercomes first.









D-11Replace the Hydraulic FilterElements

Genie requires that this procedure be performedevery 1000 hours or annually, whichever comesfirst.

Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Tank Return Filter:

Burn hazard. Beware of hot oil.Contact with hot oil may causesevere burns.


1 Open the ground controls side turntable sidecover and locate the tank return filters.

2 Place a suitable container under the hydraulictank return filters.

3 Remove each filter with an oil filter wrench.


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June 2011


4 Apply a thin layer of clean oil to the new oil filtergaskets.

5 Install the new hydraulic return filter element andtighten it securely by hand. Clean up any oil thatmay have spilled during the installationprocedure.

6 Use a permanent ink marker to write the dateand number of hours from the hour meter on thefilters.


8 Inspect the filters and related components tobe sure that there are no leaks.

Medium and High Pressure Hydraulic Filters:

Burn hazard. Beware of hot oil.Contact with hot oil may causesevere burns.

Note: The medium pressure filter is for the chargepump and the high pressure filters are for the drivecircuit.


1 Open the engine side turntable cover and locatethe three filters mounted to the bulkhead.

a high pressure filtersb medium pressure filter

2 Place a suitable container under the filters.

3 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housing.

4 Remove the filter element from the housing.

5 Inspect the housing seal and replace it ifnecessary.

6 Install the new medium pressure filter elementinto the housing and tighten it securely.

7 Install the new high pressure filter elements intothe housings and tighten them securely.

8 Clean up any oil that may have spilled during theinstallation procedure.

a

b


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 61

June 2011

REV A CHECKLIST D PROCEDURES

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.


11 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.


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REV B

2 Close the two hydraulic shut-off valves locatedat the hydraulic tank.

Component damage hazard. Theengine must not be started with thehydraulic tank shutoff valves in theclosed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Remove the drain plug from the hydraulic tankand allow all of the oil from the tank to drain intoa suitable container. Refer to Section 2,Specifications.

4 Remove the ground controls support bracketretaining fasteners and remove the groundcontrol box assembly from the machine.

Component damage hazard.Be sure to properly support theground control box. Do not allowthe ground control box to hang bythe wiring or cables.

5 Tag and disconnect the wires from the horn.Remove the horn retaining fasteners andremove the horn from the machine.

6 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tank shut-offvalves. Cap the fittings.

7 Tag, disconnect and plug the supply hose forthe auxiliary power unit. Cap the fitting on thehydraulic tank.

8 Tag, disconnect and plug the case drain hose atthe return filter. Cap the fitting on the return filterhead.

9 Disconnect and plug the T-fitting located at thereturn filter with the 2 hoses connected to it.Cap the fitting on the return filter head.

open closed

E-1Test or Replace the Hydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed more frequently.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: Perform this procedure with the boom in thestowed position and the axles extended.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Remove the ground controls side turntable sidecover. Refer to Repair Section 5-1, How toRemove a Hinged Turntable Cover.

Checklist E ProceduresREV C


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REV B

10 Remove the hydraulic tank breather filter fromthe tank.

11 Remove the hydraulic tank strap retainingfasteners and remove the hydraulic tank strapsfrom the machine.

12 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an overheadcrane.

13 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if it is not properlysupported and secured to theoverhead crane when it is removedfrom the machine.

14 Remove the hydraulic tank return filter from thehydraulic tank return filter head.

15 Remove the case drain filter from the case drainfilter head.

16 Remove the suction strainers from the tank andclean them using a mild solvent.

17 Rinse out the inside of the tank using a mildsolvent.

18 Install the suction strainers using pipe threadsealant on the pipe threads.

19 Install the drain plug using pipe thread sealanton the pipe threads.

Note: Always use pipe thread sealant on all pipethreads.

20 Install the hydraulic tank onto the machine.

21 Install the hydraulic tank retaining straps andinstall the hydraulic tank retaining fasteners.

22 Install the horn and horn retaining fasteners ontothe machine. Connect the wiring.

23 Install the ground control box assembly andassembly retaining fasteners onto the machine.

24 Install the two suction hoses and the supplyhose for the auxiliary power unit onto themachine.

25 Install the case drain hose onto the return filterhead.

26 Install the T-fitting and 2 hoses connected to itto the hydraulic tank return filter head.

27 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.

28 Apply pipe thread sealant to the threads of thehydraulic tank filter mount.

29 Install a new tank breather filter onto the filtermount and tighten it securely by hand.

30 Use a permanent ink marker to write the dateand number of hours from the hour meter on thefilter.

31 Install a new tank case drain return filter ontothe filter mount and tighten it securely by hand.


33 Install a new tank return filter onto the filtermount and tighten it securely by hand.


35 Clean up any oil that may have spilled during theprocedure.

36 Open the hydraulic tank shut-off valves.

Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank. Refer to Repair Section 9-2,How to Prime the Pumps.

37 Install the turntable side cover.

CHECKLIST E PROCEDURESREV C


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REV BCHECKLIST E PROCEDURES

E-3Perform Engine Maintenance -Perkins Models










E-2Perform Engine Maintenance -Cummins Models

Engine specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.








REV C


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 65

June 2011

REV B


Engine specifications require that this procedure beperformed every 2 years.









CHECKLIST E PROCEDURES

E-5Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedure beperformed every 2 years.









REV C


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REV B





















CHECKLIST E PROCEDURES REV C


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 67

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REV B













Engine specifications require that this procedure beperformed every 6000 hours or 3 years, whichevercome first.









REV C


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REV B






















REV C


Part No. 102916 S-100 • S-105 • S-120 • S-125 3 - 69

June 2011

REV B CHECKLIST E PROCEDURES











E-13Replace the Boom Extend/Retract Cables

Genie specifications require that this procedure beperformed every 10 years.

The boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube on the S-100 and S-105, and the numbers 2and 3 boom tubes on the S-120 and S-125.Replacement of the boom extend/retract cables isessential to good machine performance and safemachine operation. The boom extend/retractfunctions should operate smoothly and be free ofhesitation, jerking and unusual noise.

1 Replace the boom extend cables. Refer toRepair Procedure 4-5, How to Replace theBoom Extend/Retract Cables.

REV C


3 - 70 S-100 • S-105 • S-120 • S-125 Part No. 102916

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Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 1

June 2011 Section 4 • Repair Procedures

REV ARepair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie S-100 &Genie S-105 Operator’s Manual and theGenie S-120 & Genie S-125 Operator’s Manual.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Use only Genie approved replacement parts.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom between the circle-end wheels

· Turntable secured with the turntable rotation lock pin

· Key switch in the OFF position with the key removed

· Wheels chocked

· All external AC power supply disconnectedfrom the machine

123456789012345123456789012345123456789012345123456789012345123456789012345123456789012345123456789012345

4 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916

June 2011Section 4 • Repair Procedures

REV EDisplay Module

This table lists the various screens and menu options of the operating software. Some display menus arefor informational purpose only, while others can be changed to alter the machine operating parameters.

The key switch must be in the OFF position before entering the programming mode.

Use the or buttons to scroll through the screens.

To change parameter values, use the button (to increase) or the button (to decrease) or to select a

setting. Press the button to save the new value to memory. An audible beep will indicate a save tomemory.

You must exit the programming mode for the changes to take effect.

To Exit Programming Mode:

Use the scroll button to scroll through the menu until the screen displays EXIT, then press the

plus button once, and change NO to YES, then press the enter button once to accept change.

Note: If Programming mode is not exited properly, all machine programming may be lost.

Screen orMenu

Procedure Description Range or Selection

Hour meter (on power up)Engine speedEngine oil pressure PSI (English)Engine oil pressure kPa (metric)Engine temperature °F (English)Engine temperature °C (metric)Primary boom angle sensorTurntable level sensor X°Turntable level sensor Y°Platform angleBattery voltage

Operator

MachineStatus

Unit ofMeasureandLanguage

Engine temperature is notdisplayed until engine isabove 100°F / 38°C

Default

With key switch

ON, press the

and at thesame time.

Hydraulic pressure PSI (English)Hydraulic pressure kPa (metric)Boom angleAxle status

Metric/English measurements

Language selection

Use +/- buttons to change

English, German, French,Spanish, Portuguese,Italian, Dutch and Swedish

With key switchOFF, press and

hold the button and turnthe key switch tothe ON position.

Release the button andpress

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 3


REV E DISPLAY MODULE

Screen orMenu


Drive output max forward

Drive output max reverse

Elevated drive (>75 ft / 24 m) %

Elevated drive (<75 ft / 24 m) %

Stowed drive %

Drive acceleration %

Drive deceleration %

Speed limit on steer angle

DriveFunctions

BoomFunctionSpeeds




100% max and 10% min,100 % (default)100% max and 10% min,90% (default)120% max and 50% min,100% (default)120% max and 50% min,100% (default)120% max and 50% min,100% (default)125% max and 25% min,100% (default)125% max and 25% min,100% (default)100% max and 0% min,50% (default)




.

120% max and 10% min,100% (default)120% max and 10% min,100% (default)80% max and 10% min,80% (default)80% max and 10% min,80% (default)35% max and 10% min,29% (default)35% max and 10% min,29% (default)25% max and 10% min,20% (default)25% max and 10% min,20% (default)60% max and 10% min,60% (default)40% max and 10% min,35% (default)120% max and 75% min,100% (default)120% max and 50% min,100% (default)120% max and 50% min,100% (default)

Boom up speed stowed %

Boom down speed stowed %

Boom up speed % <75 ft

Boom down speed % <75 ft

Boom up speed % >75 ft

Boom down speed % >75 ft

Boom up speed % >100 ft

Boom down speed % >100 ft

Boom extend speed %

Boom retract speed %

Turntable rotate speed % <75 ft

Turntable rotate speed % >75 ft

Jib boom up/down speed %

4 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV EDISPLAY MODULE

Screen orMenu


Boom up/downramp acceleration %Boom up/downramp deceleration %Boom extend/retractramp acceleration %Turntable rotateramp acceleration %Turntable rotateramp deceleration %Jib up/down rampdeceleration %

LiftFunctionRampSettings

ValveCalibration




5000 max and 100 min,5000 (5.0 sec) (default)2600 max and 100 min,500 (0.50 sec) (default)1600 max and 100 min,500 (0.50 sec) (default)5000 max and 100 min,2000 (2.0 sec) (default)3000 max and 100 min,250 (0.25 sec) (default)3000 max and 0 min,250 (0.25 sec) (default)




Reset drive valve defaults

Reset boom up/downvalve defaultsReset boom extend/retractvalve defaultsReset turntable rotatevalve defaultsAllow boom up/downspeed calibrationAllow turntable rotatespeed calibrationReset drive joystickdefaultsReset boom up/downjoystick defaultsReset boom extend/retractjoystick defaultsreset turntable rotatejoystick defaultsReset steer joystickdefaults

LevelSensorCalibration




Set unit level to gravityTurntable Y-axis millivoltsper degreeTurntable X-axis millivoltsper degreePlatform level to gravityPlatform millivolts per degree

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 5


REV E DISPLAY MODULE

Screen orMenu


Reset drive functions

Reset boom function speeds

Reset lift function ramps

Reset all (Contact Genie IndustriesService Department before using thisoption)

Clear all safety switch faults

DefaultReset

Options With key switchOFF, press and






Limit boom height to 100 ft / 80 ft

AC generator

Alarm

Lift / drive cutouts

Auxiliary drive

Proximity kill switch

Platform overload sensing

Work lights

Flashing beacon

Drive lights

Disable steer mode changewhile driving

Rocker joystick steering

Generator off delay (0-10 sec)

(100 FT / 80 FT)

(NONE, BELT, HYD)

(NO, MOTION, TRAVEL, DESCENT, TRAVEL

AND DESCENT)(0, 1, 2, 3, 4, 5)(NO, DRIVE CUTOUT WHILE NOT STOWED,LIFTING OR DRIVING)(YES/NO)

(NONE/PROX)

(NONE/PLTFS)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(O TO 10 SECONDS, 2 IS THE DEFAULT.SHOWN ONLY WHEN HYD GEN IS SELECTED)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

(YES/NO)

4 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916


The platform controls contains two printed circuitboards:

The membrane circuit board is mounted to theunderside of the control box lid which contains theLEDs and touch-sensitive buttons for machinefunctions. The membrane circuit board sends theinput from the operator to the platform controlsECM circuit board. The ECM circuit board sendsthe data to the turntable control box for processing.

The platform controls ECM circuit boardcommunicates with the turntable controls. Thejoystick controllers at the platform controls utilizeHall Effect technology and require no adjustment.The operating parameters of the joysticks arestored in memory at the turntable controls. If ajoystick controller error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-3,How to Calibrate a Joystick Controller.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a platform ECM circuit boardb boom extend/retract

joystick controllerc drive/steer joystick controllerd membrane circuit boarde boom up/down and turntable rotate

left/right joystick controller

Platform Controls

a

d

b

ce

REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 7


7 Locate the ECM circuit board mounted to theinside of the platform control box.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

8 Remove the ECM circuit board mountingfasteners.

9 Carefully remove the ECM circuit board fromthe platform control box.

How to Remove the MembraneCircuit Board1 Push in the Emergency Stop button to the OFF

position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

1-1Circuit Boards

Note: When an ECM circuit board is replaced, thejoystick controllers will need to be calibrated. See1-3, How to Calibrate a Joystick Controller.

How to Remove the ECMCircuit Board1 Push in the Emergency Stop button to the OFF


2 Remove the platform control box mountingfasteners. Remove the platform control boxfrom the machine.

Component damage hazard.Cables can be damaged if theyare kinked or pinched.

3 Locate the cables that connect to the bottom ofthe control box. Number each cable and itslocation at the control box.

4 Disconnect the cables from the bottom of theplatform control box.

5 Remove the control cable plug retainingfasteners from the bottom of the platformcontrol box.


PLATFORM CONTROLSREV B

4 - 8 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV BPLATFORM CONTROLS

3 Locate the membrane circuit board mounted tothe inside of the platform control box lid.


Note: Component damage hazard. Electrostaticdischarge (ESD) can damage printed circuit boardcomponents. Maintain firm contact with a metalpart of the machine that is grounded at all timeswhen handling printed circuit boards OR use agrounded wrist strap.

4 Carefully disconnect the two ribbon cables fromthe membrane circuit board.

5 Remove the membrane circuit board retainingfasteners.

6 Carefully remove the membrane circuit boardfrom the platform control box lid.

1-2Membrane Decal

How to Replace the MembraneDecalThe membrane decal is a special decal thatconsists of a decal with an electronic membraneon the backside. The membrane contains touchsensitive areas that, when pushed, activates themachine functions. The membrane buttonsactivate machine functions similar to toggleswitches, but do not have any moving parts.

1 Push in the Emergency Stop button to the OFF



3 Carefully disconnect the two ribbon cables fromthe membrane circuit board.


Note: Component damage hazard. Electrostaticdischarge (ESD) can damage printed circuit boardcomponents. Maintain firm contact with a metalpart of the machine that is grounded at all timeswhen handling printed circuit boards OR use agrounded wrist strap.

REV B

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REV C

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 9


REV B PLATFORM CONTROLS

4 Close the control box lid.

5 Remove the decal from the platform control box.

6 Carefully remove the membrane decal from theplatform control box while guiding the ribboncables out of the control box lid.

7 Remove any decal adhesive from the controlbox lid with a mild solvent.

Note: Do not allow any solvent to come in contactwith the membrane circuit board.

8 Install the new membrane decal (Genie partnumber 50810) while guiding the ribbon cablesthrough the control box lid.

Note: Be sure that all LED locations on themembrane decal align with the LED's on themembrane circuit board.

9 Install a new platform controls decal (Genie partnumber 65182) over the membrane decal.

10 Open the control box lid and carefuly connectthe ribbon cables from the membrane decal tothe membrane circuit board.

1-3Joysticks

How to Calibrate a JoystickThe joystick controllers on this machine utilizedigital Hall Effect technology for proportionalcontrol. If a joystick controller is disconnected orreplaced, it must be calibrated before that particularmachine function will operate.

Note: The joystick must be calibrated before thethreshold, max-out or ramp rate can be set.

Note: It is possible to reset multiple joystickdefaults before exiting the programming mode.

Note: After each joystick is calibrated, check thedisplay at the ground control box. There should beno calibration faults shown on the display. Ifcalibration faults exist, repeat steps 1 through 8 forthat joystick controlled function.

Note: Contact Genie Industries Service Departmentbefore using the reset all joystick default option.


The calibration procedure for each joystick beginson the next page.

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REV C

4 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV BPLATFORM CONTROLS REV B

Steer functions:

Note: If the calibration fault is already displayed atthe ground box begin with step 6.

1 Turn the key switch to the off position. Confirmthe red Emergency Stop button at the platformand ground controls is in the on position.

2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.

3 Press the minus button twice, then press theenter button twice.

4 Use the scroll button to scroll through themenu until RESET STEER JOYSTICK DEFAULTS isdisplayed. Press the button to select YES,then press the button.

5 Exit programming mode.

Note: To exit programming mode, use the scrollbutton to scroll through the menu until the

screen displays exit, then press the plus button once, change the NO to YES, and press the enterbutton .

6 Do not start the engine.

7 Locate the drive/steer joystick.

8 Move the drive/steer joystick full stroke in theleft direction and hold for 5 seconds, then returnto the center or neutral position.

9 Move the drive/steer joystick full stroke in theright direction and hold for 5 seconds, thenreturn to the center or neutral position.

Result: The alarm at the ground controls shouldsound for a successful calibration.

Result: If the alarm does not sound, repeat thecalibration procedure, beginning with step 1.

Drive functions:





4 Use the scroll button to scroll through themenu until RESET DRIVE JOYSTICK DEFAULTS isdisplayed. Press the button to select YES,then press the button.





7 Locate the drive/steer joystick.

8 Move the drive/steer joystick full stroke in theforward direction and hold for 5 seconds, thenreturn to the center or neutral position.

9 Move the drive/steer joystick full stroke in thereverse direction and hold for 5 seconds, thenreturn to the center or neutral position.



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REV C

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 11


REV B

Primary boom extend/retract functions:





4 Use the scroll button to scroll through themenu until RESET PRIMARY BOOM EXTEND/RETRACT

JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button.





7 Locate the primary boom/turntable rotatejoystick.

8 Move the primary boom extend/retract joystickfull stroke in the extend direction and hold for 5seconds, then return to the center or neutralposition.

9 Move the primary boom extend/retract joystickfull stroke in the retract direction and hold for 5seconds, then return to the center or neutralposition.




Primary boom up/down functions:





4 Use the scroll button to scroll through themenu until RESET PRIMARY BOOM UP/DOWN JOYSTICK

DEFAULTS is displayed. Press the button toselect YES, then press the button.






8 Move the boom/turntable rotate joystick fullstroke in the up direction and hold for 5seconds, then return to the center or neutralposition.

9 Move the boom/turntable rotate joystick fullstroke in the down direction and hold for 5seconds, then return to the center or neutralposition.



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REV C

4 - 12 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV B

Turntable rotate functions:





4 Use the scroll button to scroll through themenu until RESET TURNTABLE ROTATE JOYSTICK

DEFAULTS is displayed. Press the button toselect YES, then press the button.






8 Move the boom/turntable joystick full stroke inthe left direction and hold for 5 seconds, thenreturn to the center or neutral position.

9 Move the boom/turntable joystick full stroke inthe right direction and hold for 5 seconds, thenreturn to the center or neutral position.



How to Reset a ProportionalValve Coil DefaultNote: Use this procedure for any software versionother than 2.00. For software version 2.00 refer tothe following procedure.

Note: This procedure only needs to be performed ifa proportional valve has been replaced.

Note: After the valve coil defaults have been set,each machine function threshold and defaultfunction speed must be set. See How to Set theFunction Thresholds and Default Function Speeds.

1 Turn the key switch to the off position.



4 Use the scroll button to scroll through themenu until the function valve that needs to bereset is displayed. Press the button toselect YES, then press the button to save thesetting.

Note: Choices are: Propel (drive) valve reset;Boom up/down valve reset; Boom extend/retractvalve reset; or TT rotate valve reset.

5 Push one of the LCDscreen buttons shownuntil EXIT is displayed.

6 Press the plus button or minus button toselect YES and then press the enter button .

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REV C

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 13


REV B

How to Set the FunctionThresholds and FunctionSpeedsNote: Before the threshold and default functionspeeds can be set, the boom function proportionalvalve coil defaults must be set first.See How to Reset a Proportional Valve CoilDefault.

Note: If a boom function proportional valve coil hasnot been replaced and just want to reset thefunction speed to original factory settings, beginwith step 10.


2 Press down the foot switch.

Note: Be sure the engine rpm is set to foot switchactivated high idle.

Function threshold:

3 Select a joystick controlled function that needsto have the threshold set.

4 Slowly move the joystick off center in eitherdirection just until the machine function starts tomove, then move the joystick very slowlytowards the neutral or center position just beforethe machine function stops.Do not let go of the joystick.

5 While holding the joystick in position, press theengine start button at the platform controlsto set the joystick controller threshold.

6 Slowly move the joystick off center in theopposite direction just until the machine functionstarts to move, then move the joystick veryslowly towards the neutral or center position justbefore the machine function stops.Do not let go of the joystick.


How to Reset a ProportionalValve Coil Default(software version 2.00)Note: Software version 2.00 requires the use ofWeb GPI to perform this procedure.Refer to 5-5, Software.

Note: This procedure only needs to be performed ifa proportional valve has been replaced.

Note: After the valve coil defaults have been set,each machine function threshold and defaultfunction speed must be set. See How to Set theFunction Thresholds and Default Function Speeds.

1 Open Web GPI and connect to the TCON.

2 Select the valve screen of the proportional valveyou want to reset.

Note: Choices are: Propel (drive) valve reset;Boom up/down valve reset; Boom extend/retractvalve reset; or TT rotate valve reset.

3 Press "set Defaults" and enter the level 2password (obtained from field servicepersonnel).

4 Enter "0" (zero) into the threshold boxes.

5 Press "send" and enter the level 2 password(obtained from field service personnel).

6 Disconnect from the TCON and proceed withcalibration.

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REV C

4 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV B

Function speeds:

Note: Be sure the machine is in the stowed positionand the boom is rotated between the circle endtires.

Note: Perform this procedure with the machineparked on a firm, level surface which is free ofobstructions.


13 Select a boom function that needs the functionspeed set.

14 Boom up/down functions: Starting in thestowed position, move the joystick full stroke inthe up direction. When the alarm sounds, movethe joystick in the opposite direction full strokeuntil the alarm sounds again. Return the joystickto center.

Boom extend/retract functions: Raise theboom until the low-speed drive function isenabled. Move the joystick full stroke in theextend direction. When the alarm sounds, movethe joystick in the opposite direction full strokeuntil the alarm sounds again. Return the joystickto center.

Turntable rotate functions: Raise the boomuntil the low-speed drive function is enabled.Move the joystick full stroke to the left (cw) untilthe drive enable light turns on. Then move thejoystick full stroke to the right (ccw). When thealarm sounds, move the joystick in the oppositedirection full stroke until the alarm soundsagain. Return the joystick to center.

15 Once all the joystick controllers have beencalibrated, push in the red Emergency Stopbutton at the platform controls to save thesettings in memory.

Note: The red Emergency Stop button at theplatform controls must be pushed in to the offposition following calibration of the joystickcontrollers to save the settings in memory.

16 At the ground controls, turn the key switch tothe off position, wait a moment and then turnthe key switch to platform controls.

17 Check the display at the ground controls to besure there are no calibration faults.

Note: There should be no calibration faults shownon the display. If calibration faults exist, repeat thisprocedure.

How to Adjust the FunctionSpeeds1 Pull out the red Emergency Stop button to the

on position at both the ground and platformcontrols.

PLATFORM CONTROLS REV B

7 While holding the joystick in position, press theengine start button at the platform controlsto set the joystick controller threshold.

8 Repeat steps 3 through 7 for each joystickcontrolled machine function (boom up/down andturntable rotate left/right, boom extend/retract,and drive forward/reverse).

9 Once all the joystick controllers have beencalibrated, push in the Emergency Stop buttonat the platform controls to save the settings inmemory.

Note: The red Emergency Stop button at theplatform controls must be pushed in to the offposition following calibration of the joystickcontrollers to save the settings in memory.

10 At the ground controls, turn the key switch tothe off position, wait a moment and then turnthe key switch to platform controls.

11 Check the display at the ground controls to besure there are no calibration faults.

Note: There should be no calibration faults shownon the display. If calibration faults exist, repeat thisprocedure.

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REV C

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 15


REV B PLATFORM CONTROLS

Specifications

Ramp rate (factory settings)

Turntable rotateaccelerate 2 secondsdecelerate 0.25 second

Primary boom up/downaccelerate 3 secondsdecelerate 0..25 second

Primary boom extend/retractaccelerate 2 secondsdecelerate 0.25 second

Jib boom up/downaccelerate 2 secondsdecelerate 0.25 second

Driveaccelerate 2 seconds

REV B

2 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls. Hold the enterbutton for approximately 5 seconds.

3 Press the plus button twice, then press theminus button twice.

4 Press the scroll button until the function tobe adjusted is displayed.

5 Press the plus button to increase the speedor press the minus button to decrease thespeed.

6 Press the enter button to save the setting inmemory.


8 Press the plus button to select YES and thenpress the enter button .

9 Continue to perform this procedure until themachine function speed meets specification.Refer to Section 2, Specifications for functionspeeds.

How to Adjust the FunctionRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.

Note: Perform this procedure with the boom in thestowed position.


2 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls. Hold the enterbutton for approximately 5 seconds.

3 Press the plus button twice, then press thescroll button twice.

4 Press the scroll button until the function tobe adjusted is displayed.

5 Press the plus button to increase the ramprate or press the minus button to decreasethe ramp rate.




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REV C

4 - 16 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV BPlatform Components

2-1Platform

How to Remove the Platform1 Separate the foot switch quick disconnect plug.

2 Support the platform with an appropriate liftingdevice.

3 Locate the cables that connect to the bottom ofthe control box. Number each cable and itslocation at the platform control box.


5 Remove the platform control box mountingfasteners. Remove the platform control box andset it aside.

6 Remove the air line to platform bracket retainingfasteners (if equipped).

7 Remove the weld cables from the platform(if equipped).


8 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformmay become unbalanced and fallwhen it is removed from themachine if it is not properlysupported.

2-2Platform Leveling Cylinder

The platform leveling cylinder keeps the platformlevel through the entire range of boom motion. Theplatform is maintained level to the turntable. TheECM at the ground controls compares thedifference in readings between the platform anglesensor and the turntable level sensor. The ECM atthe ground controls sends a signal to the platformcontrols to open or close the appropriate platformlevel proportional valve on the platform manifold tomaintain a level platform. The platform levelingcylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.

How to Remove the PlatformLeveling CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Extend the boom until the platform levelingcylinder barrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks underthe platform.

3 Lower the boom until the platform is resting onthe blocks just enough to support the platform.

Note: Do not rest the entire weight of the boom onthe blocks.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 17


REV B PLATFORM COMPONENTS

4 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling cylinder at thebulkhead fittings located inside the boom tubeat the platform end and connect them togetherusing a connector. Cap the bulkhead fittings onthe boom tube.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

5 Remove the pin retaining fastener fromthe 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 asuitable lifting device. Protect the cylinder rodfrom damage.

8 Use a soft metal drift to remove the rod-endpivot pin.

Crushing hazard. The platform(S-100 and S-120 models) or jibboom (S-105 and S-125 models)will fall when the platform levelingcylinder rod-end pivot pin isremoved if it is not properlysupported.

Crushing hazard. The platformleveling cylinder will fall if it is notproperly supported when the rod-end pivot pin is removed.

Component damage hazard. Theplatform leveling cylinder rod canbecome damaged if it is allowed tofall.

9 Use a soft metal drift to remove the barrel-endpivot pin.

10 Carefully pull the platform leveling cylinder out ofthe boom.


4 - 18 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV BPLATFORM COMPONENTS

How to Bleed the PlatformLeveling CylinderNote: Do not start the engine. Use auxiliary powerfor all machine functions in this procedure.

Note: The boom must remain below 10° to properlyperform this procedure.


2 Activate auxiliary power.

3 Push the platform level up and down buttonsthrough two complete platform leveling cyclesto remove any air that might be in the system.

2-3Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Remove the platform. See 2-1,How to Remove the Platform.

2 Disconnect the electrical connector from theplatform angle sensor.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 19


REV B

3 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on platform rotatormanifold. Cap the fittings on the manifold.


4 Remove the platform manifold mountingfasteners. Lay the platform manifold to the side.


5 Remove the power to platform cover plate fromthe electrical outlet box. Do not disconnect thewiring.


6 Remove the power to platform electrical outletbox from the platform and lay it to the side.

7 Remove the weld cable from the platform(if equipped).


PLATFORM COMPONENTS

8 Support the platform mounting weldment, but donot apply any lifting pressure.

9 Remove the eight mounting bolts from theplatform mounting weldment.

10 Remove the center bolt and slide the platformmounting weldment off of the platform rotator.

Crushing hazard. The platformmounting weldment may becomeunbalanced and fall if it is notproperly supported.

11 Support the platform rotator. Do not applyany lifting pressure.

S-100 and S-120 models:

12 Support the rod end of the platform levelingcylinder. Protect the cylinder rod from damage.

13 Remove the pin retaining fastener from theplatform level cylinder rod-end connecting linkpivot pin and the platform rotator pivot pin. Donot remove the pins.

14 Use a soft metal drift to remove both pins andremove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if it is not properlysupported.

Component damage hazard. Theplatform angle sensor is a verysensitive instrument. It can bedamaged internally if the platformrotator is dropped or sustains anyphysical shock, even if thedamage is not visible.

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REV B


12 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.

13 Support the jib boom leveling arms with asuitable lifting device.

14 Use a soft metal drift to remove both pins andremove the platform rotator from the machine.

Crushing hazard. The jib boomleveling arms may fall if they arenot properly supported when thejib boom leveling arm pivot pin isremoved.

Component damage hazard. Theplatform angle sensor is a verysensitive instrument. It can bedamaged internally if the platformrotator is dropped or sustains anyphysical shock, even if thedamage is not visible.

How to Bleed the PlatformRotatorNote: Do not start the engine. Use auxiliary powerfor all machine functions in this procedure.

S-105 (Before serial number 251) andS-125 models (Before serial number 999):

1 At the ground controls, simultaneously hold theauxiliary power button and the platform rotateright button until the platform is fully rotated tothe right.

PLATFORM COMPONENTS

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Secure the container tothe boom.

3 Slowly open the top bleed valve on the rotator.Do not remove the bleed valve from theplatform rotator.


a top bleed valveb bottom bleed valvec clear hosed container

c

a

bd

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 21


REV B

4 Hold the platform rotate left button until theplatform is fully rotated. Continue holding thebutton until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear of theplatform during rotation.

5 Connect the clear hose to the bottom bleedvalve and slowly open the valve. Do not removethe bleed valve.

6 Hold the platform rotate right button until theplatform is fully rotated. Continue holding thebutton until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear of theplatform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform full right then left andinspect the bleed valves for leaks.

9 Clean up any oil that may have spilled duringthis procedure.

S-100, S-120, S-105 (after serial number 250) andS-125 models (after serial number 998):

1. Rotate the platform full right, then full left until airis completely out of the rotator. Bleeding thevalve is not necessary.

PLATFORM COMPONENTS

2-4Platform Level Sensor

The platform level sensor is mounted to the side ofthe platform rotator. The platform level sensor ismonitored by the control system to maintain a levelplatform throughout boom range of motion. If aplatform level sensor is replaced, it must becalibrated prior to machine operation.

How to Calibrate thePlatform Level SensorNote: Perform this procedure with the machine on afirm, level surface and in the stowed position.

1 Secure a digital level to one of the side railingsof the platform.

2 Start the machine and level the platform togravity. Push the red Emergency stop button into stop the engine.

2 Press and hold the enter button on theground control panel while pulling out the redEmergency Stop button.

3 Press the plus button , then press the enterbutton twice before again pressing the plusbutton .

4 Press the enter button three timees untilPLATFORM LEVEL TO GRAVITY is displayed on theLCD screen.

5 Press the plus button once.


7 Push one of the LCDscreen buttons shownuntil PLATFORM LEVEL SENSOR

MV PER DEGREE is displayed.

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REV B

2-5Platform Overload System

The platform overload system is designed toprevent the machine from continuing to operatewhen the load in the platform exceeds maximumrated capacity. Refer to the machine serial label formaximum capacity information.

If maximum platform capacity is exceeded, thealarm will sound at the platform controls and theplatform overload indicator lights will flash at boththe ground and platform controls. The ground andplatform controls will become disabled. Beforenormal machine operation can continue, the excessload will need to be removed from the platform.

If the excess load cannot be removed or if theoperator at the platform controls is unable to correctthe overloaded condition, another person at theground controls can operate the machine usingauxiliary power. There will be limited control ofboom functions from the ground controls whenusing auxiliary power. Auxiliary power can be usedto correct the overloaded platform condition in orderto resume normal, safe operation of the machine.

How to Calibrate the PlatformOverload System (if equipped)Calibration of the platform overload system isessential to safe machine operation. Continued useof an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Note: Perform this procedure with the machine on afirm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

PLATFORM COMPONENTS

8 Confirm that the number shown on the display isthe same as that shown on the data sheetsupplied with the new platform level sensor.

Result: If the number shown on the display isthe same as that shown on the data sheetsupplied with the new platform level sensor,continue to step 10.

Result: If the number shown on the display isnot the same as that shown on the data sheetsupplied with the new platform level sensor,continue to step 9.

9 Press the plus button or the minus buttonto correct the display to match the data sheet.Then press the enter button to save thesetting in memory.



Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 23


REV B

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the enter of the platform floor.

5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. Proceed to step 6.

Result: The alarm is sounding. The platformoverload indicator light is flashing at theplatform controls and “PLATFORMOVERLOAD” should be displayed on the LCDscreen at the ground controls. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.


Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds. Proceed to step7.

Result: The alarm should be sounding.The platform overload indicator light should beflashing at the platform controls and“PLATFORM OVERLOAD” should be displayedon the LCD screen at the ground controls.Repeat this procedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.

PLATFORM COMPONENTS

4 - 24 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A


Result: All platform control functions should notoperate.

10 Turn the key switch to ground control.


Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: All platform control functions shouldoperate normally.

PLATFORM COMPONENTS


Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. Proceed to step 8.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.


8 Add an additional test weight to the platform.S-105 and S-125- 10 lb / 4.5 kgS-100 and S-120- 12 lb / 5.4 kg.

Result: The alarm should be sounding.The platform overload indicator light should beflashing at the platform controls and“PLATFORM OVERLOAD” should be displayedon the LCD screen at the ground controls.Proceed to step 9.

Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. Remove the additional 10 lb / 4.5 kgtest weight. Repeat this procedure beginningwith step 6.


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REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 25


REV A

3-1Jib Boom,S-105 and S-125 Models

How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.



2 Remove the platform mounting weldmentand the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Remove the hose and cable cover retainingfasteners from the jib boom leveling arm.Remove the hose and cable cover from themachine.

4 Support the jib boom with a suitable liftingdevice.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Support the barrel end of the cylinder with asuitable lifting device.

7 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the pin and letthe cylinder hang down.

9 Attach a lifting strap from an overhead crane tothe jib boom.

10 Remove the pin retaining fastener from the jibboom pivot pin.

11 Use a soft metal drift to remove the pin andremove the jib boom from the primary boom.

Crushing hazard. The jib boommay become unbalanced and fallwhen it is removed from themachine if it is not properlysupported.

Jib Boom Components, S-105 / S-125 Models

4 - 26 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

12 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

13 Slide both of the jib boom leveling arms off ofthe jib boom pivot pin and lay them off to theside.

14 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

15 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin. Remove the jib boomlift cylinder from the jib boom bellcrank.

Crushing hazard. The jib boom liftcylinder may become unbalancedand fall when it is removed fromthe machine if it is not properlysupported.

16 Attach a lifting strap from an overhead crane tothe jib boom bellcrank.

17 Support the rod end of the platform levelingcylinder with a suitable lifting device. Protect thecylinder rod from damage.

18 Remove the pin retaining fastener from theplatform leveling cylinder rod-end pivot pin.

19 Use a soft metal drift to remove the platformleveling cylinder rod-end pivot pin.

Crushing hazard. The platformleveling cylinder may fall if it is notproperly supported when the rod-end pivot pin is removed.

Crushing hazard. The jib boombellcrank may fall if it is notproperly supported when theplatform leveling cylinder rod-endpivot pin is removed.

20 Remove the pin retaining fastener from the jibboom bellcrank pivot pin.

21 Use a soft metal drift to remove the jib boombellcrank pivot pin. Remove the jib boombellcrank from the machine.

Crushing hazard. The jib boombellcrank may becomeunbalanced and fall if it is notproperly supported when it isremoved from the machine.

JIB BOOM COMPONENTS, S-105 AND S-125 MODELS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 27


REV A JIB BOOM COMPONENTS, S-105 AND S-125 MODELS

3-2Jib Boom Lift Cylinder,S-105 and S-125 Models

How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.


1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Lowerthe jib boom until the platform is resting on theblocks just enough to support the platform.

Note: Do not rest the entire weight of the boom onthe blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.



4 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

5 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out andlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

6 Support the jib boom lift cylinder with a suitablelifting device.

7 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pivotpin.

8 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin. Remove the jib boomlift cylinder from the machine.

Crushing hazard. The jib boom liftcylinder may become unbalancedand fall when it is removed fromthe machine if it is not properlysupported.

4 - 28 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV ABoom Components

a Number 0b Number 1c Number 2d Number 3

a Number 1b Number 2c Number 3

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 29


REV A

4-1Cable Track

The cable track and boom cable tube guides cablesand hoses running up the boom. The cable trackcan be repaired link by link without removing thecables and hoses that run through it. Removing theentire cable track assembly may be necessarywhen performing major repairs that involveremoving the boom.

How to Remove the BoomCable TrackNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.

Note: Perform this procedure with the boom fullystowed.


2 Remove the protective coil sleeve from thehose and cable bundle at the platform end ofthe boom cable tube.

3 Tag, disconnect and plug all hydraulic hosesfrom the boom cable tube to the platformmanifold.

Note: If your machine is equipped with an airline toplatform option and/or weld cable option, the airlineand/or cable must be disconnected from theplatform before the cable track is removed.

4 Tag and disconnect the black electricalconnector from the bottom of the control box.

5 Remove the platform-end boom cable tubemounting fasteners at the engine side of themachine.

6 Remove the cable track mounting fastenersfrom the cable track support at the engine sideof the machine.

7 Remove the wear pad mounting weldment fromthe cable track support bracket at the engineside of the machine.

8 Remove the hose and cable clamp from thecable track support bracket at the engine sideof the machine.

9 Place blocks between the cable track and theboom cable tube for support.

10 Strap together the boom cable tube, blocks ofwood, and the cable track at the engine side ofthe machine.

Component damage hazard.Cables, hoses, boom cable tubeand cable track can be damaged ifthey are kinked or pinched.

11 Remove the limit switch cover retainingfasteners from the top of the number 2 boomtube at the platform end of the machine.Remove the limit switch cover.

12 Tag and disconnect the wiring connectors fromthe proximity and limit switches on top of thenumber 2 boom tube at the platform end of themachine.

BOOM COMPONENTS

4 - 30 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV ABOOM COMPONENTS

13 Remove the cable track roller guide mountingfasteners from the ground controls side of themachine at the platform end.

14 Remove the roller guide from the cable trackguide bracket at the engine side of themachine.

15 Tag, disconnect and plug the hydraulic hosesfrom the bottom of the bulkhead fittings on thecable track support at the ground controls sideof the machine.


16 Remove the bulkhead fitting locknuts from thebulkhead fittings on the cable track support atthe ground controls side of the machine.Remove and cap the fittings.

17 Tag and disconnect the wiring connectors.

Note: The wiring connectors that need to bedisconnected are located next to the hose fittingsthat were removed in step 16.

If not removing the boom from the machine,proceed to step 19.

18 Tag, disconnect and plug the primary extensioncylinder hydraulic hoses on the side of thenumber 2 boom tube at the ground controls sideof the machine. Cap the fittings.


19 Remove the cable track mounting fastenersfrom the cable track support at the groundcontrols side of the machine.

20 Remove the side panels from the boom cabletube located under the cable track at the groundcontrols side of the machine.

21 Remove the hose and cable cover mountingfasteners from the pivot end of the boom at theground controls side of the machine. Removethe cover.

22 Remove the hose and cable clamps from thehoses and cables located below the boom pivoton the inside of the turntable riser at the groundcontrols side of the machine.

23 Tag and disconnect the electrical cables fromthe cable track to the ground controls side ofthe machine.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 31


REV A BOOM COMPONENTS

If not removing the boom from the machine,proceed to step 25.

24 Pull the hydraulic hoses from the boom cabletube located under the cable track at the groundcontrols side of the machine.

25 Place blocks between the cable track and thecable track tube at the ground controls side ofthe machine. Secure the cable track and thecable track tube together.


26 Attach a lifting strap from an overhead crane tothe cable track assembly at the engine side ofthe boom. Lift the cable track assembly overthe boom and carefully set the assembly on topof the longer boom cable tube at the groundcontrols side of the machine.

Crushing hazard. If the cable trackassemblies are not properlysecured together, the cable trackmay become unbalanced and fallwhen it is removed from themachine.

27 Strap both cable track assemblies together.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

Component damage hazard.Cable tracks can be damaged ifthey are twisted.

28 Attach a lifting strap from an overhead crane toeach end of the cable track assembly. Carefullylift the assembly from the boom and set it on astructure capable of supporting it.

Crushing hazard. If the cable trackassemblies are not properlysecured together, the cable trackassemblies may becomeunbalanced and fall when it isremoved from the machine.


Component damage hazard. Theboom cable tube and cable trackscan be damaged if they aretwisted.

How to Repair the BoomCable Track

Component damage hazard.The boom cable track can bedamaged if it is twisted.

Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department.

Before serial number 881 (S-120/125) and210 (S-100/105):Use part number 62320 which includes a 1-linksection of cable track. If the cable track has beenreplaced using cable track kit, Genie part number102054, use part number 102214. If unsure whichcable track is on the machine, contact GenieIndustries Service Department.

4 - 32 S-100 • S-105 • S-120 • S-125 Part No. 102916



After serial number 880 (S-120/125) and209 (S-100/105):Use part number 102214 which includes a 3-linksection of cable track.

1 Visually inspect the cable track and determinewhich section needs to be replaced.

2 Remove the snap-on cable track spacers.

3 Remove the external snap rings from the pivotpins at each end of the 3-link section to beremoved.

4 Lift up the hoses and cables and carefullyremove the damaged 3-link section of cabletrack.

Component damage hazard.Hoses and cables can be damagedif they are kinked or pinched.

5 Remove the snap-on spacers from thereplacement section of cable track.

6 Lift up the hoses and cables and carefully insertthe new 3-link section of cable track.

Component damage hazard. Hosesand cables can be damaged if theyare kinked or pinched.

7 Connect the ends of the replacement cable tracksection to the existing cable track using thepivot pins and external snap rings.

Note: Be sure that the pivot pins are installed fromthe inside out so the external snap rings are on theoutside of the cable track.

8 Install the cable track snap-on spacers.

4-2Boom

How to Shim the Boom1 Measure each upper, side and lower wear pad.


Note: If a wear pad is not less than specification,perform the following procedure.

2 Remove the retaining fasteners from theappropriate black plastic boom tube cover atthe platform end of the boom. Remove thecover.

3 Extend the boom until the wear pads areaccessible.

4 Loosen the wear pad mounting fasteners.

5 Fit as many shims as can be installed by hand.

6 Tighten the mounting fasteners.

7 Remove the boom end cover retaining fastenersat the pivot end of the boom. Remove the boomend cover from the machine.

8 Remove the boom side inspection coverretaining fasteners from the boom at the pivotend of the boom. Remove the boom inspectioncover from the machine to access boom 3 wearpads.

9 Loosen the wear pad mounting fasteners.

10 Fit as many shims as can be installed by hand.

11 Tighten the mounting fasteners.

12 Replace the covers.

13 Extend and retract the boom through an entirecycle. Check for tight spots that may causebinding of the boom.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 33



How to Remove the BoomBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



2 Remove the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 S-105 and S-125 models: Remove the JibBoom. See 3-1, How to Remove the Jib Boom.

4 Remove the cable track. See 4-1, How toRemove the Boom Cable Track.

5 Raise the boom approximately 4 feet / 1.2 m.

6 Attach a lifting strap from an overhead crane tothe rod end of the boom lift cylinder.

7 Attach an overhead 10 ton / 10,000 kg crane tothe platform end of the boom for support. Do notlift the boom.

8 Remove the boom storage area cover retainingfasteners. Remove the cover from the machine.

9 Place support blocks under the boom liftcylinder.

10 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

Crushing hazard. The boom liftcylinder may fall when the rod-endpivot pin is removed if the boom liftcylinder is not properly supportedby the overhead crane.

Crushing hazard. The boom mayfall when the rod-end pivot pin isremoved if the boom is notproperly supported by theoverhead crane.

11 Carefully raise the boom with the overheadcrane until the rod end of the boom lift cylindercan be removed.

12 Carefully lower the rod end of the boom liftcylinder down onto the support blocks.

13 Lower the boom with the overhead crane to ahorizontal position.

14 Remove the boom end cover retaining fastenersfrom the pivot end of the boom. Remove thecover.

15 Locate the cable break limit switch above theprimary boom extension cylinder at the pivotend of the boom.

4 - 34 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

16 Tag and disconnect the wiring connector fromthe cable break limit switch.

17 Tag, disconnect and plug the hydraulic hosesfrom the primary boom extension cylinder. Capthe fittings on the cylinder.


18 Attach a second overhead 10 ton / 10,000 kgcrane to the pivot end of the boom for support.Do not apply any lifting pressure.

19 Remove the pin retaining fastener from theboom pivot pin. Do not remove the pin.

20 Use a soft metal drift to remove the boom pivotpin.

Component damage hazard. Becareful not to damage the boomenvelope limit switch(s) located onthe inside of the engine sideturntable riser when removing theboom assembly. The boomenvelope switch(s) can bedamaged even if the damage isnot visible.

21 Carefully remove the boom assembly from themachine and place it on a structure capable ofsupporting it.

Crushing hazard. The boom maybecome unbalanced and fall whenit is removed from the machine if itis not properly supported by theoverhead cranes.

BOOM COMPONENTS

How to Disassemble the Boom,S-120 and S-125 ModelsNote: Complete disassembly of the boom is onlynecessary if the outer or inner boom tubes must bereplaced. The primary boom extension cylinder canbe removed without completely disassembling theboom. See 4-4, How to Remove the PrimaryExtension Cylinder.

1 Remove the boom. See 4-2,How to Remove the Boom.

2 Remove the retaining fasteners from the accesscovers on both sides of the boom at the pivotend. Remove the access covers.

a side access covers

3 Secure the number 2 and number 3 boom tubestogether with a strap or chain to prevent themfrom moving.

4 Remove the cable clamp from the cable breaklimit switch wiring.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 35


REV A

a cable break limit switchb cable pulley

5 Disconnect the wiring connector from the cablebreak limit switch.



7 Remove the fasteners from the inner cabletrack mounting bracket at the primary boomextension cylinder.

8 Lay the inner cable track and hoses down andout of the way.

9 Remove the pulley pivot pin retaining fastenersfrom the number 2 boom tube at the pivot end ofthe boom.

BOOM COMPONENTS

10 Remove the pulley pivot pins, cable guards andpulleys.

Note: When installing the pulleys, be sure that theside of the pulley with the taller flange is facing thecenter of the boom tube.

11 Locate the number 3 boom tube extension cableclevis pins on both sides of the number 2 boomtube at the pivot end of the boom.

12 Remove the cotter pin and clevis pin from bothcables.

Note: When installing a clevis pin, always replacethe cotter pin with a new one.

13 Remove the lower external snap ring and washerfrom the cable break limit switch actuator pivotpin.

14 Remove the cable break actuator mounting plateretaining fasteners. Remove the lower platefrom the machine.

15 Remove the upper plate and actuator pivot pin.Do not remove the cable break limit switch fromthe mounting plate.

16 Push the cable break actuator and cablestowards the platform end of the boomapproximately 18 inches / 46 cm.

17 Remove the red cable adjustment lockingbracket retaining fasteners. Remove the redlocking bracket from the machine.

Bodily injury hazard. Failure toinstall the red cable adjustmentlocking bracket will allow the cablemounting bolts to loosen and fallout which could result in death orserious injury.

a

b

4 - 36 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

a red cable adjustmentlocking bracket

18 Remove the two cable adjustment bolts.

19 Remove the cable-end block mounting platefasteners. Remove the cable-end blockmounting plate from the machine.

20 Remove the trunnion pin retaining fasteners.

21 Use a slide hammer to remove the trunnion pinsfrom the primary boom extension cylinder.

22 Remove the primary boom extension cylinderhold down brackets at the pivot end of theboom.

23 Attach a lifting strap from an overhead crane tothe lifting eye on the primary boom extensioncylinder.

BOOM COMPONENTS

24 Support and slide the primary boom extensioncylinder out of the boom assembly while guidingthe cables out of the boom and place it on astructure capable of supporting it.

Crushing hazard. The primaryboom extension cylinder maybecome unbalanced and fall whenit is removed from the boom if it isnot properly supported andattached to the overhead crane.


Note: During removal, the overhead crane strap willneed to be adjusted for proper balancing.

25 Remove the retaining fasteners from the limitswitch cover on top of the number 2 boom tubeat the platform end of the machine.

26 Carefully remove the cover with proximity andlimit switches from the top of the number 2boom tube at the platform end of the boom.

Tip-over hazard. Failure to installthe correct proximity and/or limitswitches in the correct location willresult in the machine tipping over,resulting in death or serious injury.

27 Tag and disconnect the wiring connectors fromthe proximity and limit switches at the top of thenumber 2 boom tube at the platform end of theboom. Do not remove the proximity or limitswitches.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 37


REV A

28 Remove the retaining fasteners from the limitswitch cover on the side of the number 0 boomtube at the platform end of the boom.

29 Carefully remove the cover with proximity andlimit switches from the number 0 boom tube atthe platform end of the boom.


30 Tag and disconnect the wiring connectors fromthe proximity and limit switches at the groundcontrols side of the number 0 boom tube at theplatform end of the boom. Do not remove theproximity or limit switches.

31 Remove the retaining fasteners from each blackplastic boom tube cover at the platform end ofthe machine. Remove the covers.

32 Remove and label the top and side wear padsof the number 3 boom tube at the pivot end ofthe boom. Do not remove the bottom wearpads.

Note: Pay careful attention to the location andamount of shims used with each wear pad.

33 Remove and label the top and side wear padsfrom the number 2 boom tube at the platformend of the boom. Do not remove the bottomwear pads.


BOOM COMPONENTS

34 Attach a lifting strap from an overhead crane tothe number 3 boom tube at the platform end ofthe boom.

35 Support and slide the number 3 boom tube outof the number 2 boom tube. When the number3 boom tube is approximately halfway removed,remove the bottom wear pads from the number2 boom tube at the platform end of the boom.

Crushing hazard. The number 3boom tube may becomeunbalanced and fall when it isremoved from the number 2 boomtube if it is not properly supportedand attached to the overheadcrane.


36 Remove and label the top and side wear padsfrom the number 2 boom tube at the pivot endof the boom. Do not remove the bottom wearpads.





4 - 38 S-100 • S-105 • S-120 • S-125 Part No. 102916






40 Remove the secondary boom extend cylindercover retaining fasteners. Remove the covers.

Bodily injury hazard. Do notoperate the machine unless thesecondary extend cylinder coversare properly installed. Operatingthe machine with the coversremoved could result in death orserious injury.

41 Tag, disconnect and plug the secondary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


42 Support the secondary boom extension cylinderwith an overhead crane or other suitable liftingdevice.

43 Remove the pin retaining fasteners from boththe rod-end and barrel-end pivot pins. Do notremove the pins.

44 Use a soft metal drift to remove both pivot pinsand remove the secondary boom extensioncylinder from the machine while guiding thebarrel end of the cylinder out of the boom.

Crushing hazard. The secondaryboom extension cylinder maybecome unbalanced and fall if it isnot properly supported when it isremoved from the machine.

Component damage hazard. Theboom lift cylinder rod can becomedamaged if the barrel end of thesecondary boom extensioncylinder is allowed to come incontact with it.

45 Remove and label the top and side wear padsfrom the number 1 boom tube at the pivot end ofthe boom. Do not remove the bottom wear pads.


Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 39


REV A







BOOM COMPONENTS

How to Disassemble the Boom,S-100 and S-105 ModelsNote: Complete disassembly of the boom is onlynecessaryif the outer or inner boom tubes must be replaced.The primary boom extension cylinder can beremoved without completely disassembling theboom. See 4-4, How to Remove the PrimaryExtension Cylinder.

1 Remove the boom. See 4-2,How to Remove the Boom.

2 Remove the retaining fasteners from the accesscovers on both sides of the boom at the pivotend. Remove the access covers.

a side access covers



4 - 40 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

a cable break limit switchb cable pulley




7 Remove the pulley pivot pin retaining fastenersfrom the number 2 boom tube at the pivot endof the boom.


Note: When installing the pulleys, be sure that theside of the pulley with the taller flange is facing thecenter of the boom tube.





12 Remove the cable break actuator mounting plateretaining fasteners. Remove the lower platefrom the machine.



15 Remove the red cable adjustment lockingbracket retaining fasteners. Remove the redlocking bracket from the machine.

Bodily injury hazard. Failure toinstall the red cable adjustmentlocking bracket will allow the cablemounting bolts to loosen and fallout which could result in death orserious injury.


17 Remove the cable-end block mounting platefasteners. Remove the cable-end blockmounting plate from the machine.



a

b

BOOM COMPONENTS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 41


REV A


20 Remove the primary boom extension cylinderhold down brackets at the pivot end of theboom.






23 Remove the retaining fasteners from the limitswitch cover on top of the number 2 boom tubeat the platform end of the machine.

24 Carefully remove the cover with proximity andlimit switches from the top of the number 2boom tube at the platform end of the boom.


25 Tag and disconnect the wiring connectors fromthe proximity and limit switches at the top of thenumber 2 boom tube at the platform end of theboom. Do not remove the proximity or limitswitches.

26 Remove the retaining fasteners from the limitswitch cover on the side of the number 1 boomtube at the platform end of the boom.

27 Carefully remove the cover with proximity andlimit switches from the number 1 boom tube atthe platform end of the boom.


28 Tag and disconnect the wiring connectors fromthe proximity and limit switches at the groundcontrols side of the number 1 boom tube at theplatform end of the boom. Do not remove theproximity or limit switches.

29 Remove the retaining fasteners from each blackplastic boom tube cover at the platform end ofthe machine. Remove the covers.

BOOM COMPONENTS

4 - 42 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

30 Remove and label the top and side wear padsof the number 3 boom tube at the pivot end ofthe boom. Do not remove the bottom wearpads.





33 Support and slide the number 3 boom tube outof the number 2 boom tube. When the number 3boom tube is approximately halfway removed,remove the bottom wear pads from the number2 boom tube at the platform end of the boom.



34 Remove and label the top and side wear padsfrom the number 2 boom tube at the pivot endof the boom. Do not remove the bottom wearpads.





37 Support and slide the number 2 boom tube outof the number 1 boom tube. When the number 2boom tube is approximately halfway removed,remove the bottom wear pads from the number1 boom tube at the platform end of the boom.



BOOM COMPONENTS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 43


REV A

4-3Boom Lift Cylinder

How to Remove the BoomLift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.

1 Raise the boom until there is approximately4 feet / 1.2 m between the turntable and boomrest pad.

2 Attach a lifting strap from an overhead crane orother suitable lifting device to the rod end of thethe boom lift cylinder.

3 Attach an overhead 10 ton / 9071 kg crane tothe platform end of the boom for support. Do notlift the boom.

4 Remove the boom storage area cover retainingfasteners. Remove the cover from the machine.

5 Place support blocks under the boom liftcylinder.

6 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin. Protect thecylinder rod from damage.

Crushing hazard. The boom liftcylinder may fall when the rod-endpivot pin is removed if the boom liftcylinder is not properly supportedby the overhead crane.

Crushing hazard. The boom mayfall when the rod-end pivot pin isremoved if the boom is notproperly supported by theoverhead crane.

7 Carefully raise the boom with the overheadcrane until the rod end of the boom lift cylindercan be removed.

8 Carefully lower the rod end of the boom liftcylinder down onto the support blocks.

9 Carefully raise the boom with the overheadcrane until the barrel end of the boom liftcylinder is accessible.

10 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on thecylinder.


BOOM COMPONENTS

4 - 44 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

17 With the boom lift cylinder being supported bythe overhead crane, pull the boom lift cylindertoward the platform until it is out.

Crushing hazard. The boom liftcylinder may become unbalancedand fall if it is not properlysupported when it is removed fromthe machine.

Component damage hazard. Becareful not to damage theproximity and/or limit switcheswhen removing the boom liftcylinder.

Component damage hazard. Thecables and hydraulic hoses can bedamaged if the boom lift cylinder ispulled across them.





Crushing hazard. Failure to installthe bolt into the engine pivot plateanchor hole to secure it frommoving could result in death orserious injury.

14 Remove the pin retaining fastener from thebarrel-end pivot pin. Do not remove the pin.

15 Support the boom lift cylinder with an overheadcrane.

16 Use a slide hammer to remove the boom liftcylinder barrel-end pivot pin through the accesshole in the engine side turntable riser.

BOOM COMPONENTS

ba

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 45


REV A

4-4Extension Cylinders

The primary boom extension cylinder is locatedinside the boom assembly and incorporates cablesand pulleys that are responsible for extending thenumber 2 and 3 boom tubes. The secondary boomextension cylinder (S-120 and S-125 models) islocated underneath the number 0 boom tube and isresponsible for extending the number 1 boom tube.The extension cylinders are equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Extension Cylinder




2 Remove the retaining fasteners from the boomend cover at the pivot end of the boom.Remove the cover from the machine.

BOOM COMPONENTS

3 Remove the access cover retaining fastenersfrom both sides of the boom. Remove theaccess covers.



a cable break limit switch




a

4 - 46 S-100 • S-105 • S-120 • S-125 Part No. 102916



8 S-120 and S-125 models: Remove thefasteners from the inner cable track mountingbracket at the primary boom extension cylinder.

9 S-120 and S-125 models: Lay the inner cabletrack and hoses down and out of the way.

10 Remove the pulley pivot pin retaining fastenersfrom the number 2 boom tube at the pivot end ofthe boom.


Note: When installing the pulleys, be sure that theside of the pulley with the shorter flange is facingthe inside of the boom tube.





15 Remove the cable break actuator mounting plateretaining fasteners. Remove the lower plate.



18 Remove the retaining fasteners from the redcable adjustment locking bracket. Remove thered locking bracket.

Bodily injury hazard. Failure toinstall the red cable adjustmentlocking bracket would allow thecable mounting bolts to loosen andfall out which could result in deathor serious injury.


Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 47


REV A

How to Remove the SecondaryBoom Extension Cylinder,S-120 and S-125 Models



1 Raise the boom until the secondary boomextension cylinder barrel-end pivot pin is abovethe turntable covers.

2 Remove the secondary boom extend cylindercover retaining fasteners. Remove the covers.

Bodily injury hazard. Do notoperate the machine unless thesecondary extend cylinder coversare properly installed. Operatingthe machine with the coversremoved could result in death orserious injury.

BOOM COMPONENTS


20 Remove the cable-end block mounting platefasteners. Remove the cable-end blockmounting plate.



Note: Use a 1/2 -13 bolt thread on each end of the

slide hammer.




Component damage hazard.Cables can be damaged if they arekinked, pinched or snagged duringremoval.


4 - 48 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

3 Tag, disconnect and plug the secondary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


4 Support the secondary boom extension cylinderwith an overhead crane or other suitable lifingdevice.

5 Remove the pin retaining fasteners from boththe rod-end and barrel-end pivot pins. Do notremove the pins.

6 Protect the boom lift cylinder rod from damage.

7 Use a soft metal drift to remove both pivot pins.

8 Remove the secondary boom extension cylinderfrom the machine while guiding the barrel end ofthe cylinder out of the boom.

Crushing hazard. The secondaryboom extension cylinder maybecome unbalanced and fall if it isnot properly supported when it isremoved from the machine.

Component damage hazard. Theboom lift cylinder rod can becomedamaged if the barrel end of thesecondary boom extensioncylinder is allowed to come incontact with it.

BOOM COMPONENTS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 49



b

a

c

d

4-5Boom Extend/Retract Cables

How to Adjust the Boom Extend/Retract CablesProperly adjusted extend/retract cables areessential to safe machine operation. Failure tomaintain proper adjustment of the cables couldresult in unsafe operating conditions and maycause component damage. The boom extend andretract functions should operate smoothly and befree of hesitation, jerking and unusual noise.

Note: A flashlight may be necessary to be able tosee the extend/retract cables inside of the boomassembly.

Note: Perform this procedure with the boom fullyretracted.



3 Stop the engine.

4 Remove the boom end cover from the pivot endof the machine.

5 Locate the red locking bracket (c) covering thecable adjustment bolts at the pivot end of theboom (illustration 1).

6 Remove the retaining fastener from the redlocking bracket and remove the bracket fromthe machine.

7 Locate the retract cable equalizer bolt under thenumber 1 boom tube at the platform end of theboom assembly (illustration 3).

8 Loosen the nylock (g) and jam nut (h) on thecable tension equalizer bracket. Do not removethe nuts.

a limit switchb extend cable adjustment boltsc red cable adjustment locking bracketd boom tube distance

Illustration 1

9 At the pivot end of the boom (illustration 1), turnthe cable adjustment bolts (b) clockwise toobtain 63/4 inches / 17 cm between the end ofthe number 3 boom tube and the end of thenumber 2 boom tube (d). As a guide (Illustration2), the end of the extension cable coupling (i)should be approximately mid-point (k) betweenthe guide plate (l) and the cable retainer bracket(j). Illustration 2 is visible by removing the boomside covers.

Note: Adjust the cable adjustment bolts evenly sothe cable break limit switch (a) stays centered inthe limit switch actuator (Illustration 1).

Note: If the distance is greater than 63/4 inches / 17cm, loosen the extend cable adjustment bolts andtighten the hex jam nut on the cable tensionequalizer bolt until the distance is less than63/4 inches / 17 cm. Loosen the jam nut and repeatstep 9.

4 - 50 S-100 • S-105 • S-120 • S-125 Part No. 102916



gh

e

f

10 At the platform end of the boom, tighten the hexjam nut (h) on the cable tension equalizerbracket located underneath the number 1 boomtube (Illustration 3). Tighten the hex jam nutuntil it is snug. Do not overtighten.

11 Hold the hex jam nut with a wrench and tightenthe nylock nut (g) against the hex jam nut.

12 Re-check that the cable break limit switch iscentered in the limit switch actuator. Adjust theextension cable adjustment bolts to center it.

13 At the pivot end of the boom, measure thedistance between the end of the number 3 boomtube and the end of the number 2 boom tube.

Result: The measurement between the end ofthe number 3 boom tube and the end of thenumber 2 boom tube should be63/4

to

67/8 inches / 17 to 17.5 cm (d).

e boom tube 1f boom tube 2g nylock nuth hex jam nut

Illustration 3

14 Install the red locking bracket over the cableadjustment bolts. A flat edge of each bolt head(b) must be on top for the locking bracket tosecure the bolts.

Bodily injury hazard. Failure to re-install the red cable adjustmentlocking bracket would allow thecable mounting bolts to loosen andfall out which could result in deathor serious injury.

15 Lower the boom to the stowed position.


i

k

l

j

Illustration 2

i extension cable couplingj cable retainer bracketk equal distancel guide plate

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 51



How to Replace the BoomExtend/Retract CablesNote: The cable pulleys must also be replacedwhen replacing the cables.

1 Remove the boom extension cylinder. See 4-4,How to Remove the Primary Boom ExtensionCylinder.

Boom extend cables:

2 Remove the retaining fasteners that secure theextension cable retainer to the pulley mount.Remove the retainer.

3 Remove the cables from the lower boom extendcable bracket that attaches to the number 3boom tube.

4 Remove the front and rear fasteners from theanchor bracket that supports the cable anchors.Remove the bracket.

5 Remove the pulley and boom extend cablesfrom the extension cylinder assembly. Discardthe old cables and pulleys.

6 Route the new boom extend cables through theboom extend pulley bracket.

Note: Be sure before installing the extend cablesthrough the boom adjustment coupling that the tallend of the cable anchors are facing down.

7 Install the new boom extend cable pulley, pivotpin and snap rings.

Note: Be sure the boom extend cables are routedthrough the grooves of the pulley and the upperwear pad on the extension cylinder.

8 Install the boom extend cables to the lowerextend cable bracket that mounts to the number3 boom tube.

m figure 3 platform endn figure 2, boom tube 3o figure 1, pivot end

Illustration 4

Boom Tube One

Boom Tube Two

Boom Tube Three

Boom Tube One

o

m

n

17 Extend the boom approximately 2 feet / 0.6 m.

18 Retract the boom. While retracting the boom,visually inspect the number 2 and number 3boom tubes.

Result: The number 2 should not move morethan 1/2 inch (13 mm) before the number 3boom tube begins to retract.

Note: If the number 2 boom tube moves more than1/2 inch (13 mm) before the number 3 boom tubebegins to retract, repeat the procedure until thenumber 2 boom moves less than 1/2 inch before thenumber 3 boom begins to retract.

4 - 52 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

20 Secure the number 2 and number 3 boomstogether at the platform end with a chain orstrap to prevent them from moving.

21 Install the boom extension cylinder assemblyinto the boom.

Note: Before lowering the extension cylinder intothe saddles of the number 1 boom tube, wrap theboom retract cables around the pulleys.

22 Remove the chain or strap from the platform endof the number 2 and number 3 boom tubes.

23 Adjust the boom extend/retract cables.See, How to Adjust the Boom Extend/RetractCables.

Boom retract cables:

9 Remove the fasteners from the boom retractcables at the platform end of the boom.

10 Attach a rope to one of the boom retract cablesat the pivot end of the boom.

11 At the platform end of the boom, pull on theboom retract cable that has the rope attachedto it.

12 Pull the old cable completely out of the boomtube. Discard the old boom retract cable.

13 Remove the rope from the old cable andsecurely attach the rope to the same end of thenew boom retract cable.

14 At the pivot end of the boom, carefully pull therope with the new retract cable attached.

15 Pull the new cable towards the pivot end of theboom until the end of the cable is at the end ofthe boom tube. Remove the rope.

16 Repeat steps 11 through 16 for the other boomretract cable.

17 At the platform end of the boom, install theretract cables and fasteners to the adjustmentplate.

18 Remove and discard the old boom retractpulleys from the pivot end of the boomextension cylinder.

19 Install the new boom retract pulleys to the pivotend of the boom extension cylinder.

BOOM COMPONENTS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 53


REV A

5-1Turntable Covers

In addition to the standard hinged turntable covers,there are two fixed turntable covers. One fixedcover protects the fuel tank on the engine side ofthe machine and the other protects the turntablerotator assembly on the ground controls side of themachine.

How to Remove a HingedTurntable Cover1 Raise the turntable cover. Support and secure

the open cover to an overhead crane or forklift.Do not lift it.

Crushing hazard. Due to its heavyweight, do not attempt to supportthe cover by hand.

Component damage hazard.Protect the cover from damage byusing carpet or padding on thecrane or forklift forks.

2 Remove the upper and lower retaining clipsfrom the gas strut.

3 Gently pry the strut pivot sockets off of the ballstuds and remove the strut. Protect the strutcylinder rod from damage.

Crushing hazard. The turntablecover will fall when the gas strutsare removed if it is not properlysupported.

Turntable Covers

4 Mark the location of the hinges on the bulkheadto ensure proper cover alignment duringinstallation.

5 Remove the cover hinge to bulkhead retainingfasteners.

6 Carefully lift and remove the cover fromthe machine.

Crushing hazard. The turntablecover could become unbalancedand fall when it is removed fromthe machine if it is not properlysupported and secured to aappropriate lifting device.

Bodily injury hazard. Safety decalsare essential to safe machineoperation. Failure to replace allsafety and instructional decalscould result in death or seriousinjury. If a turntable cover must bereplaced, be sure that allappropriate safety andinstructional decals are applied tothe new cover.

Note: Alignment adjustments may be necessarywhen a new cover is installed.

4 - 54 S-100 • S-105 • S-120 • S-125 Part No. 102916

March 2011Section 4 • Repair Procedures

How to Remove a FixedTurntable Cover1 Ground controls side: Remove the top

retaining fasteners from the power to platformplug panel and loosen the bottom retainingfasteners. Do not disconnect the wiring.

2 Support the cover with a suitable lifting device.Protect the cover from damage.

3 Remove the cover mounting fasteners.

4 Carefully remove the cover from the machine.

Crushing hazard. The turntablecover may become unbalancedand fall when it is removed fromthe machine if it is not properlysupported.

Bodily injury hazard. Safety decalsare essential to safe machineoperation. Failure to replace allsafety and instructional decalscould result in death or seriousinjury. If a turntable cover must bereplaced, be sure that allappropriate safety andinstructional decals are applied tothe new cover.

Note: Alignment adjustments may be necessarywhen a new cover is installed.

TURNTABLE COMPONENTS REV A

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 55

March 2011 Section 4 • Repair Procedures

6-1RPM Adjustment

Refer to Maintenance Procedure B-12,Check and Adjust the Engine RPM.

6-2Flex Plate

The flex plate couples the engine to the pump. Theflex plate is bolted to the engine flywheel and has acut-out in the center for the pump coupler.

a pumpb pump shaftc couplerd flex platee flywheelf Deutz models- .245 inch / 6.2 mm gap

Cummins or Perkins models-.255 inch / 6.5 mm gap

Engines

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic

proportional controller located on the drivepump.

2 Remove the hose clamp from the air cleanerhose at the air cleaner. Carefully disconnectthe 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 retainingfasteners from the pump mounting plate. Donot disconnect the fuel hoses.

5 Remove the fuel filter/water separator and lay itto the side.

6 Support the drive pump assembly with anappropriate lifting device. Then remove all ofthe pump mounting plate to engine bell housingbolts.

7 Carefully pull the pump away from the engineand secure it from moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

8 Remove the flex plate mounting fasteners,then remove the flex plate from the flywheel.

a b c e

f

d

REV B

4 - 56 S-100 • S-105 • S-120 • S-125 Part No. 102916


ENGINES

1

2

3

4

56

7

8

1

2

3

4 5

6

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Apply Loctite® removable thread sealant to themounting fasteners. Then torque the flex platemounting bolts in sequence to:Cummins engines: 23 ft-lbs / 31.2 Nm.Deutz and Perkins engines: 28 ft-lbs / 38 Nm.

3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

4 Apply Loctite® removable thread sealant to thepump coupler set screw.Perkins and Cummins engines before serialnumber 1029 and Deutz 913 engines:Torque the set screw to 20 ft-lbs / 27 Nm.Perkins and Cummins engines after serialnumber 1028 and Deutz 2011 engines:Torque the set screw to 61 ft-lbs / 83 Nm.

5 Install the bell housing/mounting plateassembly. Apply Loctite® removable threadsealant to the mounting fasteners. Then torquethe pump retaining fasteners to:Cummins, Perkins and Deutz 913 engines:28 ft-lbs / 38 Nm.Deutz 2011 engines: 47 ft-lbs / 63 Nm.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.

1

2

3

4

56

7

8

Perkins EnginesCummins Engines

After Serial Number 1028

Deutz 2011 Engines

Perkins EnginesCummins Engines

Before Serial Number 1029Deutz 913 Engines

REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 57


6-4Oil Pressure and TemperatureSending Units - Deutz Models

The engine oil temperature sending unit is anelectrical device. If the engine oil temperaturereaches 275° F / 135° C, the ECM will shut theengine off to prevent damage and will not start untilthe engine oil temperature drops below275° F / 135° C. The engine temperature will beshown on the display screen at the ground controlswhen the key is ON and the Emergency Stop Buttonis pulled out to the ON position. Use the scrollbuttons and scroll to the Engine Temperaturescreen.

Component damage hazard.Do not crank the engine witha oil temperature fault shown onthe display at the ground controls.

The oil pressure sending unit is an electricaldevice. If the oil pressure drops below12 psi / 0.8 bar, the ECM will shut the engine off toprevent damage. The engine oil pressure will beindicated on the display screen at the groundcontrols while the engine is running. Use the scrollbuttons and scroll to the Engine Oil Pressurescreen.

Component damage hazard.Do not crank the engine with a lowoil pressure fault shown on thedisplay at the ground controls.

6-3Oil Pressure and CoolantTemperature Sending Units -Cummins and Perkins Models

The coolant temperature sending unit is anelectrical device. If the coolant temperaturereaches 210° F / 99° C, the ECM will shut theengine off to prevent damage and will not start untilthe coolant temperature drops below210° F / 99° C. The engine temperature will beshown on the display screen at the ground controlswhen the key is ON and the Emergency Stop Buttonis pulled out to the ON position. Use the scrollbuttons and scroll to the ENGINE TEMPERATURE screen.

Component damage hazard.Do not crank the engine witha water temperature fault shownon the display at the groundcontrols.

The oil pressure sending unit is an electricaldevice. If the oil pressure drops below12 psi / 0.8 bar, the ECM will shut the engine off toprevent damage. The engine oil pressure will beindicated on the display screen at the groundcontrols while the engine is running. Use the scrollbuttons and scroll to the ENGINE OIL PRESSURE

screen.

Component damage hazard.Do not crank the engine with a lowoil pressure fault shown on thedisplay at the ground controls.

ENGINESREV B

4 - 58 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

The ground control box (TCON) is thecommunication and operations center for themachine. The ground control box contains two keyswitches. The key switch towards the top of thecontrol box is for selection of ground or platformcontrols. The key switch at the bottom of thecontrol box is the Service Bypass key switch. It isused to allow the boom to be raised above 10° withthe axles retracted and to correct an out-of-levelplatform. If the machine trips an envelope safetyswitch, the operator at the ground controls can turnand hold the Service Bypass key switch in theRECOVER position and the machine will automaticallylower the boom to the stowed position insequence.

The ground control box contains a replaceablemembrane decal with touch sensitive buttons forvarious machine functions. The ground control boxalso contains two printed circuit boards:

The LCD (Liquid Crystal Display) circuit boardis mounted to the inside of the control box lid whichcontrols the LCD display screen.

The ECM circuit board is the main circuit boardfor the machine. There are relays on the ECMcircuit board that can be replaced. All operatingparameters and configuration of options for themachine are stored in the ECM memory.

Note: The ECM circuit board inside the groundcontrol box (TCON) cannot be replaced by itself. Ifthe ECM circuit board is faulty and needs to bereplaced, contact the Genie Industries ServiceDepartment.

Note: When an ECM circuit board is replaced, theproportional valves will need to be calibrated. See1-3, How to Calibrate a Joystick.

7-1Circuit Boards

How to Remove the LCD DisplayScreen Circuit Board1 Push in the Emergency Stop button to the OFF


2 Remove the platform control box mountingfasteners. Remove the platform control boxfrom the machine.


3 Locate the cables that connect to the bottom ofthe control box. Number each cable and itslocation at the control box.


5 Remove the control cable plug retainingfasteners from the bottom of the platformcontrol box.

6 Remove the platform control box lid fasteners.Open the control box lid.

Ground Controls

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 59


REV A

7 Locate the ECM circuit board mounted to theinside of the platform control box.



8 Remove the ECM circuit board mountingfasteners.

9 Carefully remove the ECM circuit board fromthe platform control box.

7-2Membrane Decal

The membrane decal is a special decal thatconsists of a decal with an electronic membrane onthe backside. The membrane contains touchsensitive areas that, when pushed, activates themachine functions. The membrane buttonsactivate machine functions similar to toggleswitches, but do not have any moving parts.

How to Replace the MembraneDecal1 Turn the key switch at the ground controls to

the OFF position.

2 Push in the Emergency Stop button to the OFF


3 Remove the ground control box lid fasteners.Open the control box lid.

4 Carefully disconnect the two ribbon cables fromthe membrane decal at the ECM circuit board.



GROUND CONTROLS

4 - 60 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AGROUND CONTROLS

5 Carefully remove the membrane decal from thecontrol box lid while guiding the ribbon cablesout of the control box lid.

6 Remove any decal adhesive from the controlbox lid with a mild solvent.

Note: Do not allow any solvent to come in contactwith the LCD display screen.

7 Install the new membrane decal (Genie partnumber 50811) while guiding the ribbon cablesthrough the control box lid.

8 Connect the ribbon cables to the ECM circuitboard.

9 Close the control box lid and install the retainingfasteners.

7-3Control Relays

Relays used for single function switching are singlepole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay



1 Turn the key switch to the OFF position.

2 Open the ground control box and remove therelay to be tested from the ECM circuit board.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 61


REV A

Control Relay Schematic

3 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany 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 groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87 to 87a no continuity(infinite )

terminal 87a to 30 no continuity(infinite )

terminal 87 to 30 continuity(zero )

GROUND CONTROLS

4 - 62 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

S-100 and S-105 Models S-120 and S-125 Models

Limit Switches 123456789012123456789012123456789012123456789012123456789012123456789012123456789012

REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 63


REV A LIMIT SWITCHES

8-1Limit Switches

How to Test the Limit SwitchesThere are 2 types of limit switches: Mechanical(roller arm) and proximity. Mechanical limitswitches are activated by a part of the machinephysically moving the roller arm of the switch.Proximity switches are a magnetic type of switchand are activated by the close presence of aferrous metal.

Mechanical Operational Limit Switch:

1 Manually activate the limit switch.

Result: The limit switch arm should move freelyand spring return to center. A distinct clickshould be felt and heard.

2 Connect the leads from an ohmmeter orcontinuity tester to the deutsch connectorterminals in the combination listed below andcheck for continuity.


terminal 3 to 4 no continuity(infinite )

terminal 1 to 3 and 4 no continuity(infinite )


3 Activate the limit switch. Connect the leads froman ohmmeter or continuity tester to the deutschconnector terminals in the combination listedbelow and check for continuity.





Mechanical Safety Limit Switch:







123456789012123456789012123456789012123456789012123456789012123456789012REV B

4 - 64 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

LIMIT SWITCHES

2 Activate the limit switch. Connect the leads froman ohmmeter or continuity tester to the deutschconnector terminals in the combination listedbelow and check for continuity.






Proximity Switch:



2 Locate the target area of the proximity switch.

Proximity switcha target area

a

3 Place a piece of ferrous metal (steel, iron, etc.)in front of the target area so it is no more than1/2 inch / 12.7 mm away from the target area ofthe proximity switch.



5 Move the piece of ferrous metal (steel, iron,etc.) so it is more than 1/2 inch / 12.7 mm awayfrom the target area of the proximity switch.



How to Adjust the LimitSwitchesNote: Perform this procedure on a flat and levelarea and free from obstructions.

1 Fully retract the boom.

2 Place a digital protractor or digital level on top ofthe boom tube.

123456789012312345678901231234567890123123456789012312345678901231234567890123REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 65


REV A


3 Raise boom until the protractor reads 67.5degrees.

4 Loosen the mounting fasteners from the 68degree proximity switch (LSB14AO).

5 Disconnect the deutsch connector from the 68degree proximity switch (LSB14AO) andconnect an ohmmeter or continuity tester toterminals 3 and 4 of the deutsch connector.

6 Adjust LSB14AO until the switch contacts justopen. While observing the digital protractor,raise the boom until the switch contacts close,then lower the boom until the switch contactsopen. Repeat the process until the switchcontacts open between 67.5 and 68 degrees.

7 Tighten the 68 degree proximity switch(LSB14AO) mounting fasteners.

8 Lower the boom to 65.3 degrees.

9 Loosen the mounting fasteners from the 65degree safety switch (LSB9AS).

10 Disconnect the deutsch connector from the 65degree safety switch (LSB9AS) and connect anohmmeter or continuity tester to terminals 1 and2, and to terminals 3 and 4 of the deutschconnector.

11 Adjust LSB9AS until the switch contacts justopen. While observing the digital protractor,raise the boom until the switch contacts close,then lower the boom until the switch contactsopen. Repeat the process until the switchcontacts open between 65 and 65.5 degrees.

12 Tighten the 65 degree safety switch mountingfasteners.


All models:

14 S-100 and S-105 models: Raise the boom to52.5 degrees.

15 Loosen the mounting fasteners from the 53degree proximity switch (LSB13AO).

16 Disconnect the deutsch connector from the 53degree proximity switch (LSB13AO) andconnect an ohmmeter or continuity tester toterminals 3 and 4 of the deutsch connector.

17 Adjust LSB13AO until the switch contacts justopen. While observing the digital protractor,raise the boom until the switch contacts close,then lower the boom until the switch contactsopen. Repeat the process until the switchcontacts open between 52.5 and 53 degrees.

18 Tighten the 53 degree limit switch mountingfasteners.


20 Loosen the mounting fasteners from the 50degree safety switch (LSB8AS).

21 Disconnect the deutsch connector from the 50degree safety switch (LSB8AS) and connect anohmmeter or continuity tester to terminals 1 and2, and to 3 and 4 of the deutsch connector.

22 Adjust LSB8AS until the switch contacts justopen. While observing the digital protractor,raise the boom until the switch contacts close,then lower the boom until the switch contactsopen. Repeat the process until the switchcontacts open between 50 and 50.5 degrees.

LIMIT SWITCHES123456789012123456789012123456789012123456789012123456789012123456789012123456789012

REV B

4 - 66 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

8-2Limit Switch and Level SensorLocations

LIMIT SWITCHES

LSB2RO

LSB2RS

LSB6S

LSAX1ESLSAX1EO

LST1O

LSAX2EO

LSAX2RO

LSAX2ESPLATFORM

LEVEL

SENSOR

LSB19LO

TURNTABLE

LEVEL

SENSORLSAX1RO

LSB3RO

LSB4ES

LSB4EO

LSB3RS

LSB3EO

LSB1DO

LSB13AO

LSB8AS

LSB9AS

LSB7DS

LSB14AO

LSB19LO

123456789012123456789012123456789012123456789012123456789012123456789012123456789012

REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 67


REV A

8-3Limit Switch Functions

LSAX1RO: Operational Limit Switch, Front Axle,Retract. This switch activates when the axle is fullyretracted, activating axle retracted LED andshutting off power to axle retract coils after twoseconds.

LSAX2RO: Operational Limit Switch, Rear Axle,Retract. This switch activates when the axle is fullyretracted, activating axle retracted LED andshutting off power to axle retract coils after twoseconds.

LSAX1EO: Operational Limit Switch, Front Axle,Extend. This switch is activated when the axle isfully extended. If this switch is not activated, boomfunctions are restricted to the stowed range. If unitis out of stowed, all boom functions are disabled.Axle can be extended while driving to recover.

LSAX2EO: Operational Limit Switch, Rear Axle,Extend. This switch is activated when the axle isfully extended. If this switch is not activated, boomfunctions are restricted to the stowed range. If unitis out of stowed, all boom functions are disabled.Axle can be extended while driving to recover.

LSAX1ES: Safety Limit Switch, Front Axle,Extend. If this switch is tripped, then the axle is notfully extended. In this condition, if unit is out ofstowed, power is cut to boom up, boom extend andaxle retract.

LSAX2ES: Safety Limit Switch, Rear Axle,Extend. If this switch is tripped, then the axle is notfully extended. In this condition, if unit is out ofstowed, power is cut to boom up, boom extend andaxle retract.

Located under the drive chassis end cover at thecenter of the square end (blue): LSAX1RO,LSAX1EO, LSAX1ES

Located under the drive chassis end cover at thecenter of the round end (yellow): LSAX2RO,LSAX2EO, LSAX2ES

Located in the center of the swing chassis: LST1O

Located on the hydraulic tank tray:Turntable Level Sensor

Located on the inside of the swing chassis bulk-head at the counterweight end: LSB9AS, LSB8AS

Located at the base of the swing chassis near thecounterweight: LSB1LO

Located at the counterweight end of Boom tube 0:LSB6S

Located on the counterweight side of the liftcylinder support assembly: LSB1DO, LSB7DS,LSB13AO, LSB14AO

Located on the outside of the platform end of Boomtube 0:LSB2RO, LSB2RS

Located on the top of the platform end of Boomtube 2:LSB3EO, LSB3RS, LSB3RO, LSB2RO, LSB4ES

Located on the platform rotator: Platform LevelSensor

LIMIT SWITCHES123456789012123456789012123456789012123456789012123456789012123456789012

REV B

4 - 68 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

LSB3RO: Operational Limit Switch, 3’ Extend. Thisswitch activates anytime the boom is extendedbeyond 3 feet. If axles are not extended, boomextend is disabled and the extend axle LED andicon will flash as long as boom extend is operated.If axles are extended at this point, the motors areshifted to low and drive speed is limited to 0.7 mph.The boom up/down speed and turntable rotatespeed are limited to 60% of maximum.

LSB3RS: Safety Limit Switch, 3.5’ Extend. If axlesare not extended, this switch is activated when theboom is extended beyond 3.5 feet, cutting power toboom extend and axle retract.

LSB3EO: Operational Limit Switch, 75’ Extend.This switch activates anytime the boom is ex-tended to 75 feet or beyond. At this point drivespeed is reduced to 0.4 mph, boom up/down isreduced to 29% of maximum and turntable rotate isreduced to 40% of maximum. If boom angle is lessthan 53O, then boom extend is disabled and theraise boom LED and icon and alarm will flash aslong as boom extend is operated.

LSB4ES: Safety Limit Switch, 75.5’ Extend. Thisswitch cuts power to boom extend, boom down andengine fuel solenoid when it is mechanicallyactivated at 75.5 feet, if boom angle is less than50O.

LSB4EO: Operational Limit Switch, 100’ Extend.This switch activates anytime the boom is ex-tended to 100 feet or beyond. The boom up/down isreduced to 20% of maximum. If boom angle is lessthan 68O, then boom extend is disabled and theraise boom LED and icon and alarm will flash aslong as boom extend is operated. If boom angle isgreater than 65O, the BO lockout valve will activateallowing hydraulic flow to the external cylinder tocontinue to extend to 120 feet.

LIMIT SWITCHES

LSB6S: Safety Limit Switch, Cable Tension. Cutspower to the extend directional valve if extendcables are out of adjustment or one breaks.

LSB1DO: Operational Limit Switch, 10O Angle. Thisswitch activates anytime the boom is raised above10O. If axles are not extended, boom up is disabledand the extend axle LED and icon will flash as longas boom up is operated. At this point, if axles areextended, the motors are shifted to low and drivespeed is limited to 0.7 mph.

LSB7DS: Safety Limit Switch, 11O Angle. If axlesare not extended, this switch is activated whenboom is raised to 11O, cutting power to boom upand axle retract.

LSB13AO: Operational Limit Switch, 53O Angle.This switch activates at 53O boom angle, allowingthe boom to be extended beyond 75 feet. If theboom is lowered past this switch when the boom isbeyond 75 feet, boom extend and boom down aredisabled. The retract boom LED and icon and alarmwill flash as long as boom down is operated.

LSB8AS: Safety Limit Switch, 50O Angle. Thisswitch cuts power to boom extend, boom down andthe engine fuel solenoid when it is mechanicallyactivated at 50O if the boom length is more than75.5 feet.

LSB14AO: Operational Limit Switch, 68O Angle.This switch is activated at 68O boom angle andallows the boom to be extended beyond 100 feet. Ifthe boom is lowered past this switch when ex-tended beyond 100 feet, boom extend and boomdown are disabled. The boom retract LED and iconand alarm will flash as long as boom down isoperated.

LSB9AS: Safety Limit Switch, 65O Angle. Thisswitch cuts power to boom extend, boom down andthe engine fuel solenoid when it is mechanicallyactivated at 65O if the boom length is more than101 feet.

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REV B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 69


REV A

LSB2RS: Safety Limit Switch, 101’ Extend. Thisswitch cuts power to boom extend, boom down andengine fuel solenoid when it is mechanicallyactivated at 101 feet, if boom angle is less than65O.

LSB2RO: Operational Limit Switch, 100’ Retract.This switch is activated anytime boom length is100’ or less. Anytime the boom is being retractedwhile this switch is activated, the BN lockout valveis activated allowing hydraulic flow out of the innercylinder.

LSB19LO: Operational Limit Switch, Down Over-load. This switch disables all functions exceptboom retract and boom up and activates a mediumfrequency alarm and the boom down overloaddiagnostic code.

LST1O: Operational Limit Switch, Drive Enable.This switch is activated when the turntable isrotated in the standard drive zone.

Turntable Level Sensor: Measures the X axis andY axis of the turntable. The alarm sounds at 4.5O.

Platform Level Sensor: Measures the angle of theplatform. The range of measurement is +/- 20O. Thesafety cutout is set at +/- 10O from gravity and willdisable the primary and secondary boom up/downfunctions and the platform level up/down functions.

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4 - 70 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

9-1Function Pumps

There are three hydraulic pumps connected to theengine. There is one variable displacement pumpthat is used for drive functions and two fixeddisplacement pumps attached to the drive pumpthat are used for all other machine functions.

How to Remove theFunction PumpsNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur.If the tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

2 Tag, disconnect and plug the hydraulic hosesfrom the function pumps. Cap the fittings on thepumps.


3 Support the function pumps with an overheadcrane or other suitable lifing device.

4 Remove the pump mounting bolts. Carefullyremove the pumps.

Crushing hazard. The functionpumps may become unbalancedand fall when the mounting boltsare removed if they are notproperly supported.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpsafter installing the pumps.See 9-2, How to Prime the Pumps.

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Hydraulic Pumps

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 71


REV A

9-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call the GenieIndustries Service Department to locate your localauthorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Remove the function pumps. See How toRemove the Function Pumps.

2 Disconnect the electrical connection at theelectronic displacement controller (EDC)located on the drive pump.

3 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

4 Tag, disconnect and plug the hydraulic hosesfrom the drive pump. Cap the fittings on thepump.


5 Support the drive pump with a suitable liftingdevice and remove the two drive pumpmounting fasteners.

6 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

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HYDRAULIC PUMPS

4 - 72 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AHYDRAULIC PUMPS

7 Remove the drive pump from the machine.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

Note: Before installing the pump, verify properpump coupler spacing. Refer to the appropriate flexplate installation instructions for your engine.

How to Prime the PumpsComponent damage hazard. Besure that the hydraulic tank shutoffvalves are in the OPEN positionbefore priming the pump. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur.

1 Connect a 0 to 600 psi (0 to 41 bar) pressuregauge to one of the test ports located under thedrive pump.


2 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine to access the fuel injectionpump.




Crushing hazard. Failure to installthe bolt into the engine pivot plateanchor hole to secure it frommoving could result in death orserious injury.

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Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 73


REV A

5 Deutz models: Disconnect the engine wiringharness from the fuel shutoff solenoid at theinjector pump.

Deutz modelsa fuel shutoff solenoid

Cummins and Perkins models: Disconnectthe wire from the fuel shutoff solenoid at theinjector pump.

Cummins modelsa fuel shutoff solenoid

Perkins modelsa fuel shutoff solenoid

6 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 250 psi / 17.2 bar.

Bodily injury hazard. Keep hands,loose clothing and hair clear of allmoving engine parts while theengine is cranking.

7 Deutz models: Connect the engine wiringharness to the fuel shutoff solenoid at theinjector pump.

Cummins and Perkins models: Connect thewire to the fuel shutoff solenoid at the injectorpump.

8 Start the engine and check for hydraulic leaks.

HYDRAULIC PUMPS

4 - 74 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AHYDRAULIC PUMPS

9-3Auxiliary Pump

How to Test the Auxiliary PumpThe auxiliary pump is a 2-section, gear-type pump.Pump number 1 is the pump section closest to thepump motor and pump number 2 is the pumpsection that is farther from the pump motor. Eachsection of the pump has its own relief valve locatedwithin the pump body.


1 Disconnect and plug the high pressure hydraulichose from pump number 1.


2 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the high pressure port on pumpnumber 1.

3 Turn the key switch to ground control and pullout 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 isincorrect or the pump is bad and will need to beserviced or replaced.

5 Turn the key switch to the OFF position.

6 Remove the pressure gauge and reconnect thehydraulic hose.

7 Disconnect the hydraulic hose from the highpressure port from pump number 2.

8 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the high pressure port on pumpnumber 2.

9 Turn the key switch to ground control and pullout the Emergency Stop button to the ON

position.

10 Activate any function using auxiliary power.

Result: If the pressure gauge reads 3000 psi /207 bar, immediately stop. The pump is good.

Result: If pressure fails to reach 3000 psi/ 207 bar, the internal relief valve setting isincorrect or the pump is bad and will need to beserviced or replaced.

11 Remove the pressure gauge and reconnect thehydraulic hose.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 75


REV A

How to Remove the AuxiliaryPump1 Open the ground controls side turntable cover.

2 Tag, disconnect and plug the hydraulic hosesfrom the pumps.

3 Remove the pump mounting fasteners andremove the pump from the pump motor.

HYDRAULIC PUMPS

4 - 76 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AManifolds

10-1Function Manifold Components, S-100 and S-105 Models(serial number 136)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic

No. Description Item Function Torque

1 Relief valve, 1800 psi / 124.1 bar ..... FA ......... Boom extend pressure limit .............. 18-20 ft-lbs / 24-27 Nm

2 Proportional solenoid valve .............. FB ......... Boom extend/retractproportional speed control ......... 33-37 ft-lbs / 44.9-50.3 Nm

3 Solenoid valve, 3 position 4 way ...... FC ......... Turntable rotate left/right ............... 25-27 ft-lbs / 34-36.7 Nm

4 DO3 valve, 3 position 4 way ............. FD ........ Boom up/down .................................... 30-35 in-lbs / 3-4 Nm

5 Priority flow regulator valve,0.1 gpm / 0.38 L/min .......................... FE ......... Bleeds off differential

sensing valves to tank ......................18-20 ft-lbs / 24-27 Nm

6 Proportional solenoid valve .............. FF ......... Boom up/down proportionalspeed control .............................. 33-37 ft-lbs / 44.9-50.3 Nm

7 Proportional solenoid valve .............. FG ......... Turntable rotate proportionalspeed control ....................................18-20 ft-lbs / 24-27 Nm

8 Counterbalance valve,3200 psi / 220.6 bar FH Boom down circuit ............................ 30-35 ft-lbs / 38-41 Nm

9 Relief valve, 2600 psi / 179.3 bar ..... FI .......... Turntable rotate, boom lift andboom retract pressure limit ............ 25-27 ft-lbs / 34-36.7 Nm

10 Check valve ....................................... FJ ......... Load sensing circuit,boom up/down .................................. 12-14 ft-lbs / 16-19 Nm

This list continues. Please turn the page.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 77


REV A MANIFOLDS

FQ

FR

FA FD

FE

FB FC

FF

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FJ

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FLFM

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4 - 78 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

Function Manifold Components, S-100 and S-105 Models, continued(serial number 136)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


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-lbs / 34-37 Nm

16 Solenoid valve, 2 position 3 way ...... FQ ......... Boom retract control ......................... 25-27 ft-lbs / 34-37 Nm

17 Solenoid valve, 2 position 3 way ...... FR ......... Boom extend control ........................ 52-60 ft-lbs / 71-82 Nm

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 79


REV A MANIFOLDS

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FR

FA FD

FE

FB FC

FF

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FJ

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FLFM

TP

FP

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4 - 80 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-2Function Manifold Components, S-100 and S-105 Models(after serial number 136)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


1 Solenoid Valve Assembly,3 position 4 way, DO3, 12V DC ........ FD ......... Boom up/down .................................... 30-35 in-lbs / 3-4 Nm

6 Solenoid Valve, 3 position 4 way ...... FC ......... Turntable rotate control, left/right ...... 25-27 ft-lbs / 34-37 Nm

7 Proportional Solenoid Valve ............. FG ......... Turntable rotate,proportional speed control ............... 18-20 ft-lbs / 25-27 Nm

8 Solenoid Valve, 2 position 3 way ...... AA ......... Auxiliary drive/steer selector ............ 25-27 ft-lbs / 34-37 Nm

9 Relief Valve, 3000 psi / 206.8 bar ..... AC ........ Platform manifold pressure limit ....... 18-20 ft-lbs / 24-27 Nm

10 Flow Regulator Valve,3 gpm / 11.36 L/min ........................... AD ........ Priority flow to platform ..................... 25-27 ft-lbs / 34-37 Nm

11 Check Valve, 5 psi / 0.34 bar ............ AE ......... Blocks flow from pump 2to auxiliary pump ........................... 12-14 ft-lbs / 16.3-19 Nm

12 Proportional Solenoid Valve, N.C. .... FF ......... Primary lift, proportionalvalve speed control .......................... 33-37 ft-lbs / 45-50 Nm

13 Check Valve, 10 psi / 0.69 bar .......... AB ......... Blocks flow from pump 1 and 2to auxiliary pump ........................ 18-20 ft-lbs / 24.5-27.2 Nm

14 Check Valve ...................................... AG ........ Blocks flow from auxiliary pump,port 2A to pump 1 ............................. 33-37 ft-lbs / 45-50 Nm

15 Check Valve, 5 psi / 0.34 bar ............ AF ......... Blocks flow from auxiliary pump,ports 2A and 3A to pump 2 ............... 25-27 ft-lbs / 34-37 Nm

This list continues on the next page.

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 81


REV A

FQ

FR

FA

AC

FD

FE

AD

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FI

FJ

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FK

FL

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AG

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MANIFOLDS

4 - 82 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Function Manifold Components, S-100 and S-105 Models, continued(after serial number 136)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


16 Relief Valve, 2600 psi / 179.3 bar ..... FI .......... Turntable, primary lift andboom retract pressure limit ............... 25-27 ft-lbs / 34-37 Nm

17 Counterbalance Valve,3200 psi / 220.6 bar .......................... FH ......... Primary lift, load holding ................... 30-35 ft-lbs / 38-41 Nm

18 Orifice Plug, 0.040 inch / 1.016 mm .. FK ......... Differential sensing damping

20 Diagnostic Nipple .............................. TP ......... Testing

21 Proportional Valve ............................ FB ......... Boom extend/retract solenoidvalve proportional speed control ...... 33-37 ft-lbs / 45-50 Nm

22 Check Valve, 5 psi / 0.34 bar ............ FM ........ Extension cylinderload sense check ........................... 12-14 ft-lbs / 16.3-19 Nm

23 Check Valve, 5 psi / 0.34 bar ............ FJ ......... Primary lift load sense check ......... 12-14 ft-lbs / 16.3-19 Nm

24 Differential Sensing Valve,110 psi / 7.58 bar .............................. FP ......... Directs flow to functions .................... 25-27 ft-lbs / 34-37 Nm

25 Check Valve, 5 psi / 0.34 bar ............ FL ......... Extension cylinderload sense check ........................... 12-14 ft-lbs / 16.3-19 Nm

26 Flow Regulator Valve,0.1 gpm / 0.38 L/min .......................... FE ......... Bleeds off differential

sensing valve to tank .................. 18-20 ft-lbs / 24.5-27.2 Nm

27 Solenoid Valve, 2 position 3 way ...... FQ ......... Boom retract control ......................... 52-60 ft-lbs / 71-82 Nm

28 Solenoid Valve, 2 position 3 way ...... FR ......... Boom extend control ........................ 52-60 ft-lbs / 71-82 Nm

29 Relief Valve, 1800 psi / 124.1 bar ..... FA ......... Boom extend pressure limit ........ 18-20 ft-lbs / 24.5-27.2 Nm

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 83


REV A

FQ

FR

FA

AC

FD

FE

AD

FB

FC

FF

FG

AA

AB

AE

FH

FI

FJ

TP

FK

FL

AF

FM

FP

AG

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MANIFOLDS

4 - 84 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-3Valve Adjustments - FunctionManifold, S-100 and S-105 Models

How to Adjust the FunctionManifold Relief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the test port on the function manifold.


3 Simultaneously push and hold the functionenable/high speed button and the boom retractbutton with the boom fully retracted. Observethe pressure reading on the pressure gauge.Refer to Section 2, Hydraulic Oil Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item FI).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

6 Repeat steps 2 through 5 to confirm the reliefvalve pressure.

How to Adjust the Boom ExtendRelief ValveNote: Perform this procedure with the boom in thestowed position.



3 Fully raise and extend the boom.

4 Simultaneously push and hold the functionenable/high speed button and the boom extendbutton with the boom fully extended. Observethe pressure reading on the pressure gauge.Refer to Section 2, Hydraulic Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item FA).




Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 85


REV A

10-4Proportional Valves -Function Manifold

Note: When a proportional valve cartridge or coil isreplaced or moved to a different valve cartridge orcavity, the proportional valve cartridge or coil willneed to be calibrated. See 1-3, How to Calibrate aJoystick.

MANIFOLDS

4 - 86 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-5Function Manifold Components, S-120 and S-125 Models(before serial number 431)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


1 Relief valve, 1800 psi / 124.1 bar ..... BA ........ Boom extend pressure limit ..............18-20 ft-lbs / 24-27 Nm

2 Proportional solenoid valve .............. BB ......... Boom extend/retractproportional speed control ...............33-37 ft-lbs / 45-50 Nm

3 Solenoid valve, 3 position 4 way ...... BC ........ Turntable rotate left/right ..................25-27 ft-lbs / 34-37 Nm

4 DO3 valve, 3 position 4 way ............. BD ........ Boom up/down .................................... 30-35 in-lbs / 3-4 Nm

5 Priority flow regulator valve,0.1 gpm / 0.38 L/min .......................... BE ......... Bleeds off differential

sensing valves to tank ......................18-20 ft-lbs / 24-27 Nm

6 Proportional solenoid valve .............. BF ......... Boom up/down proportionalspeed control ....................................33-37 ft-lbs / 45-50 Nm

7 Proportional solenoid valve .............. BG ........ Turntable rotate proportionalspeed 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 andboom retract pressure limit ...............25-27 ft-lbs / 34-37 Nm

10 Check valve ....................................... BJ ......... Load sensing circuit,boom up/down ..................................12-14 ft-lbs / 16-19 Nm

11 Orifice - plug,0.040 inch / 1.02 mm ......................... BK ........ Differential sensing dampening


Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 87


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BR

BA BD

BE

BB BC

BF

BG

BH

BI

BJ

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BK

BLBMBN

BO

BP

4 - 88 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

Function Manifold Components, S-120 and S-125 Models, continued(before serial number 431)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


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 control ....... 33-37 ft-lbs / 45-50 Nm

17 Differential sensing valve .................. BP ......... Directs flow to functions .................... 25-27 ft-lbs / 34-37 Nm

18 Solenoid valve, 2 position 3 way ...... BQ ........ Boom retract control ......................... 52-60 ft-lbs / 71-82 Nm

19 Solenoid valve, 2 position 3 way ...... BR ........ Boom extend control ........................ 52-60 ft-lbs / 71-82 Nm

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 89


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BR

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BE

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BG

BH

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TP

BK

BLBMBN

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BP

4 - 90 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-6Function Manifold Components, S-120 and S-125 Models(from serial number 431 to 574)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


1 DO3 Valve, 3 position 4 way, ............ BD ........ Boom up/down .................................... 30-35 in-lbs / 3-4 Nm

2 Solenoid Valve, 3 position 4 way ...... BC ........ Turntable rotate left/right .................. 25-27 ft-lbs / 34-37 Nm

3 Proportional Solenoid Valve ............. BG ........ Turntable rotate, proportionalspeed control .................................... 18-20 ft-lbs / 25-27 Nm


5 Relief Valve, 3000 psi / 206.8 bar ..... AC ........ Platform manifold pressure limit ....... 18-20 ft-lbs / 25-27 Nm

6 Flow Regulator Valve,3 gpm / 11.36 L/min ........................... AD ........ Priority flow to platform ..................... 25-27 ft-lbs / 34-37 Nm

7 Check Valve, 5 psi / 0.34 bar ............ AE ......... Blocks flow from pump 2to auxiliary pump ....................... 12-14 ft-lbs / 16.2-18.9 Nm

8 Proportional Solenoid Valve, N.C. .... BF ......... Primary lift,proportional speed control ............... 33-37 ft-lbs / 45-50 Nm

9 Check Valve ...................................... AB ......... Blocks flow from pump 1 and 2to auxiliary pump .............................. 18-20 ft-lbs / 25-27 Nm


11 Check Valve ...................................... AF ......... Blocks flow from auxiliary pump,ports 2A and 3A to pump 2 ............... 25-27 ft-lbs / 34-37 Nm

12 Relief Valve, 2600 psi / 179.3 bar ..... BI .......... Turntable, primary lift and boomretract pressure limit ......................... 25-27 ft-lbs / 34-37 Nm


MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 91


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AB

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BK

BL

AF

BM

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4 - 92 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Function Manifold Components, S-120 and S-125 Models, continued(from serial number 431 to 574)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


13 Counterbalance Valve,3200 psi / 220.6 bar .......................... BH ........ Primary lift, load holding .................. 30-35 ft-lbs / 41-47 Nm

14 Orifice Plug, 0.040 inch / 1.016 mm .. BK ......... Differential sensing damping


16 Proportional Solenoid Valve, N.C. .... BB ......... Boom extend/retract proportionalspeed control .................................... 33-37 ft-lbs / 45-50 Nm

17 Solenoid Valve,2 position 2 way, N.C. ....................... BN ........ Boom retract sequence control ...... 33-37 ft-lbs / 45-50 Nm

18 Check Valve, 5 psi / 0.34 bar ............ BM ........ Extension cylinderload sense check ........................... 12-14 ft-lbs / 16.3-19 Nm

19 Check Valve, 5 psi / 0.34 bar ............ BJ ......... Primary lift load sense check ........ 12-14 ft-lbs / 16.3-19 Nm

20 Differential Sensing Valve,110 psi / 7.58 bar .............................. BP ......... Directs flow to functions ................... 25-27 ft-lbs / 34-37 Nm

21 Check Valve, 5 psi / 0.34 bar ............ BL ......... Turntable rotateload sense check ........................... 12-14 ft-lbs / 16.3-19 Nm

22 Flow Regulator Valve,0.1 gpm / 0.38 L/min .......................... BE ......... Bleeds off differential

sensing valve to tank ........................ 18-20 ft-lbs / 25-27 Nm

23 Solenoid Valve,2 position 2 way, N.C. ....................... BO ........ Boom extend sequence control ..... 33-37 ft-lbs / 45-50 Nm

24 Solenoid Valve, 2 position 3 way ...... BQ ........ Boom retract control ....................... 52-60 ft-lbs / 71-82 Nm

25 Solenoid Valve, 2 position 3 way ...... BR ........ Boom extend control ...................... 52-60 ft-lbs / 71-82 Nm

26 Relief Valve, 1800 psi / 124.1 bar ..... BA ......... Boom extend pressure limit ............. 18-20 ft-lbs / 25-27 Nm

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 93


REV A MANIFOLDS

16

1

23

24

22

18

19

20

17

25

26

11

12

13

14

15

3

2

8

7

9

10

5

4

6

21

BQ

BR

BA

AC

BD

BE

AD

BB

BC

BG

AA

AB

AE

BH

BI

BJ

TP

BK

BL

AF

BM

BN

BO

BP

AG

BF

4 - 94 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-7Function Manifold Components, S-120 and S-125 Models(after serial number 574)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


1 Solenoid Valve Assembly,3 position 4 way, DO3, 12V DC ........ BD ........ Boom up/down .................................... 30-35 in-lbs / 3-4 Nm


3 Check Valve, 5 psi / 0.34 bar ............ AE ......... Blocks flow from pump 2to auxiliary pump ........................... 12-14 ft-lbs / 16.3-19 Nm

4 Flow Regulator Valve,3 gpm / 11.36 L/min ........................... AD ........ Priority flow to platform ............... 23-25 ft-lbs / 31.2-33.9 Nm

5 Check Valve, 10 psi / 0.69 bar .......... AB ......... Blocks flow from pump 1 and 2to auxiliary pump .............................. 18-20 ft-lbs / 25-27 Nm

6 Solenoid Valve, 3 position 4 way ...... BC ........ Turntable rotate control,left/right ............................................. 25-27 ft-lbs / 34-37 Nm

7 Proportional Solenoid Valve ............. BG ........ Turntable rotate,proportional speed control ............... 18-20 ft-lbs / 25-27 Nm

8 Differential Sensing Valve,230 psi / 15.9 bar .............................. BP ......... Directs flow to functions .................... 33-37 ft-lbs / 45-50 Nm

9 Check Valve ...................................... BL ......... Turntable rotateload sense check ........................... 12-14 ft-lbs / 16.3-19 Nm

10 Proportional Solenoid Valve ............. BB ......... Boom extend/retractproportional speed control ............... 33-37 ft-lbs / 45-50 Nm

11 Check Valve, 5 psi / 0.34 bar ............ AF ......... Blocks flow from auxiliary pump,ports 2A and 3A to pump 2 ............... 25-27 ft-lbs / 34-37 Nm


13 Relief Valve, 3000 psi / 206.8 bar ..... AC ........ Platform manifoldpressure limit ................................... 18-20 ft-lbs / 25-27 Nm


MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 95


REV A MANIFOLDS

BB

1 2 3 4 5

22

26

25

27

21

18

24

23

13

14

15

16

12

7

6

8

9

10

11

17

20

19

BR

BD AD

BC

BF

BG

AA ABAE

BH

BI

BJ

TP

BK

BE

BL

BM

BN

BS

BO

BP

BA

AC

AF

AG

BQ

4 - 96 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Function Manifold Components, S-120 and S-125 Models, continued(after serial number 574)The function manifold is mounted to the turntable next to the ground controls.

Index Schematic


14 Relief Valve, 2600 psi / 179.3 bar ..... BI .......... Turntable, primary lift andboom retract pressure limit ............ 12-14 ft-lbs / 16.3-19 Nm


16 Counterbalance Valve,3200 psi / 220.6 bar .......................... BH ........ Primary lift, load holding ................... 30-35 ft-lbs / 41-47 Nm

17 Relief Valve, 1800 psi / 124.1 bar ..... BA ......... Boom extend pressure limit .............. 18-20 ft-lbs / 25-27 Nm

18 Flow Regulator Valve,0.1 gpm / 0.38 L/min .......................... BE ......... Leads off differential

sensing valve to tank ........................ 18-20 ft-lbs / 25-27 Nm

19 Check Valve, 5 psi / 0.34 bar ............ BM ........ Extension cylinderload sense check ........................... 12-14 ft-lbs / 16.3-19 Nm

20 Check Valve, 5 psi / 0.34 bar ............ BJ ......... Primary lift load sense check ......... 12-14 ft-lbs / 16.3-19 Nm

21 Orifice Plug, 0.040 inch / 1.016 mm .. BK ......... Differential sensing damping

22 Check Valve, 30 psi / 2.06 bar .......... BS ......... Back pressure check,boom extend ..................................... 33-37 ft-lbs / 45-50 Nm

23 Proportional Solenoid Valve ............. BF ......... Primary lift,proportional speed control ............... 33-37 ft-lbs / 45-50 Nm

24 Solenoid Valve,2 position 2 way, N.C. ....................... BO ........ Boom extend sequence control ....... 33-37 ft-lbs / 45-50 Nm

25 Solenoid Valve,2 position 2 way, N.C. ....................... BN ........ Boom retract sequence control ........ 33-37 ft-lbs / 45-50 Nm

26 Solenoid Valve, 2 position 3 way ...... BQ ........ Boom retract control ......................... 52-60 ft-lbs / 71-82 Nm

27 Solenoid Valve, 2 position 3 way ...... BR ........ Boom extend control ........................ 52-60 ft-lbs / 71-82 Nm

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 97


REV A MANIFOLDS

BB

1 2 3 4 5

22

26

25

27

21

18

24

23

13

14

15

16

12

7

6

8

9

10

11

17

20

19

BR

BD AD

BC

BF

BG

AA ABAE

BH

BI

BJ

TP

BK

BE

BL

BM

BN

BS

BO

BP

BA

AC

AF

AG

BQ

4 - 98 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-8Valve Adjustments - FunctionManifold, S-120 and S-125 Models

How to Adjust the FunctionManifold Relief ValveNote: Perform this procedure with the boom in thestowed position.



3 Simultaneously push and hold the functionenable/high speed button and the boom retractbutton with the boom fully retracted. Observethe pressure reading on the pressure gauge.Refer to Section 2, Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BI).




How to Adjust the Boom ExtendRelief ValvePerform this procedure with the boom in the stowedposition.



3 Fully raise and extend the boom.

4 Simultaneously push and hold the functionenable/high speed button and the boom extendbutton with the boom fully extended. Observethe pressure reading on the pressure gauge.Refer to Section 2, Hydraulic Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BA).




Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 99


REV A

10-9Proportional Valves -Function Manifold

Note: When a proportional valve cartridge or coil isreplaced or moved to a different valve cartridge orcavity, the proportional valve cartridge or coil willneed to be calibrated. See 1-3, How to Calibrate aJoystick Controller.

MANIFOLDS

4 - 100 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-10Platform Manifold Components, S-100 and S-120 ModelsThe platform manifold is mounted to the platform mounting weldment.

Index Schematic


1 Proportional solenoid valve,3 position 4 way ................................ GH ........ Platform level up/down ..................... 18-20 ft-lbs / 24-27 Nm

2 Check valve ....................................... GF ......... Platform rotate circuit

3 Check valve ....................................... GJ ......... Platform level circuit

4 Accumulator, 500 psi / 34.5 bar ........ GM ........ Hydraulic dampening .................................. 23 ft-lbs / 31 Nm

5 Differential sensing valve, N.O. ......... GI .......... Platform level differentialsensing circuit ................................... 23-25 ft-lbs / 31-34 Nm

6 Differential sensing valve, N.O. ......... GE ........ Platform rotate differentialsensing circuit ................................... 23-25 ft-lbs / 31-34 Nm

7 Orifice - plug, 0.030 inch / 0.762 mm GB ........ Platform rotate left circuit

8 Orifice - plug, 0.030 inch / 0.762 mm GC ........ Platform rotate right circuit

9 Shuttle valve ...................................... GG ........ Platform level load sense circuit ....... 7.4-9 ft-lbs / 10-12 Nm

10 Shuttle valve ...................................... GA ........ Platform rotate load sense circuit ...... 7.4-9 ft-lbs / 10-12 Nm

11 Differential sensing valve, N.C. ......... GC ........ Directs flow to functions .................... 23-25 ft-lbs / 31-34 Nm

12 Proportional solenoid valve,3 position 4 way ................................ GD ........ Platform rotate left/right ..................... 18-20 ft-lbs / 24-27 Nm

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 101


REV A MANIFOLDS

10 9 8

41

11

12

5

6

3

7

2

GQ

GI

GE

GBGGGA

GO

GD

GH

GC

GF GJ

4 - 102 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-11Platform Manifold Components, S-105 and S-125 ModelsThe platform manifold is mounted to the platform mounting weldment.

Index Schematic


1 Proportional solenoid valve,3 position 4 way ................................ CH ........ Platform level up/down ..................... 18-20 ft-lbs / 24-27 Nm

2 Check valve ....................................... CF ......... Platform rotate circuit

3 Check valve ....................................... CJ ......... Platform level circuit

4 Proportional solenoid valve,3 position 4 way ................................ CL ......... Jib boom up/down ............................ 18-20 ft-lbs / 24-27 Nm

5 Check valve ....................................... CN ........ Jib boom circuit

6 Accumulator, 500 psi / 34.5 bar ........ CQ ........ Hydraulic dampening .................................. 23 ft-lbs / 31 Nm

7 Differential sensing valve, N.O. ......... CM ........ Jib boom differentialsensing circuit ................................... 23-25 ft-lbs / 31-34 Nm

8 Differential sensing valve, N.O. ......... CI .......... Platform level differentialsensing 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 differentialsensing circuit ................................... 23-25 ft-lbs / 31-34 Nm

11 Shuttle valve ...................................... CK ........ Jib boom load sense circuit

12 Orifice - plug, 0.030 inch / 0.762 mm CB ........ Platform rotate left circuit

13 Orifice - plug, 0.030 inch / 0.762 mm CC ........ Platform rotate right circuit

14 Shuttle valve ...................................... CG ........ Platform level load sense circuit ....... 7.4-9 ft-lbs / 10-12 Nm

15 Shuttle valve ...................................... CA ........ Platform rotate load sense circuit ...... 7.4-9 ft-lbs / 10-12 Nm

16 Differential sensing valve, N.C. ......... CO ........ Directs flow to functions .................... 23-25 ft-lbs / 31-34 Nm

17 Proportional solenoid valve,3 position 4 way ................................ CD ........ Platform rotate left/right ..................... 18-20 ft-lbs / 24-27 Nm

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 103


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12 111415

641

16

17

7

8

9

10

532

13

CD

CO

CH CLCF CJ CN CQ

CM

CP

CI

CE

CBCC CKCGCA

4 - 104 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-12Proportional Valves -Platform Manifolds

Note: When a proportional valve cartridge or coil isreplaced or moved to a different valve cartridge orcavity, the proportional valve cartridge or coil willneed to be calibrated. See 1-3, How to Calibrate aJoystick.

10-13Platform Rotate Counterbalance Valve Manifold Components

Index Schematic


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

123123123123123

12341234123412341234

A

B

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 105


REV A

10-14Turntable Rotation Manifold ComponentsThe turntable rotation manifold is mounted to the turntable rotation motor.

Index Schematic


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

123451234512345123451234512345

1234512345123451234512345

123456123456123456123456123456

4 - 106 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-15Steer and Axle Extend/Retract Manifold Components - View 1The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end

of the machine.

Index Schematic


1 Solenoid Valve, 3 position 4 way ...... EA ......... Steering cylinder control,square end, right side ....................... 18-20 ft-lbs / 24-27 Nm

2 Solenoid Valve, 3 position 4 way ...... EB ......... Steering cylinder control,square end, left side ......................... 18-20 ft-lbs / 24-27 Nm

3 Solenoid Valve, 3 position 4 way ...... EC ........ Steering cylinder control,round end, right side ........................ 18-20 ft-lbs / 24-27 Nm

4 Solenoid Valve, 3 position 4 way ...... ED ........ Steering cylinder control,round end, left side ........................... 18-20 ft-lbs / 24-27 Nm

5 Flow Regulator Valve,1.4 gpm / 5.3 L/min ............................ ET ......... Steering cylinder speed,

round end, right side, retract ............ 18-20 ft-lbs / 24-27 Nm

6 Flow Regulator Valve,2 gpm / 7.6 L/min ............................... EU ........ Steering cylinder speed,

round end, left side, extend .............. 18-20 ft-lbs / 24-27 Nm

7 Flow Regulator Valve,2 gpm / 7.6 L/min ............................... EV ......... Steering cylinder speed,

square end, right side, extend .......... 18-20 ft-lbs / 24-27 Nm

8 Flow Regulator Valve,0.1 gpm / 0.38 L/min .......................... EO ........ Bleeds off differential valve to tank ... 18-20 ft-lbs / 24-27 Nm

9 Differential Sensing Valve, 110 psi ... EP ......... Meters flow to functions sensing ...... 25-27 ft-lbs / 34-37 Nm

10 Flow Regulator Valve,1.4 gpm / 5.3 L/min ............................ EW ........ Steering cylinder speed,

square end, left side, retract ............. 18-20 ft-lbs / 24-27 Nm

11 Solenoid Valve,3 position 4 way ................................ ES ......... Axle extend contrrol .......................... 25-27 ft-lbs / 34-37 Nm

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 107


REV A

ES

57 6

21 3

11

10

9

8

4

EO

EB EC

ED

ETEU

EP

EV

EW

EA

MANIFOLDS

4 - 108 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-16Steer and Axle Extend/Retract Manifold Components - View 2The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end

of the machine.

Index Schematic


1 Flow Regulator Valve,2 gpm / 7.6 L/min ............................... EE ......... Steering cylinder speed ................... 18-20 ft-lbs / 25-27 Nm

2 Flow Regulator Valve,1.4 gpm / 5.3 L/min ............................ EJ ......... Steering cylinder speed, circle end,

left side, retract ................................. 18-20 ft-lbs / 25-27 Nm

3 Flow Regulator Valve,1.4 gpm / 5.3 L/min ............................ EQ ........ Steering cylinder speed,

square end, right side, retract ........... 18-20 ft-lbs / 25-27 Nm

4 Flow Regulator Valve,2 gpm / 7.6 L/min ............................... ER ........ Steering cylinder speed,

square end, left side, extend ............ 18-20 ft-lbs / 25-27 Nm

5 Check Valve, 5 psi / 0.34 bar ............ EX ......... Axle extend load sense,both ends ....................................... 12-14 ft-lbs / 16.3-19 Nm

6 Relief Valve, 1800 psi / 124 bar ........ EQQ ...... Axle extend ....................................... 18-20 ft-lbs / 25-27 Nm

7 Relief Valve, 3000 psi / 207 bar ........ EZ ......... Steering pressure limit ..................... 18-20 ft-lbs / 25-27 Nm(Removed from S-120/125 at serial number 522, S-100/105 at serial number 148)

8 Check Valve, 5 psi / 0.34 bar ............ EY ......... Axle retract load sense,both ends ....................................... 12-14 ft-lbs / 16.3-19 Nm

9 Check Valve, 5 psi / 0.34 bar ............ EKK ...... Steering load sense, square end,right side, extend ........................... 12-14 ft-lbs / 16.3-19 Nm

10 Check Valve, 5 psi / 0.34 bar ............ EII ......... Steering load sense, square end,right side, retract ............................ 12-14 ft-lbs / 16.3-19 Nm

11 Check Valve ...................................... EM ........ Steering cylinder lock, square end,right side, extend/retract ................... 18-20 ft-lbs / 25-27 Nm

12 Check Valve, 5 psi / 0.34 bar ............ ENN ...... Steering load sense, square end,left side, retract .............................. 12-14 ft-lbs / 16.3-19 Nm

13 Check Valve, 5 psi / 0.34 bar ............ EJJ ....... Steering load sense, square end,left side, extend .............................. 12-14 ft-lbs / 16.3-19 Nm


MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 109


REV A

20 19 16 14 1213 11 10151718

4 5321

21

7

8

9

6

EH EKELLEMMEOO EPP

TP

EQ ER EXEE EJ

EQQ

EZ

EKK

EY

EIIEG EMEJJ ENN

MANIFOLDS

4 - 110 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Steer and Axle Extend/Retract Manifold Components - View 2,continuedThe steer and axle extend/retract manifold is mounted inside the drive chassis at the square end

of the machine.

Index Schematic


14 Check Valve ...................................... EK ......... Steering cylinder lock, square end,left side, extend/retract ..................... 18-20 ft-lbs / 25-27 Nm

15 Check Valve ...................................... EH ........ Steering cylinder lock, circle end,right side, extend/retract ................... 18-20 ft-lbs / 25-27 Nm

16 Check Valve, 5 psi / 0.34 bar ............ ELL ....... Steering load sense, circle end,right side, retract ............................ 12-14 ft-lbs / 16.3-19 Nm

17 Check Valve ...................................... EG ........ Steering cylinder lock, circle end,left side, extend/retract .................. 12-14 ft-lbs / 16.3-19 Nm

18 Check Valve, 5 psi / 0.34 bar ............ EMM ..... Steering load sense, circle end,right side, extend ........................... 12-14 ft-lbs / 16.3-19 Nm

19 Check Valve, 5 psi / 0.34 bar ............ EPP ...... Steering load sense, circle end,left side, extend .............................. 12-14 ft-lbs / 16.3-19 Nm

20 Check Valve, 5 psi / 0.34 bar ............ EOO ...... Steering cylinder lock, circle end,left side, retract .............................. 12-14 ft-lbs / 16.3-19 Nm

21 Diagnostic Nipple Cap ...................... TP ......... Testing

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 111


REV A

20 19 16 14 1213 11 10151718

4 5321

21

7

8

9

6

EH EKELLEMMEOO EPP

TP

EQ ER EXEE EJ

EQQ

EZ

EKK

EY

EIIEG EMEJJ ENN

MANIFOLDS

4 - 112 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-17Valve Adjustments - Steer andAxle Extend/Retract Manifold

How to Adjust the Steer andAxle Retract Relief ValveNote: Perform this procedure with the axlesretracted and the boom in the stowed position.

1 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the test port on the steer and axleextend/retract manifold.


3 Position the machine so that the left front wheelis against an immoveable object such as acurb.

4 Press down the foot switch and activate thesteer function. Steer the wheel into the curb andhold. Observe the pressure reading on thepressure gauge. Refer to Section 2, HydraulicComponent Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item EZ).



7 Repeat steps 2 through 6 to confirm relief valvepressure.

How to Adjust the Axle ExtendRelief ValveNote: Perform this procedure with the axlesretracted, the boom in the stowed position and themachine on a paved surface.

1 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the test port on the steer and axleextend/retract manifold.


3 Press down the foot switch and push the axleextend button. Observe the pressure readingon the pressure gauge. Refer to Section 2,Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item EQQ).



6 Repeat steps 2 through 5 to confirm relief valvepressure.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 113


REV A MANIFOLDS


12345678901234561234567890123456123456789012345612345678901234561234567890123456123456789012345612345678901234561234567890123456

4 - 114 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

10-18Traction Manifold Components(S-100/105- before serial number 291)(S-120/125- before serial number 1195)The drive manifold is mounted inside the drive chassis at the circle end of the machine.

Index SchematicNo. Description Item Function Torque

1 Solenoid valve, 2 position 3 way ...... DA ........ 2 speed control ................................. 25-30 ft-lbs / 38-41 Nm

2 Flow regulator valve,2 gpm / 7.57 L/min ............................. DB ........ Drive slip limit, rear ........................... 35-40 ft-lbs / 47-54 Nm

3 Flow divider/combiner valve ............. DC ........ Controls flow to rear drivemotors in forward and reverse . 130-140 ft-lbs / 176-190 Nm

4 Flow regulator valve,2 gpm / 7.57 L/min ............................. DD ........ Drive slip limit, front .......................... 35-40 ft-lbs / 47-54 Nm

5 Flow divider/combiner valve ............. DE ........ Controls flow to front drivemotors in forward and reverse . 130-140 ft-lbs / 176-190 Nm

6 Flow divider/combiner valve ............. DF ......... Controls flow to front andrear flow divider combiner valves(items DC and DE) ................... 130-140 ft-lbs / 176-190 Nm

7 Check valve ....................................... DG ........ Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm

8 Check valve ....................................... DH ........ Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm

9 Flow regulator valve,2.7 gpm / 10.22 L/min ........................ DI .......... Drive slip limit, front and rear ............ 35-40 ft-lbs / 47-54 Nm

10 Check valve ....................................... DJ ......... Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm

11 Check valve ....................................... DK ........ Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm


Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 115


REV A MANIFOLDS

911 10

1 2 3

17

16

15

12

14

13

5

6

7

8

4

DA

DO

DB DC

DD

DE

DF

DG

DH

DIDJDK

DL

TP

DM

DP

DN

4 - 116 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AMANIFOLDS

Traction Manifold Components, continued(S-100/105- before serial number 291), (S-120/125- before serial number 1195)The drive manifold is mounted inside the drive chassis at the circle end of the machine.


12 Diagnostic fitting ................................ TP ......... Testing

13 Shuttle valve,3 position 3 way ................................ DL ......... Charge pressure circuit that

gets hot oil out of low presureside of the drive pump ...................... 35-40 ft-lbs / 47-54 Nm

14 Check valve, 50 psi / 3.45 bar ........... DP ........ 2 speed/brake chargepressure 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 control17 Solenoid valve, 2 position 3 way ...... DO ........ Brake control .................................... 25-30 ft-lbs / 38-41 Nm

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 117


REV A MANIFOLDS

911 10

1 2 3

17

16

15

12

14

13

5

6

7

8

4

DA

DO

DB DC

DD

DE

DF

DG

DH

DIDJDK

DL

TP

DM

DP

DN

4 - 118 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-19Traction Manifold Components(S-100/105- after serial number 290)(S-120/125- after serial number 1194)The drive manifold is mounted inside the drive chassis at the circle end of the machine.


1 Check Valve ...................................... HA ........ Anti-cavitation ............................. 30-35 ft-lbs / 40.7-47.5 Nm

2 Solenoid Valve, 2 position 3 way ...... HB ........ Two-speed drive motor shift ....... 26-30 ft-lbs / 35.3-40.7 Nm

3 Solenoid Valve, 2 position 3 way ...... HC ........ Brake release ............................. 26-30 ft-lbs / 35.3-40.7 Nm

4 Check Valve ...................................... HD ........ Keeps brakes released if temporaryloss of charge pressure .............. 20-25 ft-lbs / 27.1-33.9 Nm

5 Shuttle Valve, 3 position 3 way ......... HE ........ Charge pressure circuit that directshot oil out of low pressure sideof drive pump .............................. 50-55 ft-lbs / 67.8-74.6 Nm

6 Relief Valve, 250 psi / 17.23 bar ....... HF ......... Charge pressure circuit .............. 20-25 ft-lbs / 27.1-33.9 Nm

7 Orifice Plug, 0.030 inch / 0.762 mm .. HG ........ Brake and two-speed circuit ....... 20-25 ft-lbs / 27.1-33.9 Nm

8 Check Valve ...................................... HH ........ Anti-cavitation ............................. 20-25 ft-lbs / 27.1-33.9 Nm

9 Check Valve ...................................... HI .......... Anti-cavitation ............................. 30-35 ft-lbs / 40.7-47.5 Nm

10 Flow Divider/Combiner Valve ........... HJ ......... Controls flow tosquare end drive motorsin forward and reverse ............ 90-100 ft-lbs / 122-135.6 Nm

11 Check Valve ...................................... HK ........ Anti-cavitation ............................. 20-25 ft-lbs / 27.1-33.9 Nm

12 Bi-directional/Flow Control Valve,2 gpm / 7.6 L/min ............................... HL ......... Equalizes pressure on both sides of

divider/combiner valve FJ .......... 30-35 ft-lbs / 40.7-47.5 Nm


MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 119


REV A MANIFOLDS

HJ

1112

1 2 3 4 5

16

18

17

14

13

15

9

10

6

7

8

HBHA HC HD HE

HF

HH

HG

HI

HKHL

HQ

HP

HM

HN

HO

HR

4 - 120 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Traction Manifold Components, continued(S-100/105- after serial number 290), (S-120/125- after serial number 1194)The drive manifold is mounted inside the drive chassis at the circle end of the machine.


13 Bi-directional/Flow Control Valve,2 gpm / 7.6 L/min ............................... HM ........ Equalizes pressure on both sides

of divider/combiner valve FQ...... 30-35 ft-lbs / 40.7-47.5 Nm

14 Bi-directional/Flow Control Valve,2 gpm / 7.6 L/min ............................... HN ........ Equalizes pressure on both sides

of divider/combiner valve FQ...... 30-35 ft-lbs / 40.7-47.5 Nm

15 Check Valve ...................................... HO ........ Anti-cavitation ............................. 20-25 ft-lbs / 27.1-33.9 Nm

16 Flow Divider/Combiner Valve ........... HP ........ Controls flow tocircle end drive motorsin forward and reverse ............ 90-100 ft-lbs / 122-135.6 Nm

17 Flow Divider/Combiner Valve ........... HQ ........ Controls flow to divider/combinervalves FJ and FP ..................... 90-100 ft-lbs / 122-135.6 Nm

18 Check Valve ...................................... HR ........ Anti-cavitation ............................. 20-25 ft-lbs / 27.1-33.9 Nm

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 121


REV A MANIFOLDS

HJ

1112

1 2 3 4 5

16

18

17

14

13

15

9

10

6

7

8

HBHA HC HD HE

HF

HH

HG

HI

HKHL

HQ

HP

HM

HN

HO

HR

4 - 122 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

10-20Valve Adjustments -Traction Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 41 bar pressure

gauge to the test port located on the drivemanifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge. Refer to Section 2, HydraulicSpecifications.

4 Turn the engine off. Use a wrench to hold thecharge pressure relief valve and remove thecap (item DM or FF).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Install the relief valvecap.


MANIFOLDS

10-21Valve Coils

How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infiniteresistance indicates the coil has failed.

Since coil resistance is sensitive to temperature,resistance values outside specification can produceerratic operation. When coil resistance decreasesbelow specification, amperage increases. Asresistance rises above specification, voltageincreases.

While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.


Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.

1 Tag and disconnect the wiring from the coil to betested.

2 Test the coil resistance using a multimeter setto resistance (. Refer to the Valve CoilResistance Specification table.

Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 123


REV A

Valve Coil ResistanceSpecificationNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 20°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Description Specification

Solenoid valve, 2 position 3 way, 12V DC 9 (schematic item DA, DO, FB, FC)

Solenoid valve, 3 position 4 way, 12V DC 9.8 (schematic item EA, EB, EC, ED)(before serial number 292)

Solenoid valve, 3 position 4 way, 12V DC 8.8 (schematic item EA, EB, EC, ED)(after serial number 291)

Proportional solenoid valve, 12V DC 5.4 (schematic item FG, BG, GD, GH)

Proportional solenoid valve, 12V DC 5 (schematic item FB, FF, BB, BF)

3 position 4 way D03 valve, 12V DC 4.6 (schematic item FD, BD)

Solenoid Valve, 2 position 3 way, 12V DC 4.6 (schematic item FQ, FR, BQ, BR)

Solenoid Valve, 2 position 2 way, 12V DC 7.2 (schematic item BN, BO)

Solenoid valve, 3 position 4 way 12V 7.2 (schematic items ES, FC, BC)(before serial number 292)

Solenoid valve, 3 position 4 way 12V 7.1 (schematic items ES)(after serial number 291)

Solenoid valve, 2 position 3 way 12V 7.2 (schematic items AA)

How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its directional valve coils except proportionalvalves and those coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.


1 Test the coil for resistance. Refer to, How toTest a Coil.

2 Connect a 10 resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Note: The battery should read 9V DC or more whenmeasured across the terminals.

9VBATTERY

10

RESISTOR

�

AMMETERCOIL

+

-

+

-

d

a

b

b

c

c

a multimeterb 9V DC batteryc 10 resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6

MANIFOLDS

4 - 124 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DC current,should be capable of reading up to 800 mA.

4 Connect the negative lead to the other terminalon the coil.

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

MANIFOLDS

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 125


REV AFuel and Hydraulic Tanks

11-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion and fire hazard. Neverdrain or store fuel in an opencontainer due to the possibility offire.

1 Remove the fixed engine side turntable cover.See 5-1, How to Remove a Fixed TurntableCover.

2 Tag, disconnect and plug the fuel supply andreturn hoses. Cap the fittings on the fuel tank.

3 Remove the fuel filler cap from the tank.

4 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Seecapacity specifications.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Note: Be sure to only use a hand operated pumpsuitable for use with diesel fuel.

5 Remove the fuel tank hold down strap retainingfasteners. Remove the straps from the fueltank.

6 Support and secure the fuel tank to anappropriate lifting device.

7 Remove the fuel tank from the machine.

Crushing hazard. The fuel tankmay become unbalanced and fallif it is not properly supported andsecured to the lifting device.

Component damage hazard. Thefuel tank is plastic and maybecome damaged if it is allowed tofall.

Note: Clean the fuel tank and inspectfor cracks and other damage before installing.

4 - 126 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AFUEL AND HYDRAULIC TANKS

11-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply lines and has an external returnline filter with a filter condition indicator.

How to Remove theHydraulic Tank

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulicsystem.


1 Remove the ground controls side turntablecover. See 5-1, How to Remove a HingedTurntable Cover.

2 Close the two hydraulic shutoff valves located atthe hydraulic tank.

Component damage hazard. Besure that the hydraulic tank shutoffvalves are in the OPEN positionbefore priming the pump. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the hydraulictank shutoff valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

3 Remove the drain plug from the hydraulic tankand allow all of the oil from the tank to drain intoa suitable container. See capacityspecifications.

open closed

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 127


REV A

4 Remove the ground controls support bracketretaining fasteners. Remove the ground controlsassembly from the machine.

Component damage hazard.Be sure to properly support theground control box. Do not allowthe ground controls to hang by thewiring.

Component damage hazard.The ground control box wiring canbe damaged if it is kinked orpinched.

5 Tag and disconnect the wiring from the horn.

6 Remove the horn retaining fasteners. Removethe horn from the machine.

7 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tank shutoffvalves.

8 Tag, disconnect and plug the supply hose forthe auxiliary power unit. Cap the fitting on thehydraulic tank.

9 Disconnect and plug the T-fitting located at thereturn 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 tankand attach the lifting straps to an overheadcrane.

12 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if it is not properlysupported and secured to theoverhead crane.

Component damage hazard. Besure to open the two hydraulictank valves and prime the pumpafter installing the hydraulic tank.See 9-2, How to Prime the Pumps.

Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.

Note: Refer to Section 2, Machine Specificationsfor hydraulic oil requirements.

FUEL AND HYDRAULIC TANKS

4 - 128 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

3 Tag, disconnect and plug the hydraulic hosesfrom the manifold that is mounted to the motor.


4 Remove the motor/brake mounting fasteners.Remove the motor from the brake.

a motorb motor/brake mounting boltsc braked drive hub mounting boltse drive hub

12-1Turntable Rotation HydraulicMotor and Drive Hub

How to Remove the TurntableRotation Hydraulic MotorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.


2 Remove the ground controls side fixed turntablecover. See 5-1, How to Remove a FixedTurntable Cover.

Turntable Rotation Components

unlocked locked

b

a

c

de

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 129


REV A

How to Remove the TurntableRotation Drive Hub1 Secure the turntable from rotating with the

turntable rotation lock pin.

2 Remove the turntable rotation motor. See Howto Remove the Turntable Rotation HydraulicMotor.

3 Remove the brake from the drive hub and set itoff to the side.

a motorb motor/brake mounting boltsc braked drive hub mounting boltse drive hub

4 Attach a lifting strap from an overhead crane orother suitable lifting device to the drive hub.

5 Remove the drive hub mounting bolts andremove the drive hub from the machine.

Tip-over hazard. If the turntablerotation lock pin is not properlyinstalled, machine stability iscompromised and the machinecould tip over when the drive hubis removed from the machine,which could result in death orserious injury.

Crushing hazard. The drive hubmay become unbalanced and fallif it is not properly supported bythe overhead crane or liftingdevice.

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 lockingseal on all bolts. Torque the drive hub mountingbolts to 280 ft-lbs / 380 Nm.

8 Install the brake onto the drive hub and torquethe mounting fasteners to 20 ft-lbs / 27 Nm.

9 Install the motor onto the brake and torque themounting fasteners to 93 ft-lbs / 126 Nm.

9 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plugs andinstall the plugs. Refer to Section 2,Specifications.

10 Adjust turntable rotation gear backlash.

unlocked locked

b

a

c

de

TURNTABLE ROTATION COMPONENTS

4 - 130 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV ATURNTABLE ROTATION COMPONENTS

How to Adjust theTurntable Rotation GearBacklashThe turntable rotation drive hub is adjustable tocontrol the gap between the rotation motor gearand the turntable bearing.

Note: Be sure to check the backlash with themachine on a flat level surface.


2 Remove the ground controls side fixed turntablecover. See 5-1, How to Remove a FixedTurntable Cover.

3 Loosen the turntable rotate drive hub mountingbolts. Do not remove them.

Note: It may be necessary to raise the boomslightly to access all the turntable rotate drive hubmounting bolts.

a adjustment bolt with lock nutb pivot plate mounting bolts

4 Loosen the lock nut on the turntable drive hubadjustment bolt.

5 Tighten the turntable drive hub adjustment boltuntil the turntable drive hub gear is fullyengaged and tight into the turntable rotate gear.

6 Turn the adjustment bolt 3/4 turncounterclockwise. Tighten the lock nut on theadjustment bolt.

7 Rotate the drive hub away from the turntablerotate gear until it contacts the adjustment bolt.Torque the turntable rotate drive hub mountingbolts. Refer to Section 2, Specifications.

8 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.

ba

unlocked locked

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 131


REV A TURNTABLE ROTATION COMPONENTS


123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678

4 - 132 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Measure the circle-end tires:

3 Press the square-end steer mode button.

4 Measure the distance between the inside of onecircle-end tire and the chassis side plate onboth sides of the axle.

Result: Both measurements should be thesame to indicate that the tires are parallel withthe chassis.

Note: If the measurements are different or if a tireis not parallel with the chassis, the steer sensor ofthat tire will need to be adjusted. See How to Adjusta Steer Sensor.

5 Repeat step 4 for the other circle-end tire.

Axle Components

13-1Steer Sensors

The steer sensor measures steer angle andcommunicates that information to the groundcontrols ECM. The steer sensor on the groundcontrols side of the machine at the square end actsas the lead sensor. The other three sensors followthe position, or steer angle, of the lead sensor.There is a steer sensor mounted to the top of eachupper yoke pivot pin.

Note: If the square-end steering function becomesinoperative, switch to circle-end steer mode and theground controls side circle-end steer sensor willbecome the lead sensor.

Note: This procedure will require a minimum of twopeople.

Note: Perform this procedure with the axlesextended.

How to Measure the TireAlignment1 Start the engine from the platform controls.

2 Press down the foot switch and push the engineidle select button until the engine switches tohigh rpm.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 133


REV A

Measure the square-end tires:

6 Press the circle-end steer mode button.

7 Measure the distance between the inside of onesquare-end tire and the chassis side plate onboth sides of the axle.

Result: Both measurements should be thesame to indicate that the tires are parallel withthe chassis.

Note: If the measurements are different or if a tireis not parallel with the chassis, the steer sensor ofthat tire will need to be adjusted. See How to Adjusta Steer Sensor.

8 Repeat step 4 for the other square-end tire.

How to Adjust a Steer SensorSquare-end steer sensors:

1 At the platform controls, press the circle-endsteer mode button.

2 Locate the steer sensor on top of the yoke pivotpin.

3 Loosen the steer sensor cover retainingfasteners. Do not remove them.

4 Rotate the steer sensor cover either clockwiseor counterclockwise. Measure the distancebetween the inside of tire and the chassis sideplate on both sides of the axle.

5 Repeat step 4 until the tire is parallel with thechassis.

6 Tighten the steer sensor cover fasteners.

7 Repeat steps 2 through 6 for the other square-end steer sensor.

AXLE COMPONENTS

4 - 134 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AAXLE COMPONENTS

Circle-end steer sensors:

8 At the platform controls, press the square-endsteer mode button.

9 Locate the steer sensor on top of the yoke pivotpin.

10 Loosen the steer sensor cover retainingfasteners. Do not remove them.

11 Rotate the steer sensor cover either clockwiseor counterclockwise. Measure the distancebetween the inside of tire and the chassis sideplate on both sides of the axle.

12 Repeat step 4 until the tire is parallel with thechassis.

13 Tighten the steer sensor cover fasteners.

14 Repeat steps 9 through 13 for the other circle-end steer sensor.

13-2Yoke and Hub

How to Remove the Yokeand HubThe yoke installation utilizes bushings and a thrustwasher that may require periodic replacement.There is a steer sensor mounted to the upper yokepivot pin.


1 Remove the hose hanger bracket retainingfasteners mounted to the top of the yoke.Remove the hose hanger bracket from themachine.

2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor and brake assembly. Capthe fittings on the drive motor and brake.


Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 135


REV A

3 Mark the mounting position of the steer sensorcover on the yoke.

Note: It is very important that the steer sensor isinstalled in the exact position it was in prior toremoval. If the steer sensor is not installedcorrectly, the steer function may operateimproperly. If any steer functions operateimproperly after removing and installing a steersensor, see 13-1, How to Adjust a Steer Sensor.

4 Remove the steer sensor cover retainingfasteners. Carefully remove the steer sensorcover and lay it out of the way.

Component damage hazard. Thesteer sensor is a very sensitiveinstrument. It can be damagedinternally if it is dropped orsustains any physical shock, evenif the damage is not visible.

5 Lay the hoses and steer sensor cable out of theway.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

6 Mark the mounting position of the steer sensoractivator pin mounted to the top of the yokepivot pin.

7 Remove the steer sensor activator pin retainingfasteners. Remove the steer sensor activatorpin from the machine.

Note: It is very important that the steer sensoractivator pin is installed in the exact position it wasin prior to removal. If the steer sensor activator pinis not installed correctly, the steer function mayoperate improperly. If any steer functions operateimproperly after removing and installing a steersensor activator pin, see 13-1, How to Adjust aSteer Sensor.

8 Loosen the wheel lug nuts. Do not remove them.

9 Center a lifting jack of ample capacity under theaxle of the yoke and drive hub to be removed.Do not raise the machine.

10 Block the wheels at the opposite end of themachine.

11 Raise the machine approximately 6 inches(15 cm) and place blocks under the chassis forsupport.

12 Remove the lug nuts and remove the tire andwheel assembly.

13 Remove the drive motor mounting fasteners.

14 Slide the drive motor shaft out of the drive huband remove the drive motor from the machine.

15 Remove the pin retaining fasteners from thesteering cylinder rod-end pivot pins. Removethe pins.

16 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.

AXLE COMPONENTS

4 - 136 S-100 • S-105 • S-120 • S-125 Part No. 102916



17 Support the yoke/drive hub assembly with alifting jack. Secure the yoke/drive hub assemblyto the lifting jack.

18 Use a soft metal drift to remove both yoke pivotpins.

19 Remove the yoke/drive hub assembly from themachine.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly supported and secured tothe lifting jack.

20 Place the yoke/drive hub assembly on a flatsurface with the drive hub facing down.

21 Remove the drive hub mounting fasteners thatattach the yoke to the drive hub. Remove theyoke weldment from the drive hub.

Note: Replace the thrust washer with a new onewhen installing the yoke/drive hub assembly ontothe axle. Refer to Section 2, Machine TorqueSpecifications.

13-3Drive Motor

How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizeddealer.

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


2 Remove the drive motor mounting fasteners.

3 Slide the drive motor shaft out of the brake anddrive hub. Remove the drive motor from themachine.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 137


REV A

13-4Drive Hub

How to Remove a Drive HubNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.

1 Remove the drive motor. See 13-3, How toRemove a Drive Motor.

2 Tag, disconnect and plug the hydraulic hosefrom the brake. Cap the fittting on the brake.


3 Loosen the wheel lug nuts. Do not removethem.

4 Center a lifting jack of ample capacity under theaxle of the drive hub to be removed. Do notraise the machine.


6 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.

7 Remove the wheel lug nuts. Remove the tire andwheel assembly.

8 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.

9 Remove the drive hub mounting bolts that attachthe drive hub to the yoke. Remove the drive hubfrom the machine.

Crushing hazard. The drivehub may become unbalanced andfall if it is not properly supportedand secured to the lifting jack.Refer to Section 2, MachineTorque Specifications.

AXLE COMPONENTS

4 - 138 S-100 • S-105 • S-120 • S-125 Part No. 102916



13-5Steering Cylinders

How to Remove aSteering CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Locate the hose bracket mounted to the steercylinder.

2 Remove the hose bracket cover retainingfasteners. Remove the hose bracket cover.

3 Remove the hose bracket retaining fastenersfrom the steering cylinder.

4 Tag, disconnect and plug the hydraulic hosesfrom the steering cylinder. Cap the fittings onthe cylinder.


5 Remove the pin retaining fasteners from thesteer cylinder pivot pins.

6 Support the steer cylinder with a suitable liftingdevice.

7 Place a rod through each steer cylinder pivot pinand twist to remove the pins.

8 Remove the steering cylinder from the machine.

Crushing hazard. The steercylinder may become unbalancedand fall if it is not properlysupported by the lifting device.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 139


REV A

13-6Extendable Axles

The extendable axles are used to widen the footprint of the drive chassis for stability.

How to Shim an Extendable AxleNote: Measure each wear pad. Replace the wearpad if it is less than 7/16 inch / 11 mm thick.If the wear pad is 7/16 inch / 11 mm thick or more,perform the following procedure.

1 Fully extend the axle.

2 Remove the wear pad retaining fasteners.

Side wear pads:

3 Install the new shims under the wear pad toobtain zero clearance and zero drag.

4 Use a round punch through the wear padmounting holes to align the shims with the wearpad. Install the wear pad retaining fasteners.

5 Extend and retract the axle through an entirecycle. Check for tight spots that could causebinding or scraping of the axle tubes.

Note: Always maintain squareness between theinner and outer axle tubes.

Top and bottom wear pads:

3 Center a lifting jack of ample capacity under theaxle that needs to be shimmed. Do not raise themachine.


5 Raise the machine just until the weight of themachine is relieved off of the axle. Do not raisethe wheels off of the ground.

6 Install the new shims under the wear pad toobtain zero clearance and zero drag.

7 Use a round punch through the wear padmounting holes to align the shims with the wearpad. Install the wear pad retaining fasteners.

8 Extend and retract the axle through an entirecycle. Check for tight spots that could causebinding or scraping of the axle tubes.

Note: Always maintain squareness between theinner and outer axle tubes.

AXLE COMPONENTS

4 - 140 S-100 • S-105 • S-120 • S-125 Part No. 102916



How to Remove an Inner AxleNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.

Note: Perform this procedure with the tires parallelto the chassis and the axles fully extended.

1 Remove the top drive chassis cover.

2 Remove the yoke and hub assembly. See 13-2,How to Remove the Yoke and Hub.

3 Remove the steering cylinder. See 13-5, How toRemove a Steering Cylinder.

4 Remove the axle cover retaining fastenerslocated above the axle. Remove the chassiscover from the machine.

5 Remove the upper wear pad retainer plateretaining fasteners. Remove the plate from themachine.

6 Attach a lifting strap from an overhead crane ofample capacity to the inner axle for support. Donot lift it.

7 Remove the retaining fasteners from the upperand lower wear pads at the outer axle. Do notremove the side wear pads.


8 Remove the pin retaining fasteners from the axlestop pin. Use a slide hammer to remove the pin.

9 Remove the access cover fasteners from theend of the inner axle to access the axleextension cylinder clevis pin. Remove thecover.

10 Place support blocks under the end of the axleextension cylinder for support.

11 Remove the cotter pin from the axle extensioncylinder clevis pin.

Note: Alwayse use a new cotter pin when installinga clevis pin.

12 Use a soft metal drift to remove the axleextension cylinder clevis pin.

13 Carefully support and slide the inner axle out ofthe chassis. Remove the axle from themachine.

Crushing hazard. The inner axlemay become unbalanced and fallwhen it is removed from themachine if it is not properlysupported by the overhead crane.

Component damage hazard. Thealuminum limit switch track andthe axle extension cylinder maybecome damaged if the axle isallowed to fall when it is removedfrom the machine.

Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

Note: When installing an inner axle, there needs tobe a minimum of 1/

8 inch / 3.1 mm gap between the

proximity switches and the aluminum limit switchtrack. Measure the gap with the axles in both theretracted and extended positions. Adjust theproximity switches as necesary to obtain a1/

8 inch / 3.1 mm gap.

Part No. 102916 S-100 • S-105 • S-120 • S-125 4 - 141


REV A

How to Remove the AxleExtension Cylinder1 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 InnerAxle.

3 Remove the access covers from the end of theremaining axle.

4 Tag, disconnect and plug the axle extensioncylinder hydraulic hoses. Cap the fittings on thecylinder.


5 Tag and disconnect the wiring connectors fromthe proximity switches and limit switch. Do notremove the switches.

Note: The wiring connectors for the switches canbe accessed through the access holes on eitherside of the chassis end plate.

6 Place blocks under the axle extension cylinderfor support.

7 Attach a lifting strap from an overhead crane tothe end of the axle extension cylinder.

Note: Attach the lifting strap to the end of thecylinder that has the inner axle removed.

8 Remove the cotter pin from the axle extensioncylinder clevis pin on the remaining inner axle.

Note: Alwayse use a new cotter pin when installinga clevis pin.

9 Use a soft metal drift to remove the pin.

Crushing hazard. The axleextension cylinder may fall if it isnot properly supported.

Component damage hazard. Theaxle extension cylinder and limitswitches can become damaged ifthe axle extension cylinder isallowed to fall.

10 Carefully support and slide the axle extensioncylinder out of the axle.

Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

AXLE COMPONENTS

4 - 142 S-100 • S-105 • S-120 • S-125 Part No. 102916




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Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 1

June 2011 Section 5 • Diagnostic Codes

REV A

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie S-100, S-105, S-120, S-125 Operator’sManual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.


Note: Perform all troubleshooting on a firm, levelsurface.

Note: Two persons will be required to safelyperform some troubleshooting procedures.

Diagnostic Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

• Machine parked on a firm, level surface

• Boom in stowed position

• Turntable rotated with the boom between the non-steer wheels

• Turntable secured with the turntable rotation lock

• Key switch in the off position with the key removed

• Wheels chocked

• All external AC power disconnectedfrom the machine

5 - 2 S-100 • S-105 • S-120 • S125 Part No. 102916

June 2011Section 5 • Diagnostic Codes

REV ADIAGNOSTIC CODES

Fault Diagnostics -Control System

How to Read Control SystemFault CodesNote: Initial fault testing occurs at power-up.

Faults are abnormal conditions that exist due tocomponent failure or System misuse. CPU,memory, LCD, LED, limited joystick and limitedoperator switch testing is done on power-up. Ifan operator switch is depressed on power-up,the display should show and error and not allowany machine functions.

Releasing the switch will clear the error andallow all machine functions. The joystickoperates similarly.

All other fault testing is done continuously.

1 When a fault is diagnosed, the PCON faultindicator will flash and a fault message will bedisplayed on the TCON LCD. The message willcontain the fault source and type.

2 Additional information, including the occurrencecounter and a time-stamp is available with aPC, connected to one of the RS232 ports. Up to16 unique fault messages can be saved. Eachfault is saved with the device identity, faulttype, engine hour time-stamp and an 8-bitoccurrence counter.

3 The fault code table on the following pages liststhe functions or components monitored by thesystem.

Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 3


REV A

Power up controller withproblem

corrected

Calibrate Thresholds

Self-clearing(transient)

Primary Boom Ext/Ret Flow Valve

Primary Boom Up/Down Flow Valve

Primary Boom Extend Valve

Primary Boom Retract Valve

Primary Boom Up Valve

Primary Boom Down Valve

Engine Speed

Oil Pressure Sensor

Oil Pressure

Water/Oil Temp Sensor

Axle Valves

Axle Extend/Retract Buttons

Water/Oil Temp

Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

Fault Check

Range Check(underspeed)Range Check

(low oil pressure)Range Check

(high temperature)

Fault Check (bothbuttons pressed)

Fault Check

Fault Check

Normal function except threshold forone or the other direction is zero,

Display message on LCD

Initiate one second beep of audiblewarning device

Limited Speed and Direction frozen atzero and neutral, Alarm sounds







Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


corrected





Axle Extend/Retract disabled, displaymessage on LCD


corrected


corrected


corrected


corrected


corrected

Error Source Error Type Recovery ActionsEffects

DIAGNOSTIC CODES

5 - 4 S-100 • S-105 • S-120 • S125 Part No. 102916


REV A


corrected

Calibrate Joystick


Primary Ext/Ret Joystick

Primary Up/Down Joystick

Steer Joystick

Primary Boom Ext/Ret switches onTCON

Primary Boom Up/Down switches onTCON

Primary Boom Angle

Primary Boom Length

Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


Fault Check(unknown angle)

Fault Check(unknown length)





Calibrate Joystick


Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


corrected


Stop all boom functions, allow onlyboom retract, once fully retracted

allow boom down. Display messageon LCD


corrected


correctedPower up controller with

problemcorrected


corrected


corrected


Primary Boom Up/Down disabled,display message on LCD

Primary Boom Ext/Retract disabled,display message on LCD

Stop all boom functions, allow onlyboom retract. Display message on

LCD

Joystick Speed and Direction frozenat zero and neutral


Calibrate Joystick


Value at 5.0 V

Value Too High

Value Too LowValue at 0 V

Not calibrated

Just calibrated




DIAGNOSTIC CODES

Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 5


REV A

Perform auto calibrateprecedurePrimary Up/Down Speed

Primary Extend/Retract Speed

SAFETY SWITCH P3

SAFETY SWITCH P6R1

SAFETY SWITCH P6R2

SAFETY SWITCH P7

SAFETY SWITCH P7R

SAFETY SWITCH P11

SAFETY SWITCH P9A

SAFETY SWITCH P10

CAN Bus

SAFETY SWITCH P12

SAFETY SWITCH P9B

Not calibrated

Fault Check

Fault Check

Display message on LCD and allowoperation at default speed

Not calibrated

Display message on LCDPower up controller with

problemcorrected


corrected

Perform auto calibrateprecedure

SAFETY SWITCH P14

SAFETY SWITCH P18

SAFETY SWITCH P22

SAFETY SWITCH P22R

Display message on LCDP3 SAFETY SWITCH FAULT

Display message on LCDP6R1 SAFETY SWITCH FAULT

Display message on LCDP6R2 SAFETY SWITCH FAULT


Display message on LCDP7R SAFETY SWITCH FAULT

Display message on LCDP9A SAFETY SWITCH FAULT

Display message on LCDP9B SAFETY SWITCH FAULT







Display message on LCDP22R SAFETY SWITCH FAULT



DIAGNOSTIC CODES

5 - 6 S-100 • S-105 • S-120 • S125 Part No. 102916


REV A

Power up controller withproblem corrected

Calibrate Joystick


Shut Down Mode

Turntable Rotate Joystick

Turntable Rotate Speed

Turntable Rotate Flow Valve

Platform Level Sensor Y-Direction

Turntable Rotate CCW Valves

Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

Fault Check





Perform auto calibrateprocedure



Normal function except threshold forone or the other directions is

zero,display message on LCD



Correct problem

Fault Check

Display message on LCD and soundaudible alarm




Value at 5.0 V

Value Too High

Value Too LowValue at 0 V

Not calibrated

Just calibrated


Turntable Level Sensor Y-Direction

Turntable Level Sensor X-Direction

Turntable Rotate CW Valves

Turntable Rotate Buttons

Platform Overload

Primary Boom Lock-Out Valve #2

Primary Boom Lock-Out Valve #1



Not calibrated

TT rotate disabled, display messageon LCD


Fault Check

Display message on LCDFault Check(if active)



DIAGNOSTIC CODES

Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 7


REV A DIAGNOSTIC CODES


corrected

Calibrate Joystick


Propel Joystick

Propel Valves (High Current)

Motor Speed Valve

Brake Valve

Platform Level Up Valve

Platform Level Down Valve

Platform Rotate CW Valve

Jib Switches

Platform Rotate CCW Valve

Jib Down Valve

Hydraulic Generator/Welder -Bypass Valve

Platform Rotate Switches

Jib Up Valve

Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


Fault Check

Fault Check




Display message on LCDInitiate one second beep of audible

warning device

Shut down engine, Limited Speed andDirection frozen at zero and neutral,

Alarm sounds



Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


corrected


Disable Generator, Display messageon LCD Display


Affected functions disabled, displaymessage on LCD


corrected

Recycle power


corrected


corrected

Platform Level Switches

Footswitch Timeout

Shut down engine, Limited Speed andDirection frozen at zero and neutral,

Alarm sounds

Limited Speed and Direction frozenat zero and neutral, Alarm sounds


Fault Check


5 - 8 S-100 • S-105 • S-120 • S125 Part No. 102916


REV ADIAGNOSTIC CODES


corrected

Calibrate Joystick


SteeringJoystick

LF Steer Angle Sensor

RF Steer Angle Sensor

LF Steer Valves

Hydraulic Generator/Welder -Bypass Valve

RF Steer Valves

Not calibrated

Just calibrated

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

Fault Check

Fault Check



Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


corrected




corrected


corrected


corrected

LR Steer Valves

RR Steer Valves

Limited Speed and Direction frozenat zero and neutral, Alarm sounds


corrected

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V






corrected

LR Steer Angle Sensor

RR Steer Angle Sensor


Part No. 102916 S-100 • S-105 • S-120 • S-125 5 - 9


REV A

Control System Fault Codes

How to Clear Boom SafetySwitch FaultsNote: Beginning with software release 3.0, theboom envelope switches will latch and faultsmust be reset in software or through the use ofthe TCON LCD. They will not clear by re-poweringthe machine.

Note: There are two methods to reset the faults,by using Web GPI or through the menu availableon the TCON LCD.

Using Web GPI

1 Connect the device containing the WEB GPIsoftware to the TCON with an RS-232 cable.

2 Select the Safety folder, then the Fault Statusscreen.

3 Change any safety switch drop down menusdisplaying FAULT to OK. Press SEND.

4 Exit Web GPI.

Using the TCON LCD

Note: Take care when using this method to avoidresetting threshold defaults.




2 Press the button until CLEAR ALL SAFETY

SWITCH FAULTS appears.




Note: This clears all latching faults, not standardfaults.

DIAGNOSTIC CODES

5 - 10 S-100 • S-105 • S-120 • S125 Part No. 102916


REV AREV ASoftware

Observe and Obey:Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:Read, understand and obey the safety rules andoperating instructions in the Genie S-100 &Genie S-105 Operator’s Manual and theGenie S-120 & Genie S-125 Operator’s Manual.

Be sure that all necessary tools and parts areavailable and ready for use.

About This SectionThis section explains various parts of the machinesoftware operating system and how to accesssome of the adjustable parameters of the controlsystem.

Web GPI

The software system used on the machine is calledWeb GPI. It is a software application that istypically used with a laptop computer. The laptopcan be connected to the ground controls via a teeharness connector (Genie part number 75094).

The Web GPI software can access all adjustableparameters for the machine. It can also be used toaid in troubleshooting and viewing fault codehistory.

June 2011 Section 6 • Schematics

Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 1

REV ASchematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theOperator's Manual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics

Bodily injury hazard. Sprayinghydraulic oil can penetrate and burnskin. Loosen hydraulic connectionsvery slowly to allow the oil pressureto dissipate gradually. Do not allowoil to squirt or spray.

General Repair Process

Malfunctiondiscovered

Identifysymptoms Troubleshoot

Return toservice

Inspectand test

Performrepairproblem

solved

problemstill exists

June 2011Section 6 • Schematics

6 - 2 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV A

Wire Circuit Legend

Circuit numbering1 Circuit numbers consist of three parts: the circuit

prefix, circuit number and circuit suffix. Thecircuit prefix indicates the type of circuit. Thecircuit number describes the function of thecircuit. The circuit suffix provides anabbreviation for the number or may be used tofurther define the function of this portion of thecircuit. It also may be used to indicate the finalend of the circuit, i.e., LS or limit sw.

2 The circuit number may be used more than oncein a circuit.

For Example:

C 74 PL – This is the circuit for the lockoutvalve #1. C stands for control, 74 is the number of the circuitfor the primary #1 lock out valve.PL stands for Primary Lockout.

S 62 BST – This is the circuit that communicates to the onboardcomputers of the machine that the boom is fully stowed. Sstands for safety, 62 is the number of the circuit for boomstowed and BST stands for Boom Stowed.

P 48 LP – P stands for power. 48 is the circuit number for worklamps and LP stands for Lamp.

R 48 LP – R stands for relay. In this case it is the wire thatfeeds the relay coil for the work lamp. All other numbers remainthe same.

Circuit prefixC ..... Control

D ..... Data

E ...... Engine

G ..... Gauges

N ..... Neutral

P ...... Power

R ..... Relay Output

S ...... Safety

V ...... Valve

Circuit suffixDefinition SuffixAC Generator GENAlternator Field AFAngle ANGAuxiliary Boom Valve ABVAuxiliary Forward Valve AFVAuxiliary Hydraulic Pump AHAuxiliary Platform Valve APVAuxiliary Reverse Valve ARVAuxiliary Steer/Drive Valve ASVAxle Extend Valve AXEAxle Oscillate AXOAxle Retract Valve AXRAxle Front Position FAPAxle Rear Position RAPBattery BATBoom Extended BEXBoom Stowed BSTBrake BRKBypass Valves BVCalibrate CALCAN Signal CANCAN Shield SHDCATS Module CATChain Break CNKData High DTHData Low DTLDrive Chassis Controller DCNDrive Enable DEDrive Enable Left DELDrive Enable Right DERElectrical Displacement Control EDCEnvelope Light ENVEngine Speed Select ESPEngine Status Lamp ESLEnvelope Lockout ENLExtend/retract Lockout ERLFilter Restricted FLRFilter Switch FLTFlashing Beacon FBFloat Switch FSFootswitch Signal FTSForward FWDFuel Pump FPFuel Select (gas/LP) FLFuel Solenoid FSL


Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 3

REV A WIRE CIRCUIT LEGEND

Definition SuffixFunction Enable FEGround Control TCNGround GNDHorn HRNHigh RPM HSHydraulic Generator HGIgnition IGNJib Bellcrank Down JBDJib Bellcrank Up JBUJib Sensor JBSJib U/D Control JUDJib Down JDJib Up/Down Flow Control JFCJib Select Valve JSVJib Up JUJib E/R Control JERJib Ext JBEJib Ret JBRJib Rotate Left (CCW) JRLJib Rotate Right (CW) JRRJoystick 5 VDC Power JPWLamps LPSLeft Front LFLeft Front Steer Sensor LFSLeft Rear LRLeft Rear Steer Sensor LRSLimit Switch LSLift Speed Reduction LSRLoad Sensor LDSLockout LOLow RPM LSLow fuel LOFMotor Shift (Speed) MSMulti Function Valve MFVPlatform Control PCNPrimary Ext/Ret Lockout PELPlatform Level Down PLDPlatform Level Flow Control PLFPlatform Level Up PLUPlatform Rotate Flow Control PRFPlatform Rotate Control PRCPlatform Rotate Left (CCW) PRLPlatform Rotate Right (CW) PRRPower PWRPower to Length Sensor PSLPlatform Tilt Alarm PTAPlatform Tilt Sensor PTS

Definition SuffixPressure Comp Enable PCEPressure Sender PSRPressure Switches PSPrimary Boom Angle Sensor PBSPrimary Boom Down PBDPrimary Boom Ext/Ret Lockout Valve PBLPrimary Boom Extend PBEPrimary Boom Extend/Retract Flow Control PERPrimary Boom Retract PBRPrimary Boom Angle Sensor PBSPrimary Boom Down PBDPrimary Boom Ext/Ret Lockout Valve PBLPrimary Boom Extend PBEPrimary Boom Extend/Retract Flow Control PERPrimary Boom Retract PBRPrimary Boom Up PBUPrimary Boom Up/Dwn Flow Control PUDPrimary Boom Extend/Retract Signal PLSPrimary Boom Up/Down Signal PESPrimary Lockout PLPrimary Length Sensor PSLPropel Signal JPLProgram Setup Enable PSEPropel Lockout PLLProportional Valve PRVProximity Sensor PXSReceptacle RECRecovery RCVRetract Lockout RLReturn RETReverse REVRight Front RFRight Front Steer Sensor RFSRight Rear RRRight Rear Steer Sensor RRSRPM RPMSecondary Boom Angle Sensor SBSSecondary Boom Elevated SBLSec Boom Down SBDSec Boom Extend SBESec Boom Extend/Retract Flow Control SERSec Boom Retract SBRSec Boom Up SBUSec Boom Up/Dwn Flow Control SUDSecondary Boom SBThis list continues on the next page.

March 2011Section 6 • Schematics

6 - 4 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV BWIRE CIRCUIT LEGEND

Definition SuffixSecondary Boom Lockout Valve (Extend) SLESecondary Boom Lockout Valve (Riser Down) SLDSensor SENSpare SPSpeed Sensor SSStart Aid (Glow Plug or choke) SAStarter STRSteer Control Signal STCSteering Valve Clockwise SCWSteering Valve Counter Clockwise SCCTemp Sender TSRTemp Switches TSTether TETTilt Alarm X axis TAXTilt Alarm Y axis TAYTurntable or Ground Control Panel TCNTurntable Rotate Flow Control TRFTurntable Rotate Right (CW) TRRTurntable Rotate Signal TRSTurntable Tilt Alarm TTATurntable Tilt Sensor TTSTest Switch TSW

Wire Coloring1 All cylinder extension colors are solid and all

retract functions are striped black. When usingblack wire, the stripe shall be white.

2 All rotations that are LEFT or CW are solid,RIGHT or CCW are striped and black. When thewire is black, the stripe is white.

3 All proportional valve wiring is striped.

Wire Color LegendBL BlueBL/BK Blue/BlackBL/RD Blue/RedBL/WH Blue/WhiteBK BlackBK/RD Black/RedBK/WH Black/WhiteBR BrownGN GreenGN/BK Green/BlackGN/WH Green/WhiteRD RedRD/BK Red/BlackRD/WH Red/WhiteOR OrangeOR/BL Orange/BlueOR/BK Orange/BlackOR/RD Orange/RedWH WhiteWH/BK White/BlackWH/RD White/RedYL Yellow

March 2011 Section 6 • Schematics

Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 5

REV B WIRE CIRCUIT LEGEND

Color, Circuit #, and Primary functionRD 1 Primary boom up driveRD/BK 2 Primary boom down driveRD/WH 3 Primary boom up/dwn FC

proportional valve driveWH 4 Turntable rotate left valve driveWH/BK 5 Turntable rotate right valve driveWH/RD 6 Turntable rotate FC proportional

valve driveBK 7 Primary boom extendBK/WH 8 Primary boom retractBK/RD 9 Primary boom Extend/Retract

proportional valve driveBL 10 Secondary boom up valve driveBL/BK 11 Secondary boom down valve driveBL/WH 12 Secondary boom up/dwn FC

proportional valve driveBL/RD 13 Drive enableOR 14 Platform level up valveOR/BK 15 Platform level down valveOR/RD 16 Platform up/dwn FC proportional

valve driveGN 17 Platform rotate left valve driverGN/BK 18 Platform rotate right valve driverGN/WH 19 Jib select valve driver circuitRD 20 12V battery supplyWH 21 12V ignition supplyBK 22 Keyswitch power to platform

ESTOPWH 23 Power to platformRD 24 Power to warning sendersWH/BK 25 Power to oil pressure senderWH/RD 26 Power to temp senderRD 27 Auxiliary powerRD/BK 28 Platform level alarmRD/WH 29 Drive motor shift (speed)WH 30 Forward/EDC-A

Color, Circuit #, and Primary functionWH/BK 31 Reverse/EDC-BWH/RD 32 BrakeBK 33 StartBK/WH 34 Start aid (glow plug or choke)BK/RD 35 High engine speed selectBL 36 Steer clockwiseBL/BK 37 Steer counterclockwiseBL/WH 38 GasBL/RD 39 LPOR 40 Limit switch signal stowedOR/BK 41 RPM signalOR/RD 42 Boom retracted signalGN 43 Jib upGN/BK 44 Jib downGN/WH 45 AC GeneratorWH 46 Drive hornWH/BK 47 Output power enableWH/RD 48 Work lampWH/BK 49 Motion lampBL 50 Auxiliary boomBL/WH 51 Auxiliary steerBL/RD 52 Auxiliary platformWH/BK 53 Boom envelope safety valve cutoffBK/WH 54 Power to safety interlock switches

(engine)GN/BK 55 Axle oscillationRD 56 Foot switch/TCON estop powerRD/WH 57 Boom down safety interlockRD/BK 58 Safety interlock to engineGN/WH 59 Chain break circuitGN/WH 60 Axle extendGN 61 Axle retractOR 62 Boom stowed (safety)OR/RD 63 Power to boom envelope safety

switchThis list continues on the next page.


6 - 6 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV B

Color, Circuit #, and Primary functionOR/BK 64 Power for operational switchesBL/WH 65 Low fuel indicationBL 66 Drive enableBL 67 Secondary boom not stowedRD 68 Primary boom lowered

(operational)BL 69 Primary boom #1 extendedBL/WH 70 Primary boom #2 retractedBL/BK 71 Primary boom #2 extendedGN 72 Secondary boom extendGN/BK 73 Secondary boom retractRD 74 Primary #1 LockoutRD/WH 75 Primary #2 LockoutBL 76 Pri boom #3 extendedWH 77 Lower angle #1 operationalWH/BK 78 Upper angle #2 operationalBK 79 power from TCON ESTOPN/A 80 Can 2.0/J1939 ShieldGN 81 Can 2.0/J1939 LowYL 82 Can 2.0/J1939 HighGN/WH 83 Tilt signal x axisGN/BK 84 Tilt signal y axisGN 85 Tilt sensor powerOR 86 Hydraulic filter restrictedRD 87 Platform level safety powerRD/BK 88 Platform level safety outputBR 89 Platform level safety groundRD/BK 90 Proximity killRD/WH 91 Gate InterlockWH/BK 92 Motor speed (LO/HI)WH/RD 93 Motor bypassWH 94 Load sensorOR 95 Tether ESTOP returnRD 96 Tether powerBK 97 Tether ESTOP powerWH 98 J1708 + (high)

Color, Circuit #, and Primary functionBK 99 J1708 - (low)WH/RD 100 Outrigger loweredWH/BK 101 Outrigger raisedOR 102 Pothole protector upOR/RD 103 Pothole protector downBK/WH 104 Proprietary data buss –

(i.e. ITT or AP)BK/RD 105 Proprietary data buss +

(i.e. ITT or AP)GN 106 SpareRD 107 Alternator fieldBL/WH 108 Engine statusGN/WH 109 Sensor pwrBK 110 Sensor returnOR 111 Steer signalRD 112 Steer signal to solenoid valveOR/RD 113 Multi function valveBK/RD 114 Load moment overweightRD/BK 115 Load moment underweightOR 116 Hydraulic oil coolerRD 117 Flashing beaconOR 118 Lift speed reductionBL 119 Hydraulic pressure sensor outputOR 120 Oil cooler fanGR 121 Axle oscillate LEFTGN/BK 122 Axle oscillate RIGHTRD/BK 123 Primary boom angle signal

operationalRD/WH 124 Secondary boom angle signal

operationalWH/RD 125 Secondary boomlockout

(Ext Enable)WH/BK 126 Secondary boom lockout

(Riser Down Enable)GN 127 ECU test switchOR/RD 128 Low engine speed

WIRE CIRCUIT LEGEND


Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 7

REV B

Color, Circuit #, and Primary functionRD/BK 129 Descent alarmWH/RD 130 Travel alarmBL 131 Motion alarmGN 132 Platform load inputGN/WH 133 Platform load alarmGN/BK 134 Key switch powerBL/WH 135 Fuel pumpRD 136 Power to safety moduleRD/WH 137 Propel power (P_38)RD/BK 138 Pri boom up/sec boom dwn-Ext

(P_11/30)WH/RD 139 Turntable rot FC safety (P_39)OR/RD 140 Boom envelope safetyRD 141 Primary boom angle signal safetyOR 142 Secondary boom angle signal

safetyBL/RD 143 Drive enable leftBL/WH 144 Drive enable rightRD/WH 145 CalibrateBL 146 Jib bellcrank up FCBL/BK 147 Jib bellcrank down FCBL/WH 148 Jib bellcrank sensorGN/WH 149 Jib Up/Down FCGN/BK 150 Hydraulic generator bypassGN 151 Hydraulic EDCoutputBK 152 Injector retardBK 153 Jib extendBK/WH 154 Jib retractOR/RD 155 Pressure comp enableGN/WH 156 Jib Up/DownBK/RD 157 Jib Ext/RetBL/RD 158 SpareBL/WH 159 Steer joystick signalWH/RD 160 Propel joystick signalWH/BK 161 Sec boom joystick signalOR 162 Joystick 5 VDC power

Color, Circuit #, and Primary functionBL/WH 163 Pri extend/retract signalRD/WH 164 Pri up/down signalWH/RD 165 TT Rotate signalOR 166 Boom length signal safetyOR/BK 167 Boom length signal operationalBL/RD 168 Primary boom hydraulic valve

lockoutGN 169 Envelope active LEDWH/RD 170 Load sense relay sourceWH/BK 171 Load sense relay sinkBL 172 UP/DN flow control groundBK 173 Ext/Ret flow control groundWH 174 Key switch power, ground positionWH/BK 175 Load sensor signal operationalGN/WH 176 Secondary extend/retract FCBL/RD 177 Extend/retract lockoutBK 178 Control module status lightGN 179 Drive power relayBK 180 Lift power relayOR 181 48 Volt alternator field (or battery)RD 182 24 Volt batteryBL 183 Envelope or load sense recoveryWH 184 Program setup enableWH 185 Encode ABL 186 Encode BBL 187 Bootstrap or program enableGN 188 Safety cross checkBK 189 Data receiveBK/WH 190 Data transmitWH/RD 191 Multi-Function pressure reliefWH/BK 192 Jib rotate leftWH/RD 193 Jib rotate rightWH/RD 194 Speed select inputOR/RD 195 Electric brake sourceYL 196 2.5V Sensor powerBR N/A Ground or return

WIRE CIRCUIT LEGEND


6 - 8 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV A

Limit Switches

Types of Limit SwitchesThere are two types of limit switches, which arefound in various locations throughout the machine:mechanical-type operational or safety switchesand magnetic proximity switches. As in aircraft,which features redundant safety systems, eachmechanical safety switch is backed up with anindependently functioning proximity switch.

The mechanical-type operational or safetyswitches are used to sense a positive displacementor movement of the limit switch actuator, or arm, asthe machine moves through its range of operationalfunctions. Included in this group are envelope limitswitches, which sense the extended length andangle of the boom, position of the axles androtational position of the turntable.For example, when the 53° operational switch isactivated by achieving a 53° boom angle, the boommay then be extended beyond 75 feet (22.9 m).Another example is the drive enable limit switch,which disables the drive function anytime the boomis rotated past the rear axles, indicated by the'square' end of the drive chassis.In some cases, the engine will be stopped if safetyparameters are exceeded.

Magnetic proximity switches are used to sensevery specific positions of a part of the machine inrelation to the remainder of the machine. Proximityswitches must be correctly aligned for the machinefunctions to operate. Proximity switches are foundat the front and rear axle, the turntable and severallocations on the boom.

Limit Switch NumberingLSAX1RO Front axle retract proximityLSAX2RO Rear axle retract proximityLSAX1EO Front axle extend proximityLSAX2EO Rear axle extend proximityLSAX1ES Front axle extend safetyLSAX2ES Rear axle extend safetyLSB6S Cable tension safetyLSB7DS Boom 11° angle safetyLSB3RS Boom 3 foot (0.9 m) extend safetyLSB2RS •• Boom 101 feet (30.8 m) extend

safetyLSB9AS •• Boom 65° angle safetyLSB8AS Boom 50° angle safetyLSB4ES Boom 76 feet (23.2 m) extend

safetyLST1O Drive enable mechanicalLSB1DO Boom 10° mechanicalLSB2RO •• Boom >100 feet (30.5 m)

retract proximity(changed to mechanical-S-100/105- sn 160S-120/125- sn 628)

LSB3RO Boom >3 feet (0.9 m) stowed mechanical

LSB3EO Boom 75 feet (22.9 m) extend proximity(changed to mechanical-S-100/105- sn 160S-120/125- sn 628)

LSB4EO •• Boom 100 feet (30.5 m) extend proximity(changed to mechanical-S-100/105- sn 160S-120/125- sn 628)

LSB13AO Boom 53° angle proximityLSB14AO •• Boom 68° angle proximityLSB19LO Load moment mechanical

(•• S-120 and S-125 models only)


Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 9

REV A LIMIT SWITCHES

S-100 & S-105 Models(S-100 shown)

S-120 & S-125 Models(S-120 shown)

LSB3RS3.5 ft (1.1 m)

LSB3RO3 ft (0.9 m)

LSB13AO53

LSB1DO10

LSB7DS11

LSB14AO68

LSB8AS50

LSB9AS65

LSB4ES75.5 ft(23 m)

LSB4EO100 ft

(30.5 m)

LSB2RS101 ft

(30.8 m)

LSB3EO75 ft

(22.9 m)

LSB2RO102 ft

(31.1 m)

LSB3RS3.5 ft (1.1 m)

LSB3RO3 ft (0.9 m)

LSB4ES75.5 ft(23 m)

LSB3EO75 ft

(22.9 m)

LSB13AO53

LSB1DO10

LSB7DS11

LSB8AS50

0 ft / 0 m

10 ft / 3 m

20 ft / 6.1 m

30 ft / 9.1 m

40 ft / 12.2 m

50 ft / 15.2 m

60 ft / 18.3 m

70 ft / 21.3 m

80 ft / 24.4 m

90 ft / 27.4 m

100 ft / 30.5 m

110 ft / 33.5 m

120 ft / 36.6 m

LSAX2ES

LSAX1ES

LSAX2EOLSAX1EO

LSAX2ROLSAX1RO

LST10


6 - 10 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV C

Relay Layout

a Fuel solenoid relay (Deutz F4L913 models only).b Oil cooler relay.c Engine cold start relay.d Starter relay.e Horn relay.f Flashing beacon relay.g CR17 relay (K7) - powers C35RPMcircuit

(Hi/low solenoid).h CR16 relay (K8) - powers C34SA circuit

(Engine cold start).i CR12 relay (K4) - powers primary valves 1 and

2, ignition, glow plug, starter relay, generator,andthe boom retract, multifunction and platform rotatevalve coils.

j CR14 relay (K2) - powers P7R or S56PRV circuitincluding the auxiliary valve, boom extend/retractand turntable rotate valve coils.

k CR10 relay (K6) - powers C21IGN and C107AFcircuits (Fuel on/off solenoid and alternator field).

l CR15 relay (K1) - powers P22R or C03PBF circuit(Boom up/down valve coil).

m CR13 relay (K5) - powers P_7 and throttle relay.n CR11 relay (K3) - powers P-6R2 or P54ENG circuits.

a dcb

f

mn

i

h

g

j

k

l

e

REV A


Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 11

REV CDrive Chassis Controller Pin Legend

J1BLACK23 PINCONNECTOR

J2WHITE23 PIN

CONNECTOR

DCONDRIVE CHASSISCONTROLLER

J11 = GND-DCON - BR

2 = P21DCON - WH

3 = P53LS - RD

4 = (UNUSED)

6 = C61AXRT - GR

5 = S56PRV - RD

7 = (UNUSED)

8 = C61LS-GR

9 = P61LS - GR

10 = (UNUSED)

12 = (UNUSED)

14 = (UNUSED)

16 = (UNUSED)

15 = C61LS(A) - GR

13 = (UNUSED)

11 = (UNUSED)

17 = D81CAN(-) - GR

18 = D82CAN(+) - YL

19 = (UNUSED)

20 = (UNUSED)

21 = (UNUSED)

22 = (UNUSED)

23 = P61LS(A) - GR

DRIVE CHASSISCONTROLLER

J2

DCON

1 = VLVRET - BR

2 = V61AXRT - GR

3 = V60AXEX - GR/WH

4 = V29MS - RD/WH

6 = V52AFV - BL/RD

5 = (UNUSED)

7 = V52REV - BL/RD

8 = V36RRS - BL

9 = V37RRS - BL/BK

10 = C111RRS - OR

12 = C111RFS - OR

14 = VLVRET2 - BR

16 = V36LRS - BL

15 = V32BRK - WH/RD

13 = C111LFS - OR

11 = C111LRS - OR

17 = V37LRS - BL/BK

18 = V36RFS - BL

19 = P110RT - BK

20 = P109ANG - GR/WH

21 = V37RFS - BL/BK

22 = V36LFS - BL

23 = V37LFS - BL/BK

PIN NUMBERING FOR23 PIN

CONNECTORS(WIRE SIDE)

16 23

1 8

DCONDRIVE CHASSIS

CONTROLLER

J21 = VLVRET - BR2 = V61AXRT - GR3 = V60AXEX - GN/WH4 = V29MS - RD/WH5 = (UNUSED)6 = (UNUSED)7 = (UNUSED)8 = V36RRS - BL9 = V37RRS - BL/BK10 = C111RRS - OR11 = C111LRS - OR12 = C111RFS - OR13 = C111LFS - OR14 = VLVRET2 - BR15 = V32BRK - WH/RD16 = V36LRS - BL17 = V37LRS - BL/BK18 = V36RFS - BL19 = P110RT - BK20 = P109ANG - GN/WH21 = V37RFS - BL/BK22 = V36LFS - BL23 = V37LFS - BL/BK

DCONDRIVE CHASSIS

CONTROLLER

J11 = GND-DCON - BR2 = P21DCON - WH3 = P53LS - GR4 = (UNUSED)5 = S56PRV - RD6 = C61AXRT - GR7 = (UNUSED)8 = P61LS - GR9 = C61LS - GR10 = (UNUSED)11 = (UNUSED)12 = (UNUSED)13 = (UNUSED)14 = (UNUSED)15 = C61LS(A) - GR16 = (UNUSED)17 = D81CAN(-) - GR18 = D82CAN(+) - YL19 = (UNUSED)20 = (UNUSED)21 = (UNUSED)22 = (UNUSED)23 = P61LS(A) - GN


6 - 12 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV C

Platform Controller Pin Legend

J1BLACK23 PINCONNECTOR

J2WHITE23 PIN

CONNECTOR



16 23

1 8

PCONPLATFORM

CONTROLLER

J11 = GNDPCON - BR

2 = P52PCON - BL/RD

3 = (UNUSED)

4 = S56PRV - RD/WH

6 = (UNUSED)

5 = (UNUSED)

7 = P56PRV - RD

8 = (UNUSED)

9 = (UNUSED)

10 = D80SHLD

12 = (UNUSED)

14 = (UNUSED)

16 = C46HN - WH

15 = C47OUT - WH/BK

13 = (UNUSED)

11 = (UNUSED)

17 = D81CAN(+) - YL

18 = D82CAN(-) - GR

19 = (UNUSED)

20 = (UNUSED)

21 = (UNUSED)

22 = (UNUSED)

23 = P23PCON - BK

PCONPLATFORM

CONTROLLER

J21 = VLVRET - BR

2 = (UNUSED)

3 = C17PRL - GR

4 = C18PRR - GR/BK

6 = C44JD - GR/BK

5 = C43JU - GR

7 = C14PLU - OR

8 = C15PLD - OR/BK

9 = (UNUSED)

10 = R90PXS - RD/BK

12 = RET94LDS - GN

14 = R94LDS - BK

16 = R56PTS - RD

15 = C88PTS - RD/BK

13 = C94LDS - WH

11 = C90PXS - RD/BK

17 = C56PTS - RD

18 = (UNUSED)

19 = PLATRET - BR

20 = C84TAY - GR/BK

21 = P85PTS - GR

22 = PTSRET - BR

23 = P87PTS - RD

PCONPLATFORM

CONTROLLER

J21 = VLVRET - BR2 = (UNUSED)3 = C17PRL - GR4 = C18PRR - GR/BK5 = C43JU - GR6 = C44JD - GR/BK7 = C14PLU - OR8 = C15PLD - OR/BK9 = (UNUSED)10 = R90PXS - RD/BK11 = C90PXS - RD/BK12 = RET94LDS - GR13 = C94LDS - WH14 = R94LDS - BK15 = C88PTS - RD/BK16 = R56PTS - RD17 = C56PTS - RD18 = (UNUSED)19 = PLATRET - BR20 = C84TAY - GR/BK21 = P85PTS - GR22 = PTSRET - BR23 = P87PTS - RD

PCONPLATFORM

CONTROLLER

J11 = GNDPCON - BR2 = P52PCON - BL/RD3 = (UNUSED)4 = S56PRV - RD/WH5 = (UNUSED)6 = (UNUSED)7 = P56PRV - RD8 = (UNUSED)9 = (UNUSED)10 = (UNUSED)11 = (UNUSED)12 = (UNUSED)13 = (UNUSED)14 = (UNUSED)15 = C47OUT - WH/BK16 = C46HN - WH17 = D81CAN(+) - YL18 = D82CAN(-) - GR19 = (UNUSED)20 = (UNUSED)21 = (UNUSED)22 = (UNUSED)23 = P23PCON - BK


Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 13

REV CTurntable Controller Pin Legend

HIGH SPEEDFUNCTION ENABLE

EMERGENCY STOP

RUN

SERVICEBYPASS

RECOVERY

ALARM

AUXILIARY POWER

LOW SPEEDFUNCTION ENABLE

MACHINENOT LEVEL

PLATFORMNOT LEVEL

EXTEND AXLE

61227 A

RAISE BOOM

RETRACT BOOM

16

23

18

16

23

18

24

35

11

2

24

35

11

2

J4WHITE35 PIN

CONNECTOR



PIN NUMBERING FOR

(WIRE SIDE)

35 PINCONNECTORS

J2BLACK35 PIN

CONNECTOR

J3WHITE23 PIN

CONNECTOR

J1

23 PINCONNECTOR

BLACK

J5WIRE LOOM

TCONTURNTABLE

CONTROLLER

J51 = BATVLV - RD

2 = BATGND - BR

3 = BATGND - BR

4 = BATECU - RD

TCONTURNTABLE

CONTROLLER

J11 = GNDPCON - BR

2 = P52PCON - WH

3 = C46HN - WH

4 = C47OUT - WH/BK

6 = S56PRV - RD/WH

5 = P23PCON - BK

7 = P56PRV - RD

8 = R48LP - WH/RD

9 = R117FB - RD

10 = D80SHLD

12 = (UNUSED)

14 = (UNUSED)

16 = (UNUSED)

15 = P97TET - BK

13 = (UNUSED)

11 = (UNUSED)

17 = D81CAN(-) - GR

18 = D82CAN(+) - YL

19 = (UNUSED)

20 = (UNSUSED)

21 = (UNUSED)

22 = UNUSED)

23 = P95TET - OR

TCONTURNTABLE

CONTROLLER

J2(S-120 & S-125 MODELS)

1 = GNDDCON - BR

2 = P21DCON - RD

3 = P53LS - WH/BK

4 = P54ENG - BK/WH

6 = P57PBD - RD/WH

5 = P56PRV - RD

7 = P58LS - RD/BK

8 = S59CNBK - GR/WH

9 = C60AXEX - GR/WH

10 = C61AXRT - GR

12 = P63LS - OR/RD

14 = C65LOFL - BL/WH

16 = (UNUSED)

15 = C66DREN - BL

13 = C64LS - OR/BL

11 = S62BSTO - OR

17 = C68PBD - RD

18 = C69PBE - BK

19 = C70PBE - BL/WH

20 = C71PBE - BL/BK

21 = (UNUSED)

22 = (UNUSED)

26 = (UNUSED)

31 = (UNUSED)

32 = (UNUSED)

33 = (UNUSED)

34 = (UNUSED)

23 = V74PRLO - RD

24 = V75PRLO - RD/WH

25 = SNSR GND - BR

27 = G119SR - BL

28 = C76PBE - BL

29 = C77AS - WH

30 = C78PS - WH/BK

35 = VLVRET1 - BR

TCONTURNTABLE

CONTROLLER

J2(S-100 & S-105 MODELS)

1 = GNDDCON - BR

2 = P21DCON - RD

3 = P53LS - WH/BK

4 = P54ENG - BK/WH

6 = P57PBD - RD/WH

5 = P56PRV - RD

7 = P58LS - RD/BK

8 = S59CNBK - GR/WH

9 = C60AXEX - GR/WH

10 = C61AXRT - GR

12 = P63LS - OR/RD

14 = C65LOFL - BL/WH

16 = (UNUSED)

15 = C66DREN - BL

13 = C64LS - OR/BL

11 = S62BSTO - OR

17 = C68PBD - RD

18 = (UNUSED)

19 = C70PBE - BL/WH

20 = C71PBE - BL/BK

21 = (UNUSED)

22 = (UNUSED)

26 = (UNUSED)

31 = (UNUSED)

32 = (UNUSED)

33 = (UNUSED)

34 = (UNUSED)

23 = V74PRLO - RD

24 = V75PRLO - RD/WH

25 = SNSR GND - BR

27 = G119SR - BL

28 = (UNUSED)

29 = C77AS - WH

30 = (UNUSED)

35 = VLVRET1 - BR

TCONTURNTABLE

CONTROLLER

J41 = VLVRET4 - BR

2 = C03PBF - RD/WH

3 = C09PERF - BK/RD

4 = C06TRF - WH/RD

6 = (UNUSED)

5 = (UNUSED)

7 = CO1PBU - RD

8 = C02PBD - RD/BK

9 = C07PBE - BK

10 = C08PBR - BK/WH

12 = (UNUSED)

14 = VLVRET5 - BR

16 = (UNUSED)

15 = (UNUSED)

13 = R49LP - WH/BK

11 = (UNUSED)

17 = C15LS - RD/BK

18 = C14LS - BK/RD

19 = (UNUSED)

20 = (UNUSED)

21 = (UNUSED)

22 = (UNUSED)

26 = C05TRR - WH/BK

31 = (UNUSED)

32 = C27AUX - RD

33 = (UNUSED)

34 = (UNUSED)

23 = C113MFV - OR/RD

24 = (UNUSED)

25 = C05TTL - WH

27 = VLVRTN7 - BR

28 = (UNUSED)

29 = (UNUSED)

30 = VLVRET6 - BR

35 = (UNUSED)

TCONTURNTABLE

CONTROLLER

J31 = (UNUSED)

2 = R35RPM - BK/RD

3 = C21IGN - WH

4 = C34SA - BK/WH

6 = V31REV - WH/BK

5 = V30FWD - WH

7 = C46HRN - WH

8 = (UNUSED)

9 = C33STR - BK

10 = C31EDC - WH/BK

12 = C25PSR - WH/BK

14 = RET85TTSR - BR

16 = VLVRET2 - BR

15 = P85TTSR - GR

13 = C26TSR - WH/RD

11 = C30EDC - WH

17 = (UNUSED)

18 = C41RPM - OR/BK

19 = C107AF - RD

20 = C83TAX - GR/WH

21 = C84TAY - GR/BK

22 = C45GEN - GR/WH

23 = VLVRET3 - BR

24 35

1 12

16 23

1 8

TCONTURNTABLE

CONTROLLER

J11 = GNDPCON - BR2 = P52PCON - WH3 = C46HN - WH4 = C47OUT - WH/BK5 = P23PCON - BK6 = S56PRV - RD/WH7 = P56PRV - RD8 = R48LP - WH/RD9 = R117FB - RD10 = (UNUSED)11 = (UNUSED)12 = (UNUSED)13 = (UNUSED)14 = (UNUSED)15 = P97TET - BK16 = (UNUSED)17 = D81CAN(-) - GR18 = D82CAN(+) - YL19 = (UNUSED)20 = (UNUSED)21 = (UNUSED)22 = (UNUSED)23 = P95TET - OR

TCONTURNTABLE

CONTROLLER

J2(S-120 & S-125 MODELS)

1 = GNDDCON - BR2 = P21DCON - RD3 = P53LS - WH/BK4 = P54ENG - BK/WH5 = P56PRV - RD6 = P57PBD - RD/WH7 = P58LS - RD/BK8 = S59CNBK - GR/WH9 = C60AXEX - GR/WH10 = C61AXRT - GR11 = S62BSTO - OR12 = P63LS - OR/RD13 = C64LS - OR/BL14 = C65LOFL - BL/WH15 = C66DREN - BL16 = (UNUSED)17 = C68PBD - RD18 = C89PBE - BK19 = C70PBE - BL/WH20 = C71PBE - BL/BK21 = (UNUSED)22 = (UNUSED)23 = V74PRLO - RD24 = V75PRLO - RD/WH25 = SNSR GND - BR26 = (UNUSED)27 = G119SR - BL28 = C76PBE - BL29 = C77AS - WH30 = C78PS - WH/BK31 = (UNUSED)32 = (UNUSED)33 = (UNUSED)34 = (UNUSED)35 = VLVRET1 - BR

TCONTURNTABLE

CONTROLLER

J2(S-100 & S-105 MODELS)

1 = GNDDCON - BR2 = P21DCON - RD3 = P53LS - WH/BK4 = P54ENG - BK/WH5 = P56PRV - RD6 = P57PBD - RD/WH7 = P58LS - RD/BK8 = S59CNBK - GR/WH9 = C60AXEX - GR/WH10 = C61AXRT - GR11 = S62BSTO - OR12 = P63LS - OR/RD13 = C64LS - OR/BL14 = C65LOFL - BL/WH15 = C66DREN - BL16 = (UNUSED)17 = C68PBD - RD18 = (UNUSED)19 = C70PBE - BL/WH20 = C71PBE - BL/BK21 = (UNUSED)22 = (UNUSED)23 = V74PRLO - RD24 = V75PRLO - RD/WH25 = SNSR GND - BR26 = (UNUSED)27 = G119SR - BL28 = (UNUSED)29 = C77AS - WH30 = (UNUSED)31 = (UNUSED)32 = (UNUSED)33 = (UNUSED)34 = (UNUSED)35 = VLVRET1 - BR

TCONTURNTABLE

CONTROLLER

J31 = (UNUSED)2 = R35RPM - BK/RD3 = C21IGN - WH4 = C34SA - BK/WH5 = V30FWD - WH6 = V31REV - WH/BK7 = C46HRN - WH8 = (UNUSED)9 = C33STR - BK10 = C30EDC - WH11 = C31EDC - WH/BK12 = C25PSR - WH/BK13 = C26TSR - WH/RD14 = RET85TTSR - BR15 = P85TTSR - GN16 = VLVRET2 - BR17 = (UNUSED)18 = C41RPM - OR/BK19 = C107AF - RD20 = C83TAX - GR/WH21 = C84TAY - GR/BK22 = C45GEN - GR/WH23 = VLVRET3 - BR

TCONTURNTABLE

CONTROLLER

J51 = BATVLV - RD2 = BATGND - BR3 = BATGND - BR4 = BATECU - RD

TCONTURNTABLE

CONTROLLER

J41 = VLVRET4 - BR2 = C03PBF - RD/WH3 = C09PERF - BK/RD4 = C06TRF - WH/RD5 = (UNUSED)6 = (UNUSED)7 = C01PBU - RD8 = C02PBD - RD/BK9 = C07PBE - BK10 = C08PBR - BK/WH11 = (UNUSED)12 = (UNUSED)13 = R49LP - WH/BK14 = VLVRET5 - BR15 = S2PLD2 - GN/BK16 = S7PLE2 - GR/WH17 = S7PLE1 - BL/BK18 = S2PLD1 - BL.RD19 = (UNUSED)20 = (UNUSED)21 = (UNUSED)22 = (UNUSED)23 = C113MFV - OR/RD24 = (UNUSED)25 = C0RTRL - WH26 = C05TRR - WH/BK27 = VLVRET7 - BR28 = (UNUSED)29 = (UNUSED)30 = VLVRET6 - BR31 = (UNUSED)32 = C27AUX - RD33 = (UNUSED)34 = (UNUSED)35 = (UNUSED)


6 - 14 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV A

Electrical Symbols Legend

Connection

no terminal

T-circuits

connect

FB

Flashing beacon

Diode

Circuits crossing

no connection

Quick disconnect

terminal

BLK

WHT

Battery

+

-

Circuit breaker

with amperage

15A

CB1

Horn or alarm

H1

Emergency Stop

button normally

closed

P1

Power relay

PR1

HM

Hour meter

N.O.

OTS2

Oil temperature

switch

normally open

N.O.

CTS1

Coolant temperature

switch

normally open

Oil pressure switch

normally closed

N.C.

OPS1 BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oil

cooling fanG1

Gauge

Tilt sensor

LED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fuse

with amperage

25A

F1

Starting aid:

glow plug or

flame ignitor

Control relay contact

normally open

CR4

N.O.

Battery separator

MA

INA

UX

Coil

Fuel or RPM

solenoid

PU

LL

IN

HO

LD

CA B

Main key switch

A-A

B-A

A-B

B-B

2

2

4

4

1

1

3

3

OFFKS1

MAINKEYSWITCHPCON

TCON

Service bypass/

recovery

key switch

SERVICE BYPASS

RUN

A-A

A-B

B-B

C-B

C-A

B-A

2

2

2

4

4

4

1

1

1

3

3

3

RECOVERY

KS2SERVICE BYPASS/

RECOVERYKEY SWITCH

Sending unit

Current limiting

device

Relay

85

87a

87

86 30

5 4

2 1

ALTERNATOR

D1ALTERNATOR

REGULATOR

BAT+

IND.

STA.

BAT-

EXCT

Starter motor

STARTER

Power relay

Steer sensor

BL

BK

RD

BA C

Chassis ground

Toggle switch


Part No. 102916 S-100 • S-105 • S-120 • S-125 6 - 15

REV AHydraulic Symbols Legend

Pump

fixed displacement

Motor

bi-directional

Shut off valve

Check valve

2 position, 3 way, shuttle valve

Double acting

cylinder

Priority

flow regulator valve

Differential

sensing valve

Solenoid operated

proportional valve

Hydraulic oil cooler

Brake

Pilot operated 3 position,

3 way, shuttle valve

Filter with

bypass valve

relief setting

25 psi

(1.7 bar)

Motor

2-speed,

bi-directional

Pump

bi-directional,

variable displacement

E

Pump prime mover

(engine or motor)

Directional valve

(mechanically activated)

o

Relief valve

with pressure setting

200 psi

(13.8 bar)

Orifice with size

.035"

(0.89 mm)

Solenoid operated 3 position,

4 way, directional valve

Directional valve

pilot operated

2 position, 2 way

Flow divider/combiner valve

with pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valve

with pressure and pilot ratio

(206.8 bar)

3000 psi

3:1

Solenoid operated 2 position,

3 way, directional valve

2 position, 2 way

solenoid valve

Accumulator


6 - 16 S-100 • S-105 • S-120 • S-125 Part No. 102916

REV A


Part No. 102916 S-100 • S-105 • S-120 • S-125 6-17


87a

87

P5

7P

BD

P5

7P

BD

S6

2B

ST

O

C6

0A

XE

X

S59CNBK

C61AXRT

88

P53LS

LSB6S

CABLE TENSION

P63LS

S62BSTO

LSB3RS

BOOM RETRACT

P5

3L

S

C60AXEX

TCON/J2/11

TCON/J2/9

TCON/J2/7

TCON/J2/12

TCON/J2/10

TCON/J2/8

DCON/J1/3

MONITORED BY ECU

S62BSTO

C60AXEX

P58LS

P6

3L

S

P_10 GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

NFET

D17

P_11

D13

P_9B

NFET

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

NFET

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

30

86

TCON/J2/5

LSB8AS

50 DEGREES

P58LS

SJ2

SJ1

LSB7DS

BOOM DOWN

P53LS

LSB2RS

101' (30.8 m)

P53LS

P57PBD

P54ENG

40A

P_7R

87a 87 85

8630

87a 87 85

8630

87a 87 85

8630

TCON/J2/4

P_

6R

2

DCON/J1/3

LSB4ES

80' (24.4 m)LSAX2ES

AXLE EXTEND

88

88

LSAX1ES

AXLE EXTEND

LSB9AS

65 DEGREES

P53LS

P57PBD

88

88

20 K

R3

D16

P_

16

P_

7R

5A

VR1

P_7R

TCON/J2/3

P_

6R

1

TCON/J2/6

P_

9A

D14

D23

P_15

P_9A

TO BOOM DOWN VALVE

NFET

PWR

STAT

IN 1

IN 2 TCON/J4/8

GND

OUT 1

OUT 2

TCON/J4/9 TO BOOM EXTEND VAVLE

85

87a

87

30

86 85

87a

87

30

86 85

TCON/J4/7 TO BOOM UP VALVE

TCON/J3/3 TO FUEL SOLENOID

TO ROTATE CCW VALVE

TO ROTATE CCW VALVE

TO ROTATE CW VALVE

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

PWR

STAT

IN 1

IN 2

PWR

STAT

IN 1

IN 2

TCON/J4/25

TCON/J4/26

GND

OUT 1

OUT 2

NFET

TCON/J4/10

TCON/J3/9TO STARTER RELAY

GND

OUT 1

OUT 2

NFET

PWR

STAT

IN 1

IN 2

GND

OUT 1

OUT 2

NFET

PWR

STAT

IN 1

IN 2

GND

OUT 1

OUT 2

NFET

TCON/J4/35TO DRIVE LP RELAY

NFET

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2NFET

NFET

TO PRIMARY 1 LOCKOUT VALVE

TO PRIMARY 2 LOCKOUT VALVE

TCON/J4/23 TO MULTIFUNCTION VALVE

TCON/J2/24

TCON/J3/2

TCON/J2/23

HI/LO

TO HI/LO SOLENOID

CHOKE

TO TURNTABLE FLOW CONTROLROTATE VALVE

TCON/J3/4TCON/J4/3

TCON/J2/23

TCON/J4/32

TCON/J3/5

TCON/J3/6

NFET

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

NFET

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

GND

OUT 1

OUT 2

PWR

STAT

IN 1

IN 2

NFET

NFET

TO REVERSE VALVE

TO FORWARD VALVE

TO AUXILIARY RELAY

TOTURNTABLE FLOW CONTROLROTATE VALVE

CB1

P_

14

P_

11

(P_18)

(P_14)

CR17 CR11 CR12

CR10

CR17

CR16

(K2) (K3) (K4)

(K6)

(K7)

(K8)

Safety Circuit Schematic


6-18

Safety Circuit Schematic

6-17

Section 6 • SchematicsJune 2011

6-19

Engine Options- Perkins and CumminsS-100/105 (before serial number 219)S-120/125 (before serial number 933)

6-20

6-20 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AEngine Options- Perkins and CumminsS-100/105 (before serial number 219)S-120/125 (before serial number 933)

R3

4S

A-B

K/W

H

87a5

854

87

2

86

1

30

C4

5G

EN

-GR

/WH

VLV

RE

T3

-BR

C8

3TA

X-G

R/W

H

C8

4TA

Y-G

R/B

K

C1

07

AF

-RD

C4

1R

PM

-OR

/BK

P8

5T

TS

R-G

R

VLV

RE

T2

-BR

RE

T8

5T

TS

R-G

R

C2

6T

SR

-WH

/RD

C2

5P

SR

-WH

/BK

C3

3S

TR

-BK

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

C4

6H

RN

-WH

V3

1R

EV-W

H/B

K

V3

0F

WD

-WH

R3

5R

PM

-BK

/RD

C3

4S

A-B

K/W

H

C2

1IG

N-W

H

VLV

RE

T1

-BR

BA

TE

CU

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TV

LV-R

D

BA

T G

ND

-BR

TO

J4

-32

WH

ITE

35

PIN

TO

J4

-30

WH

ITE

35

PIN

HI/

LO

SP

EE

DS

OLE

NO

ID

-

+

-

+

ENGINE BLOCK

PERKINS 1004-42 ENGINECUMMINS 4B3.9L ENGINE

SERVICEHORN

P29 ENG HARNJ29 PWR HARN

4

MA

IN (

SY

S)

BA

T

STA

RT

BA

T

STARTER

STARTERRELAY

87a

BA

T C

BL(A

)-R

D

P1

14

BA

T-R

D

MA

INA

UX

8587a4

87

5

8630

1 2

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

P3

3S

TR

-BK

BA

T G

ND

-BR

VLV

RE

T6

-BR

C2

7A

UX-R

D

PR

1 ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

87 85

5

30

1

86

2

BAT CBL(A)-RDF

LA

MM

STA

RT

RE

LA

Y

HORNRELAY

P4

6H

RN

(A)-

WH

VLV

RE

T2

-BR

VLV

RE

T2

-BR

WH

-PU

LL IN

BA

TG

ND

(A)

- B

K

RD

-HO

LD

PU

LL IN

HO

LD

21 3

V3

1R

EV-W

H/B

K

VLV

RE

T2

-BR

V3

0F

WD

-WH

FW

D V

LV A

SO

LE

NO

ID

SO

LE

NO

IDR

EV

VLV

B

C3

4S

A-B

K/W

H

P4

6H

RN

-WH

1

P114BAT-RD

BAT GND-BR

C45GEN-GR/WH 1

3

2

J32-ENG HARN

P1

-04

AU

X/S

TA

RT

_B

AT

_P

WR

AU

X/S

TA

RT

_B

AT

_G

ND

J5 BLACK 4 PIN

POWER HARN P1

-01

P1

-03

P1

-02

SY

S_B

AT

_P

WR

SY

S_B

AT

_G

ND

P1

-12

P1

-01

VA

LVE

RT

N1

J3 WHITE 23 PIN

ENGINE HARN

TH

RO

TT

LE

P1

-04

P1

-02

P1

-03

P1

-06

P1

-05

P1

-08

P1

-09

P1

-07

P1

-11

P1

-10

CH

OK

E/G

LO

W P

LU

G

IGN

ITIO

N/F

UE

L

FW

D

RE

V

STA

RT

ER

_R

ELA

Y

OIL

_P

RE

SS

UR

E

SE

RV

ICE

_H

OR

N

ALT

EN

AT

OR

_R

PM

TT

_T

ILT

_S

NS

R_P

WR

TT

_T

ILT

_S

NS

R_G

ND

VA

LVE

_R

TN

2

TT

_T

ILT

_Y

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_X

_A

XIS

ALT

_F

IELD

_W

IRE

VA

LVE

_R

TN

3

P1

-15

P1

-13

P1

-14

P1

-16

P1

-17

P1

-20

P1

-19

P1

-18

P1

-23

P1

-22

P1

-21

OIL

/WA

TE

R_T

EM

P

J3

1-T

ILT

SN

SR

P3

1-E

NG

HA

RN

BA

T G

ND

-BR

BA

T G

ND

-BR

FU

EL S

OLE

NO

IDR

ELA

Y

C2

1IG

N-W

H

IGN

ITO

RF

LA

MM

STA

RT

C2

6T

SR

-WT

/RD

C2

5P

SR

-WT

/BK

OIL

TE

MP

SE

ND

ER

OIL

PR

ES

SU

RE

70

A F

US

E

RET85TTSR-BR

P85TTSR-GR

C84TAY-GN/WH

C83TAX-GN/WH

BK

WH

RD

+BAT

+AUX

COM

-BAT

WH

-PU

LL IN

RD

-HO

LD

TU

RN

TA

BLE

TIL

TS

EN

SO

R

-+

+-

CB

25

A

S-500

TIME DELAYMOM N.O.TROMBETTA

0-2

0 D

EG

RE

ES

EN

SO

R A

LA

RM

SE

TA

T 4

.5 D

EG

RE

ES

PUMPAUX.

15 A FUSE

WAS 10A BEFORE:

S100/105- SN 159

S120/125- SN 619

Part No. 102916 S-100 • S-105 • S-120 • S-125 6-21


Engine Options- PerkinsS-100/105 (from serial number 219 to 247)S-120/125 (from serial number 933 to 984)

REV A

70 A FUSE

-BAT

R3

4S

A-R

D

87a5

85

4

87

2

86

1

30

C4

5G

EN

-GN

/WH

VLV

RE

T3

-BR

C8

3TA

X-G

N/W

H

C8

4TA

Y-G

N/B

K

C1

07

AF

-RD

C4

1R

PM

-OR

/BK

P8

5T

TS

R-G

N

VLV

RE

T2

-BR

RE

T8

5T

TS

R-B

R

C2

6T

SR

-WH

/RD

C2

5P

SR

-WH

/BK

C3

3S

TR

-BK

C4

6H

RN

-WH

R3

5R

PM

-BK

/RD

C3

4S

A-B

K/W

H

C2

1IG

N-W

H

BA

TE

CU

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TV

LV-R

D

BA

T G

ND

-BR

TO

J4

-32

WH

ITE

35

PIN

TO

J4

-30

WH

ITE

35 H

I/LO

SP

EE

DS

OLE

NO

ID

-

+

-

+

ENGINE BLOCK

PERKINS 1104C-44 ENGINE

SERVICEHORN

4

MA

IN (

SY

S)

BA

T

STA

RT

BA

T

STARTER

STARTERRELAY 87a

P1

14

BA

T-R

D

MA

INA

UX

8587a4

87

5

86301 2

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

BA

T G

ND

-BR

VLV

RE

T6

-BR

C2

7A

UX-R

D

PR

1 ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

87 855

301

862

P34SA-RD

GLO

WP

LU

GR

ELA

Y

HORNRELAY

R4

6H

RN

-WH

VLV

RE

T2

-BR

VLV

RE

T2

-BR

WH

-PU

LL IN

BK

-CO

M

RD

-HO

LD

PU

LL IN

HO

LD

21 3

VLV

RE

T2

-BR

C3

4S

A-B

K/W

H

P46HRN-WH

P114BAT-RD

BAT GND-BR

C45GEN-GN/WH 1

3

2

J32-ENG HARN

P1

-04

AU

X/S

TA

RT

_B

AT

_P

WR

AU

X/S

TA

RT

_B

AT

_G

ND

J5 BLACK 4 PIN

POWER HARN P1

-01

P1

-03

P1

-02

SY

S_B

AT

_P

WR

SY

S_B

AT

_G

ND

P1

-12

P1

-01J3 WHITE 23 PIN

ENGINE HARN

TH

RO

TT

LE

P1

-04

P1

-02

P1

-03

P1

-06

P1

-05

P1

-08

P1

-09

P1

-07

P1

-11

P1

-10

CH

OK

E/G

LO

W P

LU

G

IGN

ITIO

N/F

UE

L

FW

D

RE

V

OIL

_P

RE

SS

UR

E

SE

RV

ICE

_H

OR

N

ALT

EN

AT

OR

_R

PM

TT

_T

ILT

_S

NS

R_P

WR

TT

_T

ILT

_S

NS

R_G

ND

VA

LVE

_R

TN

2

TT

_T

ILT

_Y

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_X

_A

XIS

ALT

_F

IELD

_W

IRE

VA

LVE

_R

TN

3

P1

-15

P1

-13

P1

-14

P1

-16

P1

-17

P1

-20

P1

-19

P1

-18

P1

-23

P1

-22

P1

-21

OIL

/WA

TE

R_T

EM

P

J3

1-T

ILT

SN

SR

P3

1-E

NG

HA

RN

BA

T G

ND

-BR

C2

1I G

N- W

H

C2

6T

SR

-WT

/RD

C2

5P

SR

- WT

/BK

OI L

TE

MP

SE

ND

ER

OIL

PR

ES

SU

RE

RET85TTSR-BR

P85TTSR-GN

C84TAY-GN/BK

C83TAX-GN/WH

BK

WH

RD

TU

RN

TA

BLE

TIL

TS

EN

SO

R

-+

+-

CB

25

A

+BAT

+AUX

RD-HOLD

BK-COM

WH-PULL

GLO

W P

LU

GS

CO

LD

STA

RT

AD

VA

NC

E

15 A FUSE

FU

EL S

HU

TD

OW

N

C2

1I G

N- W

H

FUELPUMP

SO

LE

NO

IDF

WD

VLV

A

SO

LE

NO

IDR

EV

VLV

B

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

STA

RT

ER

_R

ELA

Y

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

TROMBETTATIME DELAYMOM N.O.

S-500

PUMPAUX.

0-20 DEGREESENSOR ALARM SETAT 4.5 DEGREES

V3

0F

WD

-WH

V3

1R

EV-W

H/B

K

SEE GENERATOR OPTIONS PAGE


6-22

Engine Options- PerkinsS-100/105 (from serial number 219 to 247)S-120/125 (from serial number 933 to 984)

6-21


6-23

Engine Options- PerkinsS-100/105 (from serial number 248)S-120/125 (from serial number 985)

6-24

6-24 S-100 • S-105 • S-120 • S-125 Part No. 102916


Engine Options- PerkinsS-100/105 (from serial number 248)S-120/125 (from serial number 985)

REV A

CB7

15A

70 A FUSE

-BAT

R3

4S

A-R

D

87a5

85

4

87

2

86

1

30

C4

5G

EN

-GN

/WH

VLV

RE

T3

-BR

C8

3TA

X-G

N/W

H

C8

4TA

Y-G

N/B

K

C1

07

AF

-RD

C4

1R

PM

-OR

/BK

P8

5T

TS

R-G

N

VLV

RE

T2

-BR

RE

T8

5T

TS

R-B

R

C2

6T

SR

-WH

/RD

C2

5P

SR

-WH

/BK

C3

3S

TR

-BK

C4

6H

RN

-WH

R3

5R

PM

-BK

/RD

C3

4S

A-B

K/W

H

C2

1IG

N-W

H

BA

TE

CU

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TV

LV-R

D

BA

T G

ND

-BR

TO

J4

-32

WH

ITE

35

PIN

TO

J4

-30

WH

ITE

35 H

I/LO

SP

EE

DS

OLE

NO

ID

-

+

-

+

ENGINE BLOCK

PERKINS ENGINE1104C-44PERKINS 804D-33T ENGINE

SERVICEHORN

4

MA

IN (

SY

S)

BA

T

STA

RT

BA

T

STARTER

STARTERRELAY 87a

P1

14

BA

T-R

D

MA

INA

UX

8587a4

87

5

86301 2

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

BA

T G

ND

-BR

VLV

RE

T6

-BR

C2

7A

UX-R

D

PR

1 ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

87 855

301

862

P34SA-RD

GLO

WP

LU

GR

ELA

Y

HORNRELAY

R4

6H

RN

-WH

VLV

RE

T2

-BR

VLV

RE

T2

-BR

WH

-PU

LL IN

BK

-CO

M

RD

-HO

LD

PU

LL IN

HO

LD

21 3

VLV

RE

T2

-BR

C3

4S

A-B

K/W

H

P46HRN-WH

P114BAT-RD

BAT GND-BR

C45GEN-GN/WH 1

3

2

J32-ENG HARN

P1

-04

AU

X/S

TA

RT

_B

AT

_P

WR

AU

X/S

TA

RT

_B

AT

_G

ND

J5 BLACK 4 PIN

POWER HARN P1

-01

P1

-03

P1

-02

SY

S_B

AT

_P

WR

SY

S_B

AT

_G

ND

P1

-12

P1

-01J3 WHITE 23 PIN

ENGINE HARN

TH

RO

TT

LE

P1

-04

P1

-02

P1

-03

P1

-06

P1

-05

P1

-08

P1

-09

P1

-07

P1

-11

P1

-10

CH

OK

E/G

LO

W P

LU

G

IGN

ITIO

N/F

UE

L

FW

D

RE

V

OIL

_P

RE

SS

UR

E

SE

RV

ICE

_H

OR

N

ALT

EN

AT

OR

_R

PM

TT

_T

ILT

_S

NS

R_P

WR

TT

_T

ILT

_S

NS

R_G

ND

VA

LVE

_R

TN

2

TT

_T

ILT

_Y

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_X

_A

XIS

ALT

_F

IELD

_W

IRE

VA

LVE

_R

TN

3

P1

-15

P1

-13

P1

-14

P1

-16

P1

-17

P1

-20

P1

-19

P1

-18

P1

-23

P1

-22

P1

-21

OIL

/WA

TE

R_T

EM

P

J3

1-T

ILT

SN

SR

P3

1-E

NG

HA

RN

BA

T G

ND

-BR

C2

1IG

N-W

H

C2

6T

SR

-WT

/RD

C2

5P

SR

-WT

/BK

OIL

TE

MP

SE

ND

ER

OIL

PR

ES

SU

RE

RET85TTSR-BR

P85TTSR-GN

C84TAY-GN/BK

C83TAX-GN/WH

BK

WH

RD

TU

RN

TA

BLE

TIL

TS

EN

SO

R

-+

+-

CB

25

A

+BAT

+AUX

RD-HOLD

BK-COM

WH-PULL

GLO

W P

LU

GS

CO

LD

STA

RT

AD

VA

NC

E

15 A FUSE

FU

EL S

HU

TD

OW

N

C2

1IG

N-W

H

FUELPUMP

SO

LE

NO

IDF

WD

VLV

A

SO

LE

NO

IDR

EV

VLV

B

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

STA

RT

ER

_R

ELA

Y

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

20 A

FUSEP116HYD-OR

OTS1N.O.

C1

16

HY

D-O

R

P1

16

HY

D-O

R

HY

D C

OO

LE

RR

ELA

Y

87a5

85

4

87

286

130

BA

T G

ND

-BR

BA

T G

ND

-BR

R1

16

HY

D-O

R

TROMBETTATIME DELAYMOM N.O.

S-613

PUMPAUX.

0-20 DEGREESENSOR ALARM SETAT 4.5 DEGREES

V3

0F

WD

-WH

V3

1R

EV-W

H/B

K

CB7 ADDED

S100- S/N 710

S125- S/N 2589


Part No. 102916 S-100 • S-105 • S-120 • S-125 6-25


Engine Options- CumminsS-100/105 (from serial number 219 to 247)S-120/125 (from serial number 933 to 984)

REV A

WH-PULL

BK-COM

RD-HOLD

+AUX

+BAT

25

A

CB

-+

+-

TU

RN

TA

BLE

TIL

TS

EN

SO

R

RD

WH

BK

C83TAX-GN/WH

C84TAY-GN/BK

P85TTSR-GN

RET85TTSR-BR

27

5 A

FU

SE

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

C2

5P

SR

-WT

/BK

C2

6T

SR

-WT

/RD

GR

ID H

EA

TE

R

C2

1IG

N-W

H

FU

EL S

OLE

NO

IDR

ELA

Y

BA

T G

ND

-BR

BA

T G

ND

-BR

P3

1-E

NG

HA

RN

J3

1-T

ILT

SN

SR

OIL

/WA

TE

R_T

EM

P

P1

-21

P1

-22

P1

-23

P1

-18

P1

-19

P1

-20

P1

-17

P1

-16

P1

-14

P1

-13

P1

-15

VA

LVE

_R

TN

3

ALT

_F

IELD

_W

IRE

TT

_T

ILT

_X

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_Y

_A

XIS

VA

LVE

_R

TN

2

TT

_T

ILT

_S

NS

R_G

ND

TT

_T

ILT

_S

NS

R_P

WR

ALT

EN

AT

OR

_R

PM

SE

RV

ICE

_H

OR

N

OIL

_P

RE

SS

UR

E

RE

V

FW

D

IGN

ITIO

N/F

UE

L

CH

OK

E/G

LO

W P

LU

G

P1

-10

P1

-11

P1

-07

P1

-09

P1

-08

P1

-05

P1

-06

P1

-03

P1

-02

P1

-04

TH

RO

TT

LE

ENGINE HARN

J3 WHITE 23 PIN

P1

-01

P1

-12

SY

S_B

AT

_G

ND

SY

S_B

AT

_P

WR

P1

-02

P1

-03

P1

-01

POWER HARN

J5 BLACK 4 PIN

AU

X/S

TA

RT

_B

AT

_G

ND

AU

X/S

TA

RT

_B

AT

_P

WR

P1

-04

J32-ENG HARN

2

3

1C45GEN-GN/WH

BAT GND-BR

P114BAT-RD

P46HRN-WH

C3

4S

A-B

K/W

H

RE

V V

LV B

SO

LE

NO

ID

SO

LE

NO

IDF

WD

VLV

A

VLV

RE

T2

-BR

31 2

HO

LD

PU

LL IN

RD

-HO

LD

BK

-CO

M

WH

-PU

LL IN

VLV

RE

T2

-BR

VLV

RE

T2

-BR

R4

6H

RN

-WH

HORNRELAY

GR

ID H

EA

TE

RR

ELA

Y

P34SA-RD

2

86

1

30

58587

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.PR

1

C2

7A

UX-R

D

VLV

RE

T6

-BR

BA

T G

ND

-BR

C1

07

AF

-RD

C4

1R

PM

-OR

/BK

8587a4

875

86301 2

MA

INA

UX

P1

14

BA

T-R

D

87a

STARTERRELAY

STARTER

STA

RT

BA

T

BA

TM

AIN

(S

YS

)

4

SERVICEHORN

CUMMINS B4.5 C80 ENGINE

ENGINE BLOCK

-

+

-

+

HI/

LO

SP

EE

DS

OLE

NO

ID

TO

J4

-30

WH

ITE

35

PIN

TO

J4

-32

WH

ITE

35

PIN

BA

T G

ND

-BR

BA

TV

LV-R

D

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TE

CU

-RD

C2

1IG

N-W

H

C3

4S

A-B

K/W

H

R3

5R

PM

-BK

/RD

C4

6H

RN

-WH

C3

3S

TR

-BK

C2

5P

SR

-WH

/BK

C2

6T

SR

-WH

/RD

RE

T8

5T

TS

R-B

R

VLV

RE

T2

-BR

P8

5T

TS

R-G

N

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

C8

4TA

Y-G

N/B

K

C8

3TA

X-G

N/W

H

VLV

RE

T3

-BR

C4

5G

EN

-GN

/WH

87a5

854

87

286

130

R3

4S

A-R

D

-BAT

70 A FUSE

P34SA-RD

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

STA

RT

ER

_R

ELA

Y

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

MOM N.O.TIME DELAYTROMBETTA

S-500

AUX.PUMP

0-20 DEGREESENSOR ALARMSET AT 4.5DEGREES

V3

0F

WD

-WH

V3

1R

EV-W

H/B

K



6-26

Engine Options- CumminsS-100/105 (from serial number 219 to 247)S-120/125 (from serial number 933 to 984)

6-25


6-27

Engine Options- CumminsS-100/105 (from serial number 248)S-120/125 (from serial number 985)

6-28

6-28 S-100 • S-105 • S-120 • S-125 Part No. 102916


Engine Options- CumminsS-100/105 (from serial number 248)S-120/125 (from serial number 985)

REV A

CB7

15A

WH-PULL

BK-COM

RD-HOLD

+AUX

+BAT

25

A

CB

-+

+-

TU

RN

TA

BLE

TIL

TS

EN

SO

R

RD

WH

BK

C83TAX-GN/WH

C84TAY-GN/BK

P85TTSR-GN

RET85TTSR-BR

27

5 A

FU

SE

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

C2

5P

SR

-WT

/BK

C2

6T

SR

-WT

/RD

GR

ID H

EA

TE

R

C2

1IG

N-W

H

FU

EL S

OLE

NO

IDR

ELA

Y

BA

T G

ND

-BR

BA

T G

ND

-BR

P3

1-E

NG

HA

RN

J3

1-T

ILT

SN

SR

OIL

/WA

TE

R_T

EM

P

P1

-21

P1

-22

P1

-23

P1

-18

P1

-19

P1

-20

P1

-17

P1

-16

P1

-14

P1

-13

P1

-15

VA

LVE

_R

TN

3

ALT

_F

IELD

_W

IRE

TT

_T

ILT

_X

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_Y

_A

XIS

VA

LVE

_R

TN

2

TT

_T

ILT

_S

NS

R_G

ND

TT

_T

ILT

_S

NS

R_P

WR

ALT

EN

AT

OR

_R

PM

SE

RV

ICE

_H

OR

N

OIL

_P

RE

SS

UR

E

RE

V

FW

D

IGN

ITIO

N/F

UE

L

CH

OK

E/G

LO

W P

LU

G

P1

-10

P1

-11

P1

-07

P1

-09

P1

-08

P1

-05

P1

-06

P1

-03

P1

-02

P1

-04

TH

RO

TT

LE

ENGINE HARN

J3 WHITE 23 PIN

P1

-01

P1

-12

SY

S_B

AT

_G

ND

SY

S_B

AT

_P

WR

P1

-02

P1

-03

P1

-01

POWER HARN

J5 BLACK 4 PIN

AU

X/S

TA

RT

_B

AT

_G

ND

AU

X/S

TA

RT

_B

AT

_P

WR

P1

-04

J32-ENG HARN

2

3

1C45GEN-GN/WH

BAT GND-BR

P114BAT-RD

P46HRN-WH

C3

4S

A-B

K/W

H

RE

V V

LV B

SO

LE

NO

ID

SO

LE

NO

IDF

WD

VLV

A

VLV

RE

T2

-BR

31 2

HO

LD

PU

LL IN

RD

-HO

LD

BK

-CO

M

WH

-PU

LL IN

VLV

RE

T2

-BR

VLV

RE

T2

-BR

R4

6H

RN

-WH

HORNRELAY

GR

ID H

EA

TE

RR

ELA

Y

P34SA-RD

2

86

1

30

58587

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.PR

1

C2

7A

UX-R

D

VLV

RE

T6

-BR

BA

T G

ND

-BR

C1

07

AF

-RD

C4

1R

PM

-OR

/BK

8587a4

875

86301 2

MA

INA

UX

P1

14

BA

T-R

D

87a

STARTERRELAY

STARTER

STA

RT

BA

T

BA

TM

AIN

(S

YS

)

4

SERVICEHORN

CUMMINS B4.5 C80 ENGINECUMMINS B3.3T ENGINE

ENGINE BLOCK

-

+

-

+

HI/

LO

SP

EE

DS

OLE

NO

ID

TO

J4

-30

WH

ITE

35

PIN

TO

J4

-32

WH

ITE

35

PIN

BA

T G

ND

-BR

BA

TV

LV-R

D

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TE

CU

-RD

C2

1IG

N-W

H

C3

4S

A-B

K/W

H

R3

5R

PM

-BK

/RD

C4

6H

RN

-WH

C3

3S

TR

-BK

C2

5P

SR

-WH

/BK

C2

6T

SR

-WH

/RD

RE

T8

5T

TS

R-B

R

VLV

RE

T2

-BR

P8

5T

TS

R-G

N

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

C8

4TA

Y-G

N/B

K

C8

3TA

X-G

N/W

H

VLV

RE

T3

-BR

C4

5G

EN

-GN

/WH

87a5

854

87

286

130

R3

4S

A-R

D

-BAT

70 A FUSE

P34SA-RD

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

STA

RT

ER

_R

ELA

Y

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

20 A

FUSEP116HYD-OR

OTS1N.O.

C1

16

HY

D-O

R

P1

16

HY

D-O

R

HY

D C

OO

LE

RR

ELA

Y

87a5

854

87

2

86

130

BA

T G

ND

-BR

BA

T G

ND

-BR

R1

16

HY

D-O

R


S-613

AUX.PUMP

0-20 DEGREESENSOR ALARMSET AT 4.5DEGREES

V3

0F

WD

-WH

V3

1R

EV-W

H/B

K

CB7 ADDED

S100- S/N 710

S125- S/N 2589



6-296-30

Electrical Schematic - Generator Options

6-30 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV A

Belt-Driven Generator Option Hydraulic Generator Option

Electrical Schematic - Generator Options

Part No. 102916 S-100 • S-105 • S-120 • S-125 6-31


REV AREV A Electrical Schematic - 12 kW Generator(welder option)


6-326-31

Electrical Schematic - 12 kW Generator(welder option)

Part No. 102916 S-100 • S-105 • S-120 • S-125 33


Hydraulic Schematic - 12 kW Generator(welder option)

REV A


6-346-33

Hydraulic Schematic - 12 kW Generator(welder option)


6-35

Hydraulic Schematic, S-100 • S-105 Models(serial number 136)

6-36

6-36 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AHydraulic Schematic, S-100 • S-105 Models(serial number 136)

Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.

Part No. 102916 S-100 • S-105 • S-120 • S-125 6-37


REV A Hydraulic Schematic, S-100 • S-105 Models(from serial number 137 to serial number 290)



6-38

Hydraulic Schematic, S-100 • S-105 Models(from serial number 137 to serial number 290)

6-37


6-39


6-40

6-40 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AHydraulic Schematic, S-100 • S-105 Models(from serial number 291 to serial number 738)


Part No. 102916 S-100 • S-105 • S-120 • S-125 6-41


REV A Hydraulic Schematic, S-100 • S-105 Models(from serial number 739)



6-42

Hydraulic Schematic, S-100 • S-105 Models(from serial number 739)

6-41


6-43


6-44

6-44 S-100 • S-105 • S-120 • S-125 Part No. 102916


REV AHydraulic Schematic, S-120 • S-125 Models(from serial number 404 to serial number 430)


Part No. 102916 S-100 • S-105 • S-120 • S-125 6-45


REV A Hydraulic Schematic, S-120 • S-125 Models(from serial number 431 to serial number 1194)



6-46


6-45


6-47


6-48

6-48 S-100 • S-105 • S-120 • S-125 Part No. 102916



REV A


Part No. 102916 S-100 • S-105 • S-120 • S-125 6-49



REV A



6-50


6-49

K6 K1

K4

K8

K5 K2

K7

K3

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

DETAIL E - TCON RELAY PARKING

K1 POWERS CKT P22R OR

CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE)

K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD,

VALVES AUX RELAY, BOOM EXT/RET,

TURNTABLE ROTATE VLV.

K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH

K4 POWERS CIRCUIT P_6R1 OR VALVES:

PRIMARY VALVES 1 & 2, THROTTLE (IGN),

GLOW PLUG, STARTER RELAY, AC GENERATOR,

BOOM RETRACT, MULTIFUNCTION VALVE,

ROTATE CW, AND ROTATE CCW.

K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY

K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.

(FUEL ON/OFF SOLENOID AND ALT FIELD)

K7 POWERS THROTTLE OR HI/LOW SOLENOID

(CKT C35RPM-BK/RD)

K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)

FU

SE

3-1

0A

J2 BLACK 35 PIN

LIMIT SWITCH HARNESS

TO

MIC

RO

TO

PLD

TO

PLD

TO

MIC

RO

TO

MIC

RO

TO

PLD

C65LO

FL-B

L/W

H

C64LS

-OR

/BK

C66D

RE

N-B

L

C64LS

-OR

/BK

1 213 2 4

J27 P27

42

C64LS

-OR

/BK

P56P

RV

-RD

2 4 3 1

P

4

P

3 4 13

SJ3-W

H

C68P

BD

-BL

S62B

ST

O-O

R

P53LS

-WH

/BK

C60A

XE

X-G

N/W

H

S56P

RV

-RD

C64LS

-OR

/BK

C77A

S-W

H

C64LS

-OR

/BK

3 1 2 43 1 2 4

SJ1-W

H/R

D

SJ2-B

K/R

D

P58LS

-RD

/BK

P57P

BD

-RD

/WH

P53LS

-WH

/BK

P54E

NG

-BK

/WH

SJ2-B

K/R

D

SJ1-W

H/R

D

J20

12 WAY

P20

12 WAY

8 9 10 11 12

S56P

RV

-RD

SJ3-W

H

C71P

BE

-BL/B

K

C64LS

-OR

/BK

P57P

BD

-RD

/WH

C78A

S-W

H/B

K

3

VLV

RE

T1-B

R

PR

I 1 L

O

PR

I 2 L

O

13 4213 2 413 2 4

S56P

RV

-RD

C64LS

-OR

/BK

S62B

ST

O-O

R

C61A

XR

T-G

N

P57P

BD

-RD

/WH

P57P

BD

-RD

/WH

SJ1-W

H/R

D

SJ2-B

K/R

D

P58LS

-RD

/BK

C70P

BE

-BL/W

H

P63LS

-OR

/RD

SJ3-W

H

V75P

RLO

-RD

/WH

V74P

RLO

-RD

3 4 5 6 78 1 2

C61A

XR

T-G

N

S62B

ST

O-O

R

P63LS

-OR

/RD

C70P

BE

-BL/W

H

C76P

BE

-BL

SJ2-B

K/R

D

SJ1-W

H/R

D

3 4 5 61 2J21

8 WAY

P21

8 WAY

S59C

NB

K-G

N/W

H

C69P

BE

-BK

P54E

NG

-BK

/WH

P53LS

-WH

/BK

P58LS

-RD

/BK

7

P56PRV-RD

43J264 WAY1

P264 WAY

2

2 43 11 2 4

C64LS

-OR

/BK

C64LS

-OR

/BK

C64LS

-OR

/BK

C71P

BE

-BL/B

K

C76P

BE

-BL

SJ1-W

H/R

D

C69P

BE

-BK

SJ2-B

K/R

D

P54E

NG

-BK

/WH

P63LS

S59C

NB

K

3

P53LS

-WH

/BK

431 2 PRESSURE SENSOR

OPTIONAL HYDRAULIC

VLV

RE

T

P2-3

3

P2-3

2

P2-3

4

P2-3

5

LS

B4E

O

LS

B13A

O

LS

B14A

O

PR

I#1 L

O

PR

I#2 L

O

SN

SR

GN

D

PR

I A

NG

P2-2

3

P2-2

8

P2-2

4

P2-2

5

P2-2

7

P2-2

6

P2-2

9

P2-3

0

P2-3

1

V74P

RLO

-RD

VLV

RE

T1-B

R

C76P

BE

-BL

C77A

S-W

H

C78P

S-W

H/B

K

V75P

RLO

-RD

/WH

SN

SR

GN

D-B

R

G119S

R-B

L

LS

B2R

O

LS

B3R

O

LS

B3E

O

FS

T1S

LS

T10

LS

B1D

O

P2-1

6

P2-1

4

P2-1

5

P2-1

7

P2-1

8

P2-1

9

P2-2

0

P2-2

2

P2-2

1

P_14

P_11

P_12

P_18

P_9A

P_7R

P_6R

2

P_9B

P_10

P2-0

6

P2-0

5

P2-0

4

P2-0

7

P2-0

8

P2-1

1

P2-0

9

P2-1

0

P2-1

2

OP

ER

SW

PW

RP

2-1

3

P57P

BD

-RD

/WH

P54E

NG

-BK

/WH

P58LS

-RD

/BK

S59C

NB

K-G

N/W

H

C60A

XE

X-G

N/W

H

C61A

XR

T-G

N

C68P

BD

-RD

C65LO

FL-B

L/W

H

C66D

RE

N-B

L

C70P

BE

-BL/W

H

C69P

BE

-BK

C71P

BE

-BL/B

K

C64LS

-OR

/BL

P63LS

-OR

/RD

S62B

ST

O-O

R

S56P

RV

-RD

DC

ON

EC

U G

ND

DC

ON

EC

U P

WR

P_6R

1

P2-0

1

P2-0

2

P2-0

3

GN

DD

CO

N-B

R

P21D

CO

N-R

D

P53LS

-WH

/BK

TO

MIC

RO

TO

PLD

TO HORN BUTTON

P_9B

PWR TO TCON ESTOP

OUT PWR ENABLE

P_6R2

TCON MODE

P_7

P10

P_22

P7R

PCON POWER

P11

P6R1

P9A

TO

MIC

RO

13 2 413 2 413 2 4

LS

B3

RO

3' E

XT

LS

B3

RS

3.5

EX

T

LS

B4

ES

75

.5'

LS

B6

S

CH

NB

RK

LS

B4

EO

10

0' E

XT

LS

B3

EO

75

' E

XT

LS

B2

RS

10

1'

TCON

LS

B2

RO

10

0'

LS

B8

AS

50

DE

G

LS

B9

AS

65

DE

G

LS

B1

4A

O

68

DE

G

LS

B1

3A

O

53

DE

G

LS

B7

DS

11

DE

G

LS

B1

DO

10

DE

G

LS

T1

O

DR

V

EN

AB

LE

FS

T1

S

LO

W

FU

EL F

S

LIMIT SWITCHES

S-120/125

D80SHLD-N/A

D80S

HLD

-N/A

D80SHLD-N/A

D80S

HLD

-N/A

TE

TF

UN

C-W

H

P96T

ET-R

D

TE

TG

ND

-BR

TETHER INTERFACE

P24 J24

DIAG/TETHER GND

DIAG/TETHER PWR

CAN HIGH

CAN LOW

CAN SHIELD

TETHER FUNC ENABLE

TETHER ESTOP PWR

TETHER ESTOP RET

P2

0

PLATFORM PCON NOT USED

PCON

ALA

RM

-

ALA

RM

+

S1-1

S1-2

S1-3

1

ALARM ROTATE LEVELPLATFORM

S2-3

S2-2

S2-1

S3-3

S3-2

S3-1

JIB

71 2 3 4 5

2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

TURNTABLE ROTATE

BOOM UP/DWN &

JOYSTICK

P1

H1_Y

OU

T

H1_G

ND

H1_X

OU

T

H1_P

WR

P2

6532 41

JOYSTICK

BOOM EXT/RET

H2_Y

OU

T

H2_G

ND

H2_P

WR

H3_G

ND

H3_P

WR

H3_Y

OU

T

41 2

P3

3 5 6 1

P4

6532 4

DRIVE & STEERING

JOYSTICK

H4_G

ND

H4_T

HU

MB

_LT

H4_T

HU

MB

_R

T

H4_X

OU

T

H4_Y

OU

T

H4_P

WR E

ST

OP

_2

ES

TO

P_1

E-STOP

ECUJ2

0

ARE CLOSED

TERM 3 & 4

LS

AX

2E

O

WHEN AXLES

ARE EXTENDED

LIMIT SWITCHES

AXLE EXTENTION

LS

AX

1E

O

J18-DRIVE CHASSIS HARN


P63LS

-OR

/RD

C60A

XE

X-G

N/W

H

P57P

BD

-RD

/WH

P1-1

0

P1-2

1

P1-2

3

P1-2

2

P1-1

9

P1-2

0

P1-1

8

P1-1

7

P1-1

6

P1-1

5

P1-1

4

P1-1

2

P1-1

3

P1-1

1

P1-0

3

P1-0

9

P1-0

8

P1-0

7

P1-0

6

P1-0

5

P1-0

4

P1-0

2

P1-0

1G

ND

-DC

ON

-BR

DC

ON

EC

U P

WR

P_6R

1

P_7R

P12

AX

LE

NO

T R

ET

SIG

AX

LE

NO

T R

ET

PW

R

CA

N S

HIE

LD

RS

232 R

XD

RS

232 T

XD

BO

OT

AX

LE

NO

T E

XT

SIG

CA

N L

OW

CA

N H

IGH

RS

232 G

ND

AX

LE

NO

T E

XT

PW

R

P21D

CO

N-W

H

P53LS

-RD

S56P

RV

-RD

C61A

XR

T-G

N

C61LS

(A)-

GN

D81C

AN

- -G

N

D82C

AN

+ -

YL

P61LS

(A)-

GN

DC

ON

EC

U G

ND

C61LS

-GN

P61LS

-GN


J1 BLACK 23 PIN

LIMIT SWITCHES

AXLE NOT EXT

LS

AX

2E

S

LS

AX

1E

S

13 2 4 13 2 44

P

3

P

3 4

WHEN AXLES

ARE CLOSED

ARE RETRACTED

TERM 3 & 4

AXLE RETRACTION

LIMIT SWITCHES

LS

AX

1R

O

P

3 4

LS

AX

2R

O

P

43

J3-OR/BL

J2-BL/RD

J1-BL/BK J4-GN/BK

AX

LE

RE

TR

AC

T

AX

LE

EX

TE

ND

MO

TO

R S

PE

ED

AU

X F

OR

WA

RD

AU

X R

EV

ER

SE

BR

AK

E

LR

ST

EE

R L

EF

T

RF

ST

EE

R R

IGH

T

LF

ST

EE

R L

EF

T

LF

ST

EE

R R

IGH

T

LR

ST

EE

R R

IGH

T

RF

ST

EE

R L

EF

T

RR

ST

EE

R L

EF

T

RR

ST

EE

R R

IGH

T

BL

BK

RD

BA C

BL

BK

RD

BA C

BL

BK

RD

BA C

P2-0

7

P2-0

1

P2-0

2

P2-0

4

P2-0

5

P2-0

6

P2-0

3

VA

LV

E R

TN

1

AX

LE

RE

TR

AC

T

AX

LE

EX

TE

ND

MO

TO

R S

PE

ED

AU

X F

OR

WA

RD

RF

ST

EE

R R

IGH

TP

2-1

8

P2-0

8

P2-0

9

P2-1

1

P2-1

3

P2-1

2

P2-1

4

P2-1

5

P2-1

6

P2-1

7

P2-1

0

RF

ST

EE

R S

NS

R

LR

ST

EE

R S

NS

R

RR

ST

EE

R S

NS

R

RR

ST

EE

R L

EF

T

RR

ST

EE

R R

IGH

T

BR

AK

E

LR

ST

EE

R S

NS

R

LR

ST

EE

R L

EF

T

P2-2

0

P2-1

9

P2-2

2

P2-2

3

P2-2

1

LF

ST

EE

R L

EF

T

ST

EE

R S

NS

R G

ND

AU

X R

EV

ER

SE

VA

LV

E R

TN

2

LR

ST

EE

R R

IGH

T

ST

EE

R S

NS

R P

WR

RF

ST

EE

R L

EF

T

LF

ST

EE

R R

IGH

T

VLV

RE

T-B

RN

V61A

XR

T-G

N

V60A

XE

X-G

N/W

H

V52A

FV

-BL/R

D

V52A

RE

V-B

L/R

D

VLV

RE

T2-B

RN

V36R

RS

-BL

V29M

S-R

D/W

H

V37R

RS

-BL/B

K

C111R

RS

-OR

C111LR

S-O

R

C111R

FS

-OR

C111LF

S-O

R

P110R

T-B

K

V36LR

S-B

L

V37LR

S-B

L/B

K

V36R

FS

-BL

V32B

RK

-WH

/RD

P109A

NG

-GN

/WH

V37R

FS

-BL/B

K

V36LF

S-B

L

V37LF

S-B

L/B

K

RR

ST

EE

R R

IGH

T

LR

ST

EE

R R

IGH

T

RF

ST

EE

R R

IGH

T

LF

ST

EE

R R

IGH

T

BK

A B

RD

BL

C

J2 WHITE 23 PIN

DRIVE CHASSIS HARNDRIVE CHASSIS HARN

DCON

OUT PWR ENABLE

PWR-PCON ESTOP

D82CAN+ -YL

D81CAN- -GN

P63LS-OR/RD

P53LS-WH/BK

C60AXEX-GN/WH

P57PBD-RD/WH

P21DCON-RD

GNDDCON-BR

S56PRV-RD

C61AXRT-GN

2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN

4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN

8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN



2 WAY DEUTSCH-PWR HARN/ENG HARN

9 WAY DEUTSCH TETHER CONNECTOR

PCON PCB TO MEMBRANE SWITCH


J29

J28

J27

J26

P29

P28

P27

P26

J24

J25

J20

J21

J23

P20

P23

P25

P24

P21

P2

P1

J2

J1

CONNECTOR DESCRIPTION AND/OR LOCATION

BLACK 23 PIN AMP CONNECTOR TCON TO BOOM HARN

BLACK 35 PIN AMP CONNECTOR TCON TO LIMIT SWITCH

WHITE 23 PIN AMP CONNECTOR TCON TO ENGINE HARN

WHITE 35 PIN AMP CONNECTOR TCON TO FUNCTION MANIFOLD

BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN

WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN

3 WAY DEUTSCH CAN CONNECTOR BOOM HARN TO SLIP RING

6 WAY DEUTSCH DCON SAFETY SW LIMIT SW TO SLIP RING

2 WAY DEUTSCH DCON ECU PWR LIMIT SW HARN TO SLIP RING

WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN

BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN

3 WAY DEUTSCH CAN CONNECTOR SLIP RING TO DCON HARN

6 WAY DEUTSCH DCON SLIP RING TO DCON HARN

2 WAY DEUTSCH SLIP RING TO DCON HARNESS

TCON PCB TO MEMBRANE SWITCH


J7P7

J16

J17

J18

J10

J11

P10

P11

P17

P18

P8

P16

J8

J1P1

P6

P2

J6

J2

P2

P1

J2

J1

BLACK 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN

JACK NO

J2P2

P5

P3

P4

J5

J4

J3

PLUG NO

P1 J1

6 WAY ENGINE HARN TO TILT SENSOR

4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR

4 WAY ENGINE HARN-AC GENERATOR

PCON MANIFOLD/TILT SENSOR

P32

P33

P31

P30

J33

J32

J31

J30

J144 10 WAY ENGINE HARN TO ENGINE

6 7 7 7

PC

ON

GN

D

PC

ON

PW

R

P7

CA

N S

HIE

LD

RS

232_R

XD

RS

232_T

XD

BO

OT

OU

T P

WR

EN

BL

HR

N R

LY

CN

TR

L

CA

N+

CA

N-

RS

232_G

ND

PW

R-P

CO

N E

ST

OP

J1 BLACK 23 PINJ2 WHITE 23 PIN

P22

J3 10PIN

P1

MEMBRANE/LED INTERFACE CARD

J1 10PIN

P1

P1

P1

P1

P1

P1

STA

RT

AS

SIS

T

AC

GE

NE

RA

TO

R

AU

XIL

IAR

Y

HO

RN

STA

RT

J2 10PIN

P1

P1

P1

P2

P2

P2

P2

P2

P2

EN

GIN

E S

PE

ED

AX

LE

RE

TR

AC

T

DR

IVE

EN

AB

LE

1

SP

AR

E 1

CR

AB

ST

EE

R

FR

ON

T S

TE

ER

DR

IVE

SP

EE

D

RE

AR

ST

EE

R

AX

LE

EX

TE

ND

42 3 5 6

PCON MEMBRANE PANEL

P2

P2

P2

P2

FU

EL T

YP

E

CO

OR

D S

TE

ER

7 8 10

9

SP

AR

E 2

P1-0

1

P1-0

2

P1-0

3

P1-0

4

P1-0

5

P1-0

6

P1-0

7

P1-0

8

P1-0

9

P1-1

1

P1-1

0

P1-1

2

P1-1

3

P1-1

4

P1-1

5

P1-2

0

P1-1

6

P1-1

7

P1-1

8

P1-1

9

P1-2

2

P1-2

1

P1-2

3

P52P

CO

N-W

H

GN

DP

CO

N-B

R

P56P

RV

-RD

S56P

RV

-RD

/WH

C47O

UT

-WH

T/B

LK

P23P

CO

N-B

K

D81C

AN

- -G

N

D82C

AN

+ -

YL

C46H

N-W

H

5

87a

87

1

2 86

30 4

85

3

5

87a

87

1

2 86

30 4

85

3

P6R

P7R

P1-2

3

P1-2

1

P1-2

2

P1-1

9

P1-1

8

P1-1

7

P1-1

6

P1-2

0

P1-1

5

P1-1

4

P1-1

3

P1-1

2

P1-1

0

P1-1

1

P1-0

9

P1-0

8

P1-0

7

P1-0

6

P1-0

5

P1-0

4

P1-0

3

P1-0

2

P1-0

1

P87P

TS

-RD

SA

FE

PL T

ILT

PW

R

SA

FE

PL T

ILT

GN

DP

TS

RE

T-B

R

PL T

ILT

SN

SR

PW

RP

85P

TS

-GN

PL T

ILT

SN

SR

C84TA

Y-G

N/B

K

PL T

ILT

SN

SR

GN

DP

LA

TR

ET-B

R

FO

OT

SW

RT

NC

56P

TS

-RD

FO

OT

SW

PW

RR

56P

TS

-RD

SA

FE

PL T

ILT

OU

TC

88P

TS

-RD

/BK

LO

AD

SN

SR

PW

R

LO

AD

SN

SR

OU

T

LO

AD

SN

SR

GN

D

PR

OX

KIL

L C

MD

C90P

XS

-RD

/BK

PR

OX

KIL

L G

ND

R90P

XS

-RD

/BK

C15P

LD

-OR

/BK

C14P

LU

-OR

C44JD

-GN

/BK

PR

OP

VLV

2_A

C43JU

-GN

ON

/OF

F V

LV

3_B

C18P

RR

-GN

/BK

ON

/OF

F V

LV

3_A

C17P

RL-G

N

VLV

RT

NV

LV

RE

T-B

RN

PR

OP

VLV

2_B

PR

OP

VLV

1_A

PR

OP

VLV

1_B

PLA

T R

OT

CC

W

PLA

T L

EV

EL D

N

PLA

T L

EV

EL U

P

JIB

DO

WN

JIB

UP

PLA

T R

OT

CW

3 1 42

PROXKILL SW.

21

P1-1

5S

AF

E P

L T

ILT

OU

T

P1-1

6F

OO

T S

W P

WR

3 1 42

PROXKILL

FOOTSWITCH

OPTIONAL

PROXIMITY

KILL WIRING

FOOTSWITCH

R56P

TS

-RD

C56P

TS

-RD

OPTIONAL

U20

9 10

7654 8321

321 654 987 10

BOOM HARNPCON MANIFOLD

21

GN

WH

BK

ASSEMBLY

PLATFORMTILT SENSOR

6P33-PCON

MANIFOLD

J31-TILT SNSR

4321 5

FU

SE

5 A

K1

K2

P23PCON-BK

P52PCON-WH

GNDPCON-BR

C46HN-WH

P56PRV-RD

S56PRV-RD/WH

C47OUT-WH/BK

D82CAN+ -YL

D81CAN- -GN

GN

J8

J7

2

4

3

6

5

2

BL

YL

BR

OR

RD1

BK

WH1

2

6

5

4

3

2

1

P7-LIMIT SW HARN

1

P8-LIMIT SW HARN

P6R1

DCON PWR

DCON GND

P18

P11

P12

P9A

P7RWH

BK22

1P18

1

GN

YL

BL

66

5

44

5

P17

OR

BR

RD

2 2

33

11

CCCAN SHIELD

B B

A

P16

AYEL

GRN

CAN HIGH

CAN LOW

CC

B

A

B

AYEL

GRN

P6-BOOM HARNJ6

(SLIP RING)

(SLIP RING)

D81CAN- -GN

D82CAN+ -YL

P57PBD-RD/WH

P21DCON-RD

C60AXEX-GN/WH

P53LS-WH/BK

P63LS-OR/RD

GNDDCON-BR

S56PRV-RD

C61AXRT-GN

PCON

PLA

T S

EN

SO

R G

ND

TIL

T S

EN

SO

R S

IG O

UT

TIL

T S

EN

SO

R P

WR

TIL

T S

WIT

CH

GN

D

PW

R T

O T

ILT

SW

ITC

H

OU

T F

RM

TIL

T S

WIT

CH

88

88

88

88

88

88

88

88

88

88

88

Genie S-100/105(before serial number 231)

Genie S-120/125(before serial number 921)

Electrical SchematicES105SD Rev C ES125SD Rev G

Genie Part Number 228879 Rev A

NOT USED

61 2 3 4 5

TURNTABLE ROTATEBOOM UP/DWN &

JOYSTICK

P1

H1_Y

OU

T

H1_G

ND

H1_X

OU

T

H1_P

WR

P2

6532 41

JOYSTICK

BOOM EXT/RET

H2_Y

OU

T

H2_G

ND

H2_P

WR

H3_G

ND

H3_P

WR

H3_Y

OU

T41 2

P3

3 5 6 1

P4

6532 4

DRIVE & STEERING

JOYSTICK

H4_G

ND

H4_T

HU

MB

_LT

H4_T

HU

MB

_R

T

H4_X

OU

T

H4_Y

OU

T

H4_P

WR

JOYSTICK CONNECTORS (after serial number S120- 1616; S100- 419)

1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7

Joystick Adaptor Harness

TO HORN BUTTON

OUT PWR ENABLE

PWR TO TCON ESTOP

P_7

TCON MODE

P7R

P_22

P6R1

PCON POWER

P11

OP

ER

. R

EC

.

SE

RV

. O

R

PLD

P15

12 VOLT

S56PRV-RD

GNDDCON-BR

P56PRV-RDP27-LIMIT SW

TO

MIC

RO

P15

P1-2

3

P1-2

2

P1-2

1

P1-2

0

BOOM HARN

J1 BLACK 23 PIN

TE

T E

ST

OP

RE

T

CA

N H

IGH

RS

232 G

ND

CA

N L

OW

CA

L F

RE

Q 2

TE

T E

ST

OP

PW

R

BO

OT

RS

232 T

XD

RS

232 R

XD

CA

N S

HIE

LD

FLA

SH

ING

BE

AC

ON

CA

L F

RE

Q 1

P1-1

8

P1-1

9

P1-1

7

P1-1

5

P1-1

6

P1-1

2

P1-1

3

P1-1

1

P1-1

0

P1-0

9

P1-1

4

P_7

P_22

WO

RK

LT

PW

R-P

CO

N E

ST

OP

OU

T P

WR

EN

BL

TCON

PC

ON

GN

D

PC

ON

PO

WE

R

HO

RN

RE

LA

Y C

OIL

P1-0

7

P1-0

6

P1-0

8

P1-0

5

P1-0

4

P1-0

1

P1-0

2

P1-0

3

D82C

AN

+ -

YL

D81C

AN

- -G

N

P97T

ET-B

K

P23P

CO

N-B

K

GN

DP

CO

N-B

R

P52P

CO

N-W

H

C46H

N-W

H

C47O

UT

-WH

/BK

S56P

RV

-RD

/WH

P56P

RV

-RD

R48LP

-WH

/RD

R49LP

-WH

/BK

P95T

ET-O

R

TO FLASHING BEACON

TO WORK LIGHTS

J27-BOOM HARN

BOOM DWN RECOVERY SIGNAL

BOOM RET RECOVERY SIGNAL

BOOM UP/DWN FC RECOVERY SIGNAL

BOOM EXT/RET FC RECOVERY SIGNAL

AUXILIARY HYD RECOVERY SIGNAL

MULTI FUNCTION VLV RECOVERY SIGNAL

BM

DW

N O

BM

E/R

FC

O

BM

RE

T O

MLT

FN

C V

LV

O

AU

X H

YD

O

BM

DW

N S

T I

BM

3' I

BM

100' I

PR

I LO

#1 O

BM

U/D

FC

O

LOCKOUT VALVE #1 SIG

PRI BOOM DOWN STATUS

PRI BOOM LENGTH 3' STATUS


GR

PK

TN

YL

BL

PR

GY

BR

WT

LT

GR

OR

OFF

PCON

TCON

RUN

RECOVERY

SERV. BYPASS

1235 468 7910

P7R

P6R

1

P22

12

13

14

15

16

P7

P11

ALA

RM

PW

R

ALA

RM

GN

D

11

OP

ER

. R

EC

.

RD

BK

LT

BL

YL/W

T

PR GR

/WT

OU

TP

UT

PW

R E

NA

BLE

SE

RV

. O

R O

PE

R. R

EC

.

TC

ON

MO

DE

PW

R T

O T

CO

N E

ST

OP

TC

ON

ES

TO

P

TE

TH

ER

ES

TO

P

TC

ON

OR

PC

ON

MO

DE

PC

ON

MO

DE

5 A

FU

SE

PW

R IN

SE

RV

OR

RE

CO

VE

RY

PR

OV

IDE

S P

WR

TO

MIN

IMA

L

HA

RD

WA

RE

30

85

87

86

87a

P21DCON-RD

C61AXRT-GN

P63LS-OR/RD

P57PBD-RD/WH

P53LS-WH/BK

C60AXEX-GN/WH30

85

87

86

87a

SE

RV

ICE

OR

RE

CO

VE

RY

MO

DE

LOAD SENSOR

ASSEMBLY OPTION

GN

WH

BK

RD

NO

NCN

OT

US

ED

CAN SHIELD

TO

PLD

TO

MIC

RO

TO

PLD

TO

PLD

TO

MIC

RO

TO

PLD

TO

MIC

RO

TO

MIC

RO

TO

PLD

TO

PLD

R49LP

- W

T/B

KD

RIV

E L

IGH

TS

RE

LA

Y

TO

MIC

RO

TO

MIC

RO

VA

LV

E_R

TN

6

AU

X_R

ELA

Y

VA

LV

E_R

TN

7

RO

TA

TE

_C

W_V

LV

MU

LT

I_F

UN

CT

_V

LV

RO

TA

TE

_C

CW

_V

LV

TO DRIVELAMPS

12 VOLT

P4-2

0

P4-2

1

P4-2

2

P4-2

5

P4-2

4

P4-2

3

P4-2

6

P4-2

7

P4-3

0

P4-2

8

P4-2

9

P4-3

1

P4-3

2

P4-3

5

P4-3

3

P4-3

4

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

P10

VA

LV

E_R

TN

5

HY

D_F

ILT

ER

1

HY

D_F

ILT

ER

2

VA

LV

E_R

TN

4

BO

OM

_E

XT

/RE

T_V

LV

BO

OM

_U

P/D

OW

N_V

LV

BO

OM

_D

OW

N_V

LV

TU

RN

TA

BLE

_R

OTA

TE

_V

LV

BO

OM

_U

P_V

LV

BO

OM

_E

XT

EN

D_V

LV

BO

OM

_R

ET

RA

CT

_V

LV

BO

OM

RE

VE

RS

E L

OA

D

BO

OM

OV

ER

LO

AD

J4 WHITE 35 PIN

VLV

RE

T5-B

R

C15LS

-RD

/BK

C14LS

-BK

/RD

P4-0

3

P4-0

2

P4-0

1

P4-1

3

P4-0

8

P4-0

4

P4-0

5

P4-0

6

P4-0

7

P4-0

9

P4-1

0

P4-1

1

P4-1

2

P4-1

4

P4-1

5

P4-1

6

P4-1

7

P4-1

8

MANIFOLD HARN

TO

MIC

RO

P4-1

9

VA

LV

E R

TN

7

VA

LV

E R

TN

6

C27A

UX

-RD

C113M

FV

-OR

/RD

C05T

TL-W

H

C06T

TR

-WH

/BK

TO

AU

X H

YD

RE

LA

Y P

R1

TU

RN

TA

BLE

RO

T C

CW

VLV

TU

RN

TA

BLE

RO

T C

W V

LV

MU

LT

I F

UN

C V

LV

4

P

3

LSB20LO

NO

3 1

C06T

RF

-WH

/RD

VLV

RE

T4-B

R

C03P

BF

-RD

/WH

C09P

ER

F-B

K/R

D

C08P

BR

-BK

/WH

C07P

BE

-BK

C02P

BD

-RD

/BK

C01P

BU

-RD

P P P

BO

OM

RE

T V

LV

BO

OM

EX

T/R

ET

F.C

.

BO

OM

UP

VLV

BO

OM

EX

TE

ND

VLV

BO

OM

DW

N V

LV

BO

OM

UP

/DW

N F

.C.

TU

RN

TA

BLE

CW

/CC

W F

.C.

5

87a

87

1

2 86

30 4

85

3

TCON MEMBRANE PANEL

JIB

DO

WN

PLT

FR

M C

W

BO

OM

CW

PLT

FR

M C

CW

JIB

UP

PLT

FR

M D

OW

N

PLT

FR

M U

P

34 2 19 8 7 6 5

SE

C. D

OW

N

BO

OM

EX

T

RA

BB

IT

TU

RT

LE

RO

OM

RE

T

BO

OM

DO

WN

14

13

12

11

10

1 P11

15

BO

OM

UP

EN

G S

PE

ED

+ B

UT

TO

N

GA

S/L

P

AU

XIL

IAR

Y

SE

C. U

P

6 5 4 3 210

9 8 7

J11

ST

RT

AS

ST

SC

RO

LL R

SC

RL F

/EN

T

- B

UT

TO

N

STA

RT

15

14

11

13

12

P1

0J1

0

BO

OM

CC

W







P11

P9A

P11

TO

MIC

RO

TCON

E35E

SP

K-B

K/R

D

87a

5

85

4

87

2

86

1

30

FUEL

SOLENOID

RELAY

BA

T G

ND

-BR

PU

LL IN

HO

LD

FAN

BELT

BREAK

SWITCH

FLA

MM

STA

RT

IGN

ITO

R

WH-PULL

COM

RD-HOLD

+AUX

+BAT

MOM N.O.

TIME DELAY

TROMBETTA

25A

CB

4.5 DEGREE

TURNTABLE

TILT

SENSOR

RD

WH

BK

C83TAX-GN/WH

C84TAY-GN/BK

P85TTSR-GN

RET85TTSR-BR

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

C25P

SR

-WT

/BK

C26T

SR

-WT

/RD

C21IG

N-W

H

FUEL

SOLENOID

RELAY

BA

T G

ND

-BR

BA

T G

ND

-BR

P31-E

NG

HA

RN

J31-T

ILT

SN

SR

OIL

/WA

TE

R_T

EM

P

P1-2

1

P1-2

2

P1-2

3

P1-1

8

P1-1

9

P1-2

0

P1-1

7

P1-1

6

P1-1

4

P1-1

3

P1-1

5

VA

LV

E_R

TN

3

ALT

_F

IELD

_W

IRE

TT

_T

ILT

_X

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_Y

_A

XIS

VA

LV

E_R

TN

2

TT

_T

ILT

_S

NS

R_G

ND

TT

_T

ILT

_S

NS

R_P

WR

ALT

EN

AT

OR

_R

PM

45

85

87

12

86

K8

30

SE

RV

ICE

_H

OR

N

OIL

_P

RE

SS

UR

E

STA

RT

ER

_R

ELA

Y

RE

V

FW

D

IGN

ITIO

N/F

UE

L

CH

OK

E/G

LO

W P

LU

G

P1-1

0

P1-1

1

P1-0

7

P1-0

9

P1-0

8

P1-0

5

P1-0

6

P1-0

3

P1-0

2

P1-0

4

TH

RO

TT

LE

4

87

85

5

86

K72

30

ENGINE HARN

J29 PWR HARN

P1-0

1

TO

MIC

RO

87a

1

P1-1

2

SY

S_B

AT

_G

ND

SY

S_B

AT

_P

WR

P1-0

2

P1-0

3

P1-0

1

POWER HARN

J5 BLACK 4 PIN

AU

X/S

TA

RT

_B

AT

_G

ND

AU

X/S

TA

RT

_B

AT

_P

WR

P1-0

4

J32-ENG HARN

2

3

1C45GEN-GN/WH

BAT GND-BR

P114BAT-RD

P46HRN-WH

C34S

A-B

K/W

H

RE

V V

LV

B

SO

LE

NO

ID

SO

LE

NO

ID

FW

D V

LV

A

VLV

RE

T2-B

R

31 2

HO

LD

PU

LL IN

RD

-HO

LD

BA

TG

ND

(A)-

BK

WH

-PU

LL IN

VLV

RE

T2-B

R

VLV

RE

T2-B

R

R46H

RN

-WH

HORN

RELAY

FLAMMSTART

RELAY

P33STR-BK

2

86

1

30

5

8587

PR

1

C27A

UX

-RD

VLV

RE

T6-B

R

BA

T G

ND

-BR

P33S

TR

-BK

C107A

F-R

D

C41R

PM

-OR

/BK

8587a

4

87

5

8630

1 2

MA

INA

UX

P114B

AT-R

D

87aSTARTER

RELAY

STA

RT

BA

T

BA

T

MA

IN (

SY

S)

4

SERVICE

HORN

DEUTZ ENGINEDEUTZ F4L913

ENGINE BLOCK

HI/LO

SPEED

SOLENOID

BA

T G

ND

-BR

BA

TV

LV

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TE

CU

-RD

C21IG

N-W

H

C34S

A-B

K/W

H

R35R

PM

-BK

/RD

C46H

RN

-WH

C30E

DC

-WH

C31E

DC

-WH

/BK

C33S

TR

-BK

C25P

SR

-WH

/BK

C26T

SR

-WH

/RD

RE

T85T

TS

R-B

R

VLV

RE

T2-B

R

P85T

TS

R-G

N

C41R

PM

-OR

/BK

C107A

F-R

D

C84TA

Y-G

N/B

K

C83TA

X-G

N/W

H

VLV

RE

T3-B

R

C45G

EN

-GN

/WH

87a

5

85

4

87

2

86

1

30

R34S

A-R

D

TO HORN BUTTON

TO HORN BUTTON

U95

P_22R

87a

87

86

85

5

30

4

12

TO MICRO

K6

TO MICRO

87

87a

4

30

1

85

5

K2

86

2

87

4

85

5

301

K1

86

2

87a

P7R

P6R1

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

87a

TO

MIC

RO

30

1

87

87a

86

K3 2

1

85

5

87a

30

86

K4 2

87

85

5

P_9B

P_6R2

OUT PWR ENABLE

PWR TO TCON ESTOP

130

86

87a

85

87

K5 2

5

TO

MIC

RO

P_22

U32

P6R1

PCON POWER

P7R

-BAT

70 A

FU

SE

R116H

YD

-OR

87a

5

85

4

87

2

86

1

30

HYD COOLER

RELAY

BA

T G

ND

-BR

BA

T G

ND

-BR

P116H

YD

-OR

C116H

YD

-OR

OTS1

N.O.

FUSE

20 A

P116HYD-OR

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

V31R

EV

-WH

/BK

V30F

WD

-WH

C30E

DC

-WH

C31E

DC

-WH

/BK

C30E

DC

-WH

C31E

DC

-WH

/BK

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

AUX.

PUMP

-

+

-

+

FAN

P_7

TCON MODE







P11

P10

P9A

TCON

VLVRET6-BR

C27AUX-RD

VLV

RE

T1-B

R

BA

T C

BL(A

)-R

D

P29 ENG HARN

1

BA

T C

BL(A

)-R

D

P33S

TR

-BK

S56PRV-RD

GNDDCON-BR

P56PRV-RD

P21DCON-RD

P63LS-OR/RD

P53LS-WH/BK

FU

SE

3-1

0A

C65LO

FL-B

L/W

H

C64LS

-OR

/BK

C66D

RE

N-B

L

C64LS

-OR

/BK

1 213 2 4

J27 P27

42

C64LS

-OR

/BK

P56P

RV

-RD

2 4 3 1

P

3 4 13

SJ3-W

H

C68P

BD

-BL

S62B

ST

O-O

R

P53LS

-WH

/BK

C60A

XE

X-G

N/W

H

S56P

RV

-RD

C64LS

-OR

/BK

C77A

S-W

H

3 1 2 4

P53LS

-WH

/BK

P54E

NG

-BK

/WH

P58LS

-RD

/BK

P57P

BD

-RD

/WH

J20

12 WAY

P20

12 WAY

8 9 10 11 12

S56P

RV

-RD

SJ3-W

H

C71P

BE

-BL/B

K

C64LS

-OR

/BK

P57P

BD

-RD

/WH

13 4213 2 413 2 4

S56P

RV

-RD

C64LS

-OR

/BK

S62B

ST

O-O

R

C61A

XR

T-G

N

P57P

BD

-RD

/WH

P57P

BD

-RD

/WH

P53LS

-WH

/BK

P54E

NG

-BK

/WH

P58LS

-RD

/BK

C70P

BE

-BL/W

H

P63LS

-OR

/RD

SJ3-W

H

3 4 5 6 78 1 2

C61A

XR

T-G

N

S62B

ST

O-O

R

P63LS

-OR

/RD

C70P

BE

-BL/W

H

P54E

NG

-BK

/WH

P53LS

-WH

/BK

3 4 5 61 2J21

8 WAY

P21

8 WAY

P58LS

-RD

/BK

7

P56PRV-RD

2 43 1

C64LS

-OR

/BK

C71P

BE

-BL/B

K


OPTIONAL HYDRAULIC

V74P

RLO

-RD

VLV

RE

T1-B

R

C77A

S-W

H

V75P

RLO

-RD

/WH

SN

SR

GN

D-B

R

G119S

R-B

L

P57P

BD

-RD

/WH

P54E

NG

-BK

/WH

P58LS

-RD

/BK

S59C

NB

K-G

N/W

H

C60A

XE

X-G

N/W

H

C61A

XR

T-G

N

C68P

BD

-RD

C65LO

FL-B

L/W

H

C66D

RE

N-B

L

C70P

BE

-BL/W

H

C71P

BE

-BL/B

K

C64LS

-OR

/BL

P63LS

-OR

/RD

S62B

ST

O-O

R

S56P

RV

-RD

GN

DD

CO

N-B

R

P21D

CO

N-R

D

P53LS

-WH

/BK

13 2 4

LS

B3

RO

3' E

XT

LS

B3

RS

3.5

EX

T

LS

B4

ES

75

.5'

LS

B6

S

CH

NB

RK

LS

B3

EO

75

' E

XT

LS

B8

AS

50

DE

G

LS

B1

3A

O

53

DE

G

LS

B7

DS

11

DE

G

LS

B1

DO

10

DE

G

LS

T1

O

DR

V

EN

AB

LE

FS

T1

S

LO

W

FU

EL F

S

J2 BLACK 35 PIN


C61AXRT-GN

P57PBD-RD/WH

C60AXEX-GN/WH

VLV

RE

T

P2-3

3

P2-3

2

P2-3

4

P2-3

5

LS

B4E

O

LS

B13A

O

LS

B14A

O

PR

I#1 L

O

PR

I#2 L

O

SN

SR

GN

D

PR

I A

NG

P2-2

3

P2-2

8

P2-2

4

P2-2

5

P2-2

7

P2-2

6

P2-2

9

P2-3

0

P2-3

1

LS

B2R

O

LS

B3R

O

LS

B3E

O

FS

T1S

LS

T10

LS

B1D

O

P2-1

6

P2-1

4

P2-1

5

P2-1

7

P2-1

8

P2-1

9

P2-2

0

P2-2

2

P2-2

1

P_14

P_11

P_12

P_18

P_9A

P_7R

P_6R

2

P_9B

P_10

P2-0

6

P2-0

5

P2-0

4

P2-0

7

P2-0

8

P2-1

1

P2-0

9

P2-1

0

P2-1

2

OP

ER

SW

PW

RP

2-1

3

DC

ON

EC

U G

ND

DC

ON

EC

U P

WR

P_6R

1

P2-0

1

P2-0

2

P2-0

3

TCON

LIMIT SWITCHES

S-100/105

5A FUSE ADDED

S100/105- SN 188

S120/125- SN 584

5A FUSE ADDED

S100/105- SN 188

S120/125- SN 584

FUSE

15 A

WAS 10A BEFORE:

S100/105- SN 159

S120/125- SN 619

WAS 40A BEFORE

S100/105- SN 134

S120/125- SN 369

SEE GENERATOR OPTIONS

SEE OPTIONS FOR OTHER ENGINES

STARTER

1

2

3

4

5

6

7

8

9

10

11

12

13

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

GL

OW

PL

UG

WH-PULL

BR-COM

RD-HOLD

+AUX

+BAT

MOM N.O.

TIME DELAY

TROMBETTA

25

A

CB

RD

WH

BK

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

C2

5P

SR

-WH

/BK

C2

6T

SR

-WH

/RD

C2

1IG

N-W

H

FUEL

SOLENOID

RELAY

BA

T G

ND

-BR

BA

T G

ND

-BR

OIL

/WA

TE

R_

TE

MP

P3

-21

P3

-22

P3

-23

P3

-18

P3

-19

P3

-20

P3

-17

P3

-16

P3

-14

P3

-13

P3

-15

VA

LV

E_

RT

N3

ALT

_F

IEL

D_

WIR

E

TT

_T

ILT

_X

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_Y

_A

XIS

VA

LV

E_

RT

N2

TT

_T

ILT

_S

NS

R_

GN

D

TT

_T

ILT

_S

NS

R_

PW

R

ALT

EN

AT

OR

_R

PM

45

85

87

12

86

K8

30

SE

RV

ICE

_H

OR

N

OIL

_P

RE

SS

UR

E

STA

RT

ER

_R

EL

AY

RE

V

FW

D

IGN

ITIO

N/F

UE

L

CH

OK

E/G

LO

W P

LU

G

P3

-10

P3

-11

P3

-07

P3

-09

P3

-08

P3

-05

P3

-06

P3

-03

P3

-02

P3

-04

TH

RO

TT

LE

4

87

85

5

86

K72

30

ENGINE HARN

J3 WHITE 23 PIN

P3

-01

TO

MIC

RO

87

a

1

P3

-12

SY

S_

BA

T_

GN

D

SY

S_

BA

T_

PW

R

P5

-02

P5

-03

P5

-01

POWER HARN

J5 BLACK 4 PIN

AU

X/S

TA

RT

_B

AT

_G

ND

AU

X/S

TA

RT

_B

AT

_P

WR

P5

-04

J32-ENG HARN

2

3

1C45GEN-GN/WH

BAT GND-BR

P114BAT-RD

P46HRN-WH

C3

4S

A-B

K/W

H

RE

V V

LV

B

SO

LE

NO

ID

SO

LE

NO

ID

FW

D V

LV

A

VLV

RE

T2

-BR

31 2

HO

LD

PU

LL I

N

RD

-HO

LD

BK

-CO

M

WH

-PU

LL I

N

VLV

RE

T2

-BR

VLV

RE

T2

-BR

R4

6H

RN

-WH

HORN

RELAY

GLOW PLUG

RELAY

P34SA-RD

2

86

1

30

5

8587

PR

1

C2

7A

UX

-RD

VLV

RE

T6

-BR

BA

T G

ND

-BR

P3

3S

TR

-BK

C1

07

AF

-RD

C4

1R

PM

-OR

/BK

8587a

4

87

5

8630

1 2

MA

INA

UX

P11

4B

AT

-RD

87a

STARTER

RELAY

STA

RT

BA

T

BA

T

MA

IN (

SY

S)

4

SERVICE

HORN

DEUTZ BF4L-2011/TD2011-L04I

ENGINES SHOWN

ENGINE BLOCK

HI/LO

SPEED

SOLENOID

BA

T G

ND

-BR

BA

TV

LV

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TE

CU

-RD

C2

1IG

N-W

H

C3

4S

A-B

K/W

H

R3

5R

PM

-BK

/RD

C4

6H

RN

-WH

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C3

3S

TR

-BK

C2

5P

SR

-WH

/BK

C2

6T

SR

-WH

/RD

RE

T8

5T

TS

R-B

R

VLV

RE

T2

-BR

P8

5T

TS

R-G

N

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

C8

4TA

Y-G

N/B

K

C8

3TA

X-G

N/W

H

VLV

RE

T3

-BR

C4

5G

EN

-GN

/WH

87a

5

85

4

87

2

86

1

30

R3

4S

A-R

D

TO HORN BUTTON

U95

P_22R

87

a8

7

86

85

5

30

4

12

TO MICRO

K6

TO MICRO

87

87

a

4

30

1

85

5

K2

86

2

87

4

85

5

301

K1

86

2

87

a

P7R

P6R1

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

87

a

TO

MIC

RO

30

1

87

87

a

86

K3 2

1

85

5

87

a

30

86

K4 2

87

85

5

130

86

87

a8

5

87

K5 2

5

TO

MIC

RO

U32

-BAT

70 A FUSE

R11

6H

YD

-OR

87a

5

85

4

87

2

86

1

30

HYD COOLER

RELAY

BA

T G

ND

-BR

BA

T G

ND

-BR

P11

6H

YD

-OR

C11

6H

YD

-OR

OTS1

N.O.

FUSE

20 A

P116HYD-OR

J1

44

-1

J1

44

-2

J1

44

-8

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

AUX.

PUMP

-

+

-

+

FAN

P_22R

P10

P7R

P6R1

P9A

P11

4.5 DEGREE

TURNTABLE

TILT

SENSOR

C83TAX-GR/WH

C84TAY-GR/BK

P85TTSR-GR

RET85TTSR-BR

P3

1-E

NG

HA

RN

J3

1-T

ILT

SN

SR

TCON

V3

1R

EV

-WH

/BK

V3

0F

WD

-WH

P1

-06

P1

-05

FW

D

RE

V

DETAIL B

HIGH CURRENT

VALVE PROPEL

OUTPUT

VLVRET6-BR

C27AUX-RD

K6 K1

K4

K8

K5 K2

K7

K3

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87


K1 POWERS CKT P22R OR

CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE)

K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD,

VALVES AUX RELAY, BOOM EXT/RET,

TURNTABLE ROTATE VLV.

K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH

K4 POWERS CIRCUIT P_6R1 OR VALVES:

PRIMARY VALVES 1 & 2, THROTTLE (IGN),

GLOW PLUG, STARTER RELAY, AC GENERATOR,

BOOM RETRACT, MULTIFUNCTION VALVE,

ROTATE CW, AND ROTATE CCW.

K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY

K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.

(FUEL ON/OFF SOLENOID AND ALT FIELD)

K7 POWERS THROTTLE OR HI/LOW SOLENOID

(CKT C35RPM-BK/RD)

K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)

TO

PL

D

TO

MIC

RO

TO

PL

D

TO

PL

D

TO

MIC

RO

TO

PL

D

TO

MIC

RO

TO

MIC

RO

TO

PL

D

TO

PL

D

R4

9L

P -

WH

/BK

DR

IVE

LIG

HT

S R

EL

AY

TO

MIC

RO

TO

MIC

RO

VA

LV

E_

RT

N6

AU

X_

RE

LA

Y

VA

LV

E_

RT

N7

RO

TA

TE

_C

W_

VLV

MU

LT

I_F

UN

CT

_V

LV

RO

TA

TE

_C

CW

_V

LV

TO DRIVE

LAMPS

12 VOLT

P4

-20

P4

-21

P4

-22

P4

-25

P4

-24

P4

-23

P4

-26

P4

-27

P4

-30

P4

-28

P4

-29

P4

-31

P4

-32

P4

-35

P4

-33

P4

-34

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

VA

LV

E_

RT

N5

HY

D_

FIL

TE

R1

HY

D_

FIL

TE

R2

VA

LV

E_

RT

N4

BO

OM

_E

XT

/RE

T_

VLV

BO

OM

_U

P/D

OW

N_

VLV

BO

OM

_D

OW

N_

VLV

TU

RN

TA

BL

E_

RO

TA

TE

_V

LV

BO

OM

_U

P_

VLV

BO

OM

_E

XT

EN

D_

VLV

BO

OM

_R

ET

RA

CT

_V

LV

BO

OM

RE

VE

RS

E L

OA

D

BO

OM

OV

ER

LO

AD

J4 WHITE 35 PIN

VLV

RE

T5

-BR

C1

5L

S-R

D/B

K

C1

4L

S-B

K/R

D

P4

-03

P4

-02

P4

-01

P4

-13

P4

-08

P4

-04

P4

-05

P4

-06

P4

-07

P4

-09

P4

-10

P4

-11

P4

-12

P4

-14

P4

-15

P4

-16

P4

-17

P4

-18

MANIFOLD HARN

TO

MIC

RO

P4

-19

VA

LV

E R

TN

7

VA

LV

E R

TN

6

C2

7A

UX

-RD

C11

3M

FV

-OR

/RD

C0

5T

TL

-WH

C0

6T

TR

-WH

/BK

TO

AU

X H

YD

RE

LA

Y P

R1

TU

RN

TA

BL

E R

OT

CC

W V

LV

TU

RN

TA

BL

E R

OT

CW

VLV

MU

LT

I F

UN

C V

LV

4

P

3

LSB20LO

NO

3 1

C0

6T

RF

-WH

/RD

VLV

RE

T4

-BR

C0

3P

BF

-RD

/WH

C0

9P

ER

F-B

K/R

D

C0

8P

BR

-BK

/WH

C0

7P

BE

-BK

C0

2P

BD

-RD

/BK

C0

1P

BU

-RD

P P P

BO

OM

RE

T V

LV

BO

OM

EX

T/R

ET

F.C

.

BO

OM

UP

VLV

BO

OM

EX

TE

ND

VLV

BO

OM

DW

N V

LV

BO

OM

UP

/DW

N F

.C.

TU

RN

TA

BL

E C

W/C

CW

F.C

.

5

87a

87

1

2 86

30 4

85

3

TCON MEMBRANE PANEL

JIB

DO

WN

PLT

FR

M C

W

BO

OM

CW

PLT

FR

M C

CW

JIB

UP

PLT

FR

M D

OW

N

PLT

FR

M U

P

34 2 19 8 7 6 5

SE

C.

DO

WN

BO

OM

EX

T

RA

BB

IT

TU

RT

LE

RO

OM

RE

T

BO

OM

DO

WN

14

13

12

11

10

1 P11

15

BO

OM

UP

EN

G S

PE

ED

+ B

UT

TO

N

GA

S/L

P

AU

XIL

IAR

Y

SE

C.

UP

6 5 4 3 210

9 8 7

J11

ST

RT

AS

ST

SC

RO

LL R

SC

RL F

/EN

T

- B

UT

TO

N

STA

RT

15

14

11

13

12

P1

0J1

0

BO

OM

CC

W

TO

MIC

RO

TCON

P2

0

PLATFORM PCON

NOT USED

PCON

AL

AR

M-

AL

AR

M+

S1

-1

S1

-2

S1

-31


S2

-3

S2

-2

S2

-1

S3

-3

S3

-2

S3

-1

JIB

71 2 3 4 5

2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

TURNTABLE ROTATE

BOOM UP/DWN &

JOYSTICK

P1

H1

_Y

OU

T

H1

_G

ND

H1

_X

OU

T

H1

_P

WR

P2

6532 41

JOYSTICK

BOOM EXT/RET

H2

_Y

OU

T

H2

_G

ND

H2

_P

WR

H3

_G

ND

H3

_P

WR

H3

_Y

OU

T

41 2

P3

3 5 6 1

P4

6532 4

DRIVE & STEERING

JOYSTICK

H4

_G

ND

H4

_R

KO

UT

H4

_X

OU

T

H4

_Y

OU

T

H4

_P

WR

ES

TO

P_

2

ES

TO

P_

1

E-STOP

ECUJ2

0

ARE CLOSED

TERM 3 & 4

LS

AX

2E

O

WHEN AXLES

ARE EXTENDED

LIMIT SWITCHES

AXLE EXTENTION

LS

AX

1E

O



P6

3L

S-O

R/R

D

C6

0A

XE

X-G

N/W

H

P5

7P

BD

-RD

/WH

P1

-10

P1

-21

P1

-23

P1

-22

P1

-19

P1

-20

P1

-18

P1

-17

P1

-16

P1

-15

P1

-14

P1

-12

P1

-13

P1

-11

P1

-03

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-02

P1

-01

GN

D-D

CO

N-B

R

DC

ON

EC

U P

WR

P_

6R

1

P_

7R

P1

2

AX

LE

NO

T R

ET

SIG

AX

LE

NO

T R

ET

PW

R

CA

N S

HIE

LD

RS

23

2 R

XD

RS

23

2 T

XD

BO

OT

AX

LE

NO

T E

XT

SIG

CA

N L

OW

CA

N H

IGH

RS

23

2 G

ND

AX

LE

NO

T E

XT

PW

R

P2

1D

CO

N-W

H

P5

3L

S-R

D

S5

6P

RV

-RD

C6

1A

XR

T-G

N

C6

1L

S(A

)-G

N

D8

1C

AN

- -G

N

D8

2C

AN

+ -

YL

P6

1L

S(A

)-G

N

DC

ON

EC

U G

ND

C6

1L

S-G

N

P6

1L

S-G

N


J1 BLACK 23 PIN

LIMIT SWITCHES

AXLE NOT EXT

LS

AX

2E

S

LS

AX

1E

S

13 2 4 13 2 44

P

3

P

3 4

WHEN AXLES

ARE CLOSED

ARE RETRACTED

TERM 3 & 4

AXLE RETRACTION

LIMIT SWITCHES

LS

AX

1R

O

P

3 4

LS

AX

2R

O

P

43

J3-OR/BL

J2-BL/RD

J1-BL/BK J4-GN/BK

AX

LE

RE

TR

AC

T

AX

LE

EX

TE

ND

MO

TO

R S

PE

ED

AU

X F

OR

WA

RD

AU

X R

EV

ER

SE

BR

AK

E

LR

ST

EE

R L

EF

T

RF

ST

EE

R R

IGH

T

LF

ST

EE

R L

EF

T

LF

ST

EE

R R

IGH

T

LR

ST

EE

R R

IGH

T

RF

ST

EE

R L

EF

T

RR

ST

EE

R L

EF

T

RR

ST

EE

R R

IGH

T

BL

BK

RD

BA C

BL

BK

RD

BA C

BL

BK

RD

BA C

P2

-07

P2

-01

P2

-02

P2

-04

P2

-05

P2

-06

P2

-03

VA

LV

E R

TN

1

AX

LE

RE

TR

AC

T

AX

LE

EX

TE

ND

MO

TO

R S

PE

ED

AU

X F

OR

WA

RD

RF

ST

EE

R R

IGH

TP

2-1

8

P2

-08

P2

-09

P2

-11

P2

-13

P2

-12

P2

-14

P2

-15

P2

-16

P2

-17

P2

-10

RF

ST

EE

R S

NS

R

LR

ST

EE

R S

NS

R

RR

ST

EE

R S

NS

R

RR

ST

EE

R L

EF

T

RR

ST

EE

R R

IGH

T

BR

AK

E

LR

ST

EE

R S

NS

R

LR

ST

EE

R L

EF

T

P2

-20

P2

-19

P2

-22

P2

-23

P2

-21

LF

ST

EE

R L

EF

T

ST

EE

R S

NS

R G

ND

AU

X R

EV

ER

SE

VA

LV

E R

TN

2

LR

ST

EE

R R

IGH

T

ST

EE

R S

NS

R P

WR

RF

ST

EE

R L

EF

T

LF

ST

EE

R R

IGH

T

VLV

RE

T-B

R

V6

1A

XR

T-G

N

V6

0A

XE

X-G

N/W

H

V5

2A

FV

-BL

/RD

V5

2A

RE

V-B

L/R

D

VLV

RE

T2

-BR

V3

6R

RS

-BL

V2

9M

S-R

D/W

H

V3

7R

RS

-BL

/BK

C111

RR

S-O

R

C111

LR

S-O

R

C111

RF

S-O

R

C111

LF

S-O

R

P11

0R

T-B

K

V3

6L

RS

-BL

V3

7L

RS

-BL

/BK

V3

6R

FS

-BL

V3

2B

RK

-WH

/RD

P1

09

AN

G-G

N/W

H

V3

7R

FS

-BL

/BK

V3

6L

FS

-BL

V3

7L

FS

-BL

/BK

RR

ST

EE

R R

IGH

T

LR

ST

EE

R R

IGH

T

RF

ST

EE

R R

IGH

T

LF

ST

EE

R R

IGH

T

BK

A B

RD

BL

C

J2 WHITE 23 PIN

DRIVE CHASSIS HARNDRIVE CHASSIS HARN

DCON

OUT PWR ENABLE

PWR-PCON ESTOP

D82CAN+ -YL

D81CAN- -GN

P63LS-OR/RD

P53LS-WH/BK

C60AXEX-GN/WH

P57PBD-RD/WH

P21DCON-RD

GNDDCON-BR

S56PRV-RD

C61AXRT-GN










J29

J28

J27

J26

P29

P28

P27

P26

J24

J25

J20

J21

J23

P20

P23

P25

P24

P21

P2

P1

J2

J1


















J7P7

J16

J17

J18

J10

J11

P10

P11

P17

P18

P8

P16

J8

J1P1

P6

P2

J6

J2

P2

P1

J2

J1


JACK NO

J2P2

P5

P3

P4

J5

J4

J3

PLUG NO

P1 J1





P32

P33

P31

P30

J33

J32

J31

J30


6 7 7 7

PC

ON

GN

D

PC

ON

PW

R

P7

CA

N S

HIE

LD

RS

23

2_

RX

D

RS

23

2_

TX

D

BO

OT

OU

T P

WR

EN

BL

HR

N R

LY

CN

TR

L

CA

N+

CA

N-

RS

23

2_

GN

D

PW

R-P

CO

N E

ST

OP


P2

2

J3 10PIN

P1


J1 10PIN

P1

P1

P1

P1

P1

P1

STA

RT

AS

SIS

T

AC

GE

NE

RA

TO

R

AU

XIL

IAR

Y

HO

RN

STA

RT

J2 10PIN

P1

P1

P1

P2

P2

P2

P2

P2

P2

EN

GIN

E S

PE

ED

AX

LE

RE

TR

AC

T

DR

IVE

EN

AB

LE

1

SP

AR

E 1

CR

AB

ST

EE

R

FR

ON

T S

TE

ER

DR

IVE

SP

EE

D

RE

AR

ST

EE

R

AX

LE

EX

TE

ND

42 3 5 6

PCON MEMBRANE PANEL

P2

P2

P2

P2

FU

EL T

YP

E

CO

OR

D S

TE

ER

7 8 10

9

SP

AR

E 2

P1

-01

P1

-02

P1

-03

P1

-04

P1

-05

P1

-06

P1

-07

P1

-08

P1

-09

P1

-11

P1

-10

P1

-12

P1

-13

P1

-14

P1

-15

P1

-20

P1

-16

P1

-17

P1

-18

P1

-19

P1

-22

P1

-21

P1

-23

P5

2P

CO

N-W

H

GN

DP

CO

N-B

R

P5

6P

RV

-RD

S5

6P

RV

-RD

/WH

C4

7O

UT

-WH

/BK

P2

3P

CO

N-B

K

D8

1C

AN

- -G

N

D8

2C

AN

+ -

YL

C4

6H

N-W

H

5

87a

87

1

2 86

30 4

85

3

5

87a

87

1

2 86

30 4

85

3

P6R

P7R

P1

-23

P1

-21

P1

-22

P1

-19

P1

-18

P1

-17

P1

-16

P1

-20

P1

-15

P1

-14

P1

-13

P1

-12

P1

-10

P1

-11

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-03

P1

-02

P1

-01

P8

7P

TS

-RD

SA

FE

PL T

ILT

PW

R

SA

FE

PL T

ILT

GN

DP

TS

RE

T-B

R

PL T

ILT

SN

SR

PW

RP

85

PT

S-G

N

PL T

ILT

SN

SR

C8

4TA

Y-G

N/B

K

PL T

ILT

SN

SR

GN

DP

LA

TR

ET

-BR

FO

OT

SW

RT

NC

56

PT

S-R

D

FO

OT

SW

PW

RR

56

PT

S-R

D

SA

FE

PL T

ILT

OU

TC

88

PT

S-R

D/B

K

LO

AD

SN

SR

PW

R

LO

AD

SN

SR

OU

T

LO

AD

SN

SR

GN

D

PR

OX

KIL

L C

MD

C9

0P

XS

-RD

/BK

PR

OX

KIL

L G

ND

R9

0P

XS

-RD

/BK

C1

5P

LD

-OR

/BK

C1

4P

LU

-OR

C4

4JD

-GN

/BK

PR

OP

VLV

2_

AC

43

JU

-GN

ON

/OF

F V

LV

3_

BC

18

PR

R-G

R/B

K

ON

/OF

F V

LV

3_

AC

17

PR

L-G

N

VLV

RT

NV

LV

RE

T-B

R

PR

OP

VLV

2_

B

PR

OP

VLV

1_

A

PR

OP

VLV

1_

B

PL

AT

RO

T C

CW

PL

AT

LE

VE

L D

N

PL

AT

LE

VE

L U

P

JIB

DO

WN

JIB

UP

PL

AT

RO

T C

W

3 1 42

PROXKILL SW.

21

P1

-15

SA

FE

PL T

ILT

OU

T

P1

-16

FO

OT

SW

PW

R

3 1 42

PROXKILL

FOOTSWITCH

OPTIONAL

PROXIMITY

KILL WIRING

FOOTSWITCH

R5

6P

TS

-RD

C5

6P

TS

-RD

OPTIONAL

U2

0

9 10

7654 8321

321 654 987 10


21

GN

WH

BK

ASSEMBLY

PLATFORMTILT SENSOR

6P33-PCON

MANIFOLD

J31-TILT SNSR

4321 5

FU

SE

5 A

K1

K2

P23PCON-BK

P52PCON-WH

GNDPCON-BR

C46HN-WH

P56PRV-RD

S56PRV-RD/WH

C47OUT-WH/BK

D82CAN+ -YL

D81CAN- -GN

GN

J8

J7

2

4

3

6

5

2

BL

YL

BR

OR

RD1

BK

WH1

2

6

5

4

3

2

1

P7-LIMIT SW HARN

1

P8-LIMIT SW HARN

P6R1

DCON PWR

DCON GND

P18

P11

P12

P9A

P7RWH

BK22

1P18

1

GN

YL

BL

66

5

44

5

P17

OR

BR

RD

2 2

33

11

CCCAN SHIELD

B B

A

P16

AYL

GN

CAN HIGH

CAN LOW

CC

B

A

B

AYL

GN

P6-BOOM HARNJ6

(SLIP RING)

(SLIP RING)

D81CAN- -GN

D82CAN+ -YL

P57PBD-RD/WH

P21DCON-RD

C60AXEX-GN/WH

P53LS-WH/BK

P63LS-OR/RD

GNDDCON-BR

S56PRV-RD

C61AXRT-GN

PCON

PL

AT

SE

NS

OR

GN

D

TIL

T S

EN

SO

R S

IG O

UT

TIL

T S

EN

SO

R P

WR

TIL

T S

WIT

CH

GN

D

PW

R T

O T

ILT

SW

ITC

H

OU

T F

RM

TIL

T S

WIT

CH

LOAD SENSOR

ASSEMBLY OPTION

88

88

88

88

88

88

88

88

88

88

88

Genie S-100/105(from s/n 231 to s/n 809)

Genie S-120/125(from s/n 921 to s/n 2709)

Electrical SchematicES0427G


JOYSTICK CONNECTORS (before serial number S120- 1617; S100- 420)

1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7

Joystick Adaptor Harness

TO HORN BUTTON

OUT PWR ENABLE

PWR TO TCON ESTOP

P_7

TCON MODE

P7R

P_22

P6R1

PCON POWER

P11

OP

ER

. R

EC

.

SE

RV

. O

R

PLD

P1

5

12 VOLT

S56PRV-RD

GNDDCON-BR


TO

MIC

RO

P1

5

P1

-23

P1

-22

P1

-21

P1

-20

BOOM HARN

J1 BLACK 23 PIN

TE

T E

ST

OP

RE

T

CA

N H

IGH

RS

23

2 G

ND

CA

N L

OW

CA

L F

RE

Q 2

TE

T E

ST

OP

PW

R

BO

OT

RS

23

2 T

XD

RS

23

2 R

XD

CA

N S

HIE

LD

FL

AS

HIN

G B

EA

CO

N

CA

L F

RE

Q 1

P1

-18

P1

-19

P1

-17

P1

-15

P1

-16

P1

-12

P1

-13

P1

-11

P1

-10

P1

-09

P1

-14

P_

7

P_

22

WO

RK

LT

PW

R-P

CO

N E

ST

OP

OU

T P

WR

EN

BL

TCON

PC

ON

GN

D

PC

ON

PO

WE

R

HO

RN

RE

LA

Y C

OIL

P1

-07

P1

-06

P1

-08

P1

-05

P1

-04

P1

-01

P1

-02

P1

-03

D8

2C

AN

+ -

YL

D8

1C

AN

- -G

N

P9

7T

ET

-BK

P2

3P

CO

N-B

K

GN

DP

CO

N-B

R

P5

2P

CO

N-W

H

C4

6H

N-W

H

C4

7O

UT

-WH

/BK

S5

6P

RV

-RD

/WH

P5

6P

RV

-RD

R4

8L

P-W

H/R

D

R11

7F

B-R

D

P9

5T

ET

-OR

TO FLASHING BEACON

TO WORK LIGHTS

J27-BOOM HARN







BM

DW

N O

BM

E/R

FC

O

BM

RE

T O

MLT

FN

C V

LV

O

AU

X H

YD

O

BM

DW

N S

T I

BM

3' I

BM

10

0' I

PR

I L

O#

1 O

BM

U/D

FC

O





GN

PK

TN

YL

BL

PR

GY

BR

WT

LT

GN

OR

OFF

PCON

TCON

RUN

RECOVERY

SERV. BYPASS

1235 468 7910

P7

R

P6

R1

P2

2

12

13

14

15

16

P7

P11

AL

AR

M P

WR

AL

AR

M G

ND

11

OP

ER

. R

EC

.

RD

BK

LT

BL

YL

/WH

PR GN

/WH

OU

TP

UT

PW

R E

NA

BL

E

SE

RV

. O

R O

PE

R.

RE

C.

TC

ON

MO

DE

PW

R T

O T

CO

N E

ST

OP

TC

ON

ES

TO

P

TE

TH

ER

ES

TO

P

TC

ON

OR

PC

ON

MO

DE

PC

ON

MO

DE

5 AF

US

E

PW

R IN

SE

RV

OR

RE

CO

VE

RY

PR

OV

IDE

S P

WR

TO

MIN

IMA

L

HA

RD

WA

RE

30

85

87

86

87a

P21DCON-RD

C61AXRT-GN

P63LS-OR/RD

P57PBD-RD/WH

P53LS-WH/BK

C60AXEX-GN/WH30

85

87

86

87a

SE

RV

ICE

OR

RE

CO

VE

RY

MO

DE

FU

SE

3-1

0A

J2 BLACK 35 PIN


TO

MIC

RO

TO

PL

D

TO

PL

D

TO

MIC

RO

TO

MIC

RO

TO

PL

D

C6

5L

OF

L-B

L/W

H

C6

4L

S-O

R/B

K

C6

6D

RE

N-B

L

C6

4L

S-O

R/B

K

1 213 2 4

J27 P27

42

C6

4L

S-O

R/B

K

P5

6P

RV

-RD

2 4 3 1

P

4

P

3 4 13

SJ3

-WH

C6

8P

BD

-BL

S6

2B

ST

O-O

R

P5

3L

S-W

H/B

K

C6

0A

XE

X-G

N/W

H

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

C7

7A

S-W

H

C6

4L

S-O

R/B

K

3 1 2 43 1 2 4

SJ1

-WH

/RD

SJ2

-BK

/RD

P5

8L

S-R

D/B

K

P5

7P

BD

-RD

/WH

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

SJ2

-BK

/RD

SJ1

-WH

/RD

J20

12 WAY

P20

12 WAY

8 9 10 11 12

S5

6P

RV

-RD

SJ3

-WH

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

K

P5

7P

BD

-RD

/WH

C7

8A

S-W

H/B

K

3

VLV

RE

T1

-BR

PR

I 1

LO

PR

I 2

LO

13 4213 2 413 2 4

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

S6

2B

ST

O-O

R

C6

1A

XR

T-G

N

P5

7P

BD

-RD

/WH

P5

7P

BD

-RD

/WH

SJ1

-WH

/RD

SJ2

-BK

/RD

P5

8L

S-R

D/B

K

C7

0P

BE

-BL

/WH

P6

3L

S-O

R/R

D

SJ3

-WH

V7

5P

RL

O-R

D/W

H

V7

4P

RL

O-R

D

3 4 5 6 78 1 2

C6

1A

XR

T-G

N

S6

2B

ST

O-O

R

P6

3L

S-O

R/R

D

C7

0P

BE

-BL

/WH

C7

6P

BE

-BL

SJ2

-BK

/RD

SJ1

-WH

/RD

3 4 5 61 2J21

8 WAY

P21

8 WAY

S5

9C

NB

K-G

N/W

H

C6

9P

BE

-BK

P5

4E

NG

-BK

/WH

P5

3L

S-W

H/B

K

P5

8L

S-R

D/B

K

7

P56PRV-RD

43J264 WAY1

P264 WAY

2

2 43 11 2 4

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

C7

1P

BE

-BL

/BK

C7

6P

BE

-BL

SJ1

-WH

/RD

C6

9P

BE

-BK

SJ2

-BK

/RD

P5

4E

NG

-BK

/WH

P6

3L

S

S5

9C

NB

K

3

P5

3L

S-W

H/B

K


OPTIONAL HYDRAULIC

VLV

RE

T

P2

-33

P2

-32

P2

-34

P2

-35

LS

B4

EO

LS

B1

3A

O

LS

B1

4A

O

PR

I#1

LO

PR

I#2

LO

SN

SR

GN

D

PR

I A

NG

P2

-23

P2

-28

P2

-24

P2

-25

P2

-27

P2

-26

P2

-29

P2

-30

P2

-31

V7

4P

RL

O-R

D

VLV

RE

T1

-BR

C7

6P

BE

-BL

C7

7A

S-W

H

C7

8P

S-W

H/B

K

V7

5P

RL

O-R

D/W

H

SN

SR

GN

D-B

R

G11

9S

R-B

L

LS

B2

RO

LS

B3

RO

LS

B3

EO

FS

T1

S

LS

T1

0

LS

B1

DO

P2

-16

P2

-14

P2

-15

P2

-17

P2

-18

P2

-19

P2

-20

P2

-22

P2

-21

P_

14

P_

11

P_

12

P_

18

P_

9A

P_

7R

P_

6R

2

P_

9B

P_

10

P2

-06

P2

-05

P2

-04

P2

-07

P2

-08

P2

-11

P2

-09

P2

-10

P2

-12

OP

ER

SW

PW

RP

2-1

3

P5

7P

BD

-RD

/WH

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

S5

9C

NB

K-G

N/W

H

C6

0A

XE

X-G

N/W

H

C6

1A

XR

T-G

N

C6

8P

BD

-RD

C6

5L

OF

L-B

L/W

H

C6

6D

RE

N-B

L

C7

0P

BE

-BL

/WH

C6

9P

BE

-BK

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

L

P6

3L

S-O

R/R

D

S6

2B

ST

O-O

R

S5

6P

RV

-RD

DC

ON

EC

U G

ND

DC

ON

EC

U P

WR

P_

6R

1

P2

-01

P2

-02

P2

-03

GN

DD

CO

N-B

R

P2

1D

CO

N-R

D

P5

3L

S-W

H/B

K

TO

MIC

RO

TO

PL

D

TO HORN BUTTON

P_9B

PWR TO TCON ESTOP

OUT PWR ENABLE

P_6R2

TCON MODE

P_7

P10

P_22

P7R

PCON POWER

P11

P6R1

P9A

TO

MIC

RO

P_7

TCON MODE

13 2 413 2 413 2 4

LS

B3R

O

3' E

XT

LS

B3R

S

3.5

EX

T

LS

B4E

S

75.5

'

LS

B6S

CH

NB

RK

LS

B4E

O

100' E

XT

LS

B3E

O

75' E

XT

LS

B2R

S

101'

TO HORN BUTTON

P_9B

P_6R2

OUT PWR ENABLE

PWR TO TCON ESTOP

P_22

P6R1

PCON POWER

P7R







P11

P10

P9A

TCON

LS

B2R

O

100'

LS

B8A

S

50 D

EG

LS

B9A

S

65 D

EG

LS

B14A

O

68 D

EG

LS

B13A

O

53 D

EG

LS

B7D

S

11 D

EG

LS

B1D

O

10 D

EG

LS

T1O

DR

V

EN

AB

LE

FS

T1S

LO

W

FU

EL F

S

LIMIT SWITCHES

S-120/125

GN

WH

BK

RD

NO

T U

SE

D

NO

NC

NO

T U

SE

D

NOT USED

61 2 3 4 5


JOYSTICK

P1

H1

_Y

OU

T

H1

_G

ND

H1

_X

OU

T

H1

_P

WR

P2

6532 41

JOYSTICK

BOOM EXT/RET

H2

_Y

OU

T

H2

_G

ND

H2

_P

WR

H3

_G

ND

H3

_P

WR

H3

_Y

OU

T41 2

P3

3 5 6 1

P4

6532 4

DRIVE & STEERING

JOYSTICK

H4

_G

ND

H4

_R

KO

UT

H4

_X

OU

T

H4

_Y

OU

T

H4

_P

WR

NO

T U

SE

D

1

2

3

4

5

6

7

8

9

10

11

12

13


15A

CB 7

CB7 ADDED

S100- S/N 710

S120- S/N 2589

SEE GENERATOR

OPTION PAGE

FU

SE

3-1

0A

C6

5L

OF

L-B

L/W

H

C6

4L

S-O

R/B

K

C6

6D

RE

N-B

L

C6

4L

S-O

R/B

K

1 213 2 4

J27 P27

42

C6

4L

S-O

R/B

K

P5

6P

RV

-RD

2 4 3 1

P

3 4 13

SJ3

-WH

C6

8P

BD

-BL

S6

2B

ST

O-O

RN

P5

3L

S-W

H/B

K

C6

0A

XE

X-G

N/W

H

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

C7

7A

S-W

H

3 1 2 4

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

P5

7P

BD

-RD

/WH

J20

12 WAY

P20

12 WAY

8 9 10 11 12

S5

6P

RV

-RD

SJ3

-WH

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

K

P5

7P

BD

-RD

/WH

13 4213 2 413 2 4

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

S6

2B

ST

O-O

R

C6

1A

XR

T-G

N

P5

7P

BD

-RD

/WH

P5

7P

BD

-RD

/WH

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

C7

0P

BE

-BL

/WH

P6

3L

S-O

R/R

D

SJ3

-WH

3 4 5 6 78 1 2

C6

1A

XR

T-G

N

S6

2B

ST

O-O

R

P6

3L

S-O

R/R

D

C7

0P

BE

-BL

/WH

P5

4E

NG

-BK

/WH

P5

3L

S-W

H/B

K

3 4 5 61 2J21

8 WAY

P21

8 WAY

P5

8L

S-R

D/B

K

7

P56PRV-RD

2 43 1

C6

4L

S-O

R/B

K

C7

1P

BE

-BL

/BK


OPTIONAL HYDRAULIC

C7

7A

S-W

H

SN

SR

GN

D-B

R

G11

9S

R-B

L

P5

7P

BD

-RD

/WH

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

S5

9C

NB

K-G

N/W

H

C6

0A

XE

X-G

N/W

H

C6

1A

XR

T-G

N

C6

8P

BD

-RD

C6

5L

OF

L-B

L/W

H

C6

6D

RE

N-B

L

C7

0P

BE

-BL

/WH

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

L

P6

3L

S-O

R/R

D

S6

2B

ST

O-O

R

S5

6P

RV

-RD

GN

DD

CO

N-B

R

P2

1D

CO

N-R

D

P5

3L

S-W

H/B

K

13 2 4

LS

B3R

O

3' E

XT

LS

B3R

S

3.5

EX

T

LS

B4E

S

75.5

'

LS

B6S

CH

NB

RK

LS

B3E

O

75' E

XT

LS

B8A

S

50 D

EG

LS

B13A

O

53 D

EG

LS

B7D

S

11 D

EG

LS

B1D

O

10 D

EG

LS

T1O

DR

V

EN

AB

LE

FS

T1S

LO

W

FU

EL F

S

J2 BLACK 35 PIN


VLV

RE

T

P2

-33

P2

-32

P2

-34

P2

-35

LS

B4

EO

LS

B1

3A

O

LS

B1

4A

O

PR

I#1

LO

PR

I#2

LO

SN

SR

GN

D

PR

I A

NG

P2

-23

P2

-28

P2

-24

P2

-25

P2

-27

P2

-26

P2

-29

P2

-30

P2

-31

LS

B2

RO

LS

B3

RO

LS

B3

EO

FS

T1

S

LS

T1

0

LS

B1

DO

P2

-16

P2

-14

P2

-15

P2

-17

P2

-18

P2

-19

P2

-20

P2

-22

P2

-21

P_

14

P_

11

P_

12

P_

18

P_

9A

P_

7R

P_

6R

2

P_

9B

P_

10

P2

-06

P2

-05

P2

-04

P2

-07

P2

-08

P2

-11

P2

-09

P2

-10

P2

-12

OP

ER

SW

PW

RP

2-1

3

DC

ON

EC

U G

ND

DC

ON

EC

U P

WR

P_

6R

1

P2

-01

P2

-02

P2

-03

LIMIT SWITCHES

S-100/105

S56PRV-RD

GNDDCON-BR

P56PRV-RD

P21DCON-RD

C61AXRT-GN

P63LS-OR/RD

P57PBD-RD/WH

P53LS-WH/BK

C60AXEX-GN/WH

DE

TA

IL B

P20

PLATFORM PCON

PCON

AL

AR

M-

AL

AR

M+

S1

-1

S1

-2

S1

-31


S2

-3

S2

-2

S2

-1

S3

-3

S3

-2

S3

-1

JIB

2 3 4 5 6 7 8 9 10

11 12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

ES

TO

P_

2

ES

TO

P_

1

E-STOP

ECUJ20

ARE CLOSED

TERM 3 & 4

LS

AX

2E

O

WHEN AXLES

ARE EXTENDED

LIMIT SWITCHES

AXLE EXTENTION

LS

AX

1E

O



P6

3L

S-O

R/R

D

C6

0A

XE

X-G

R/W

H

P5

7P

BD

-RD

/WH

P1

-10

P1

-21

P1

-23

P1

-22

P1

-19

P1

-20

P1

-18

P1

-17

P1

-16

P1

-15

P1

-14

P1

-12

P1

-13

P1

-11

P1

-03

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-02

P1

-01

GN

D-D

CO

N-B

R

DC

ON

EC

U P

WR

P_

6R

1

P_

7R

P1

2

AX

LE

NO

T R

ET

SIG

AX

LE

NO

T R

ET

PW

R

CA

N S

HIE

LD

RS

23

2 R

XD

RS

23

2 T

XD

BO

OT

AX

LE

NO

T E

XT

SIG

CA

N L

OW

CA

N H

IGH

RS

23

2 G

ND

AX

LE

NO

T E

XT

PW

R

P2

1D

CO

N-W

H

P5

3L

S-R

D

S5

6P

RV

-RD

C6

1A

XR

T-G

R

C6

1L

S(A

)-G

R

D8

1C

AN

- -G

R

D8

2C

AN

+ -

YL

P6

1L

S(A

)-G

R

DC

ON

EC

U G

ND

C6

1L

S-G

R

P6

1L

S-G

R


J1 BLACK 23 PIN

LIMIT SWITCHES

AXLE NOT EXT

LS

AX

2E

S

LS

AX

1E

S

13 2 4 13 2 44

P

3

P

3 4

WHEN AXLES

ARE CLOSED

ARE RETRACTED

TERM 3 & 4

AXLE RETRACTION

LIMIT SWITCHES

LS

AX

1R

O

P

3 4

LS

AX

2R

O

P

43

J3-OR/BL

J2-BL/RD

J1-BL/BK J4-GR/BK

AX

LE

RE

TR

AC

T

AX

LE

EX

TE

ND

MO

TO

R S

PE

ED

BR

AK

E

LR

ST

EE

R L

EF

T

RF

ST

EE

R R

IGH

T

LF

ST

EE

R L

EF

T

LF

ST

EE

R R

IGH

T

LR

ST

EE

R R

IGH

T

RF

ST

EE

R L

EF

T

RR

ST

EE

R L

EF

T

RR

ST

EE

R R

IGH

T

BL

BK

RD

BA C

BL

BK

RD

BA C

BL

BK

RD

BA C

P2

-07

P2

-01

P2

-02

P2

-04

P2

-05

P2

-06

P2

-03

VA

LVE

RT

N1

AX

LE

RE

TR

AC

T

AX

LE

EX

TE

ND

MO

TO

R S

PE

ED

RF

ST

EE

R R

IGH

TP

2-1

8

P2

-08

P2

-09

P2

-11

P2

-13

P2

-12

P2

-14

P2

-15

P2

-16

P2

-17

P2

-10

RF

ST

EE

R S

NS

R

LR

ST

EE

R S

NS

R

RR

ST

EE

R S

NS

R

RR

ST

EE

R L

EF

T

RR

ST

EE

R R

IGH

T

BR

AK

E

LR

ST

EE

R S

NS

R

LR

ST

EE

R L

EF

T

P2

-20

P2

-19

P2

-22

P2

-23

P2

-21

LF

ST

EE

R L

EF

T

ST

EE

R S

NS

R G

ND

VA

LVE

RT

N2

LR

ST

EE

R R

IGH

T

ST

EE

R S

NS

R P

WR

RF

ST

EE

R L

EF

T

LF

ST

EE

R R

IGH

T

VLV

RE

T-B

R

V6

1A

XR

T-G

R

V6

0A

XE

X-G

R/W

H

VLV

RE

T2

-BR

V3

6R

RS

-BL

V2

9M

S-R

D/W

H

V3

7R

RS

-BL

/BK

C11

1R

RS

-OR

C11

1L

RS

-OR

C11

1R

FS

-OR

C11

1L

FS

-OR

P11

0R

T-B

K

V3

6L

RS

-BL

V3

7L

RS

-BL

/BK

V3

6R

FS

-BL

V3

2B

RK

-WH

/RD

P1

09

AN

G-G

R/W

H

V3

7R

FS

-BL

/BK

V3

6L

FS

-BL

V3

7L

FS

-BL

/BK

RR

ST

EE

R R

IGH

T

LR

ST

EE

R R

IGH

T

RF

ST

EE

R R

IGH

T

LF

ST

EE

R R

IGH

T

BK

A B

RD

BL

C

J2 WHITE 23 PINDRIVE CHASSIS HARNDRIVE CHASSIS HARN

DCON

OUT PWR ENABLE

PWR-PCON ESTOP

D82CAN+ -YL

D81CAN- -GR

P63LS-OR/RD

P53LS-WH/BK

C60AXEX-GR/WH

P57PBD-RD/WH

P21DCON-RD

GNDDCON-BR

S56PRV-RD

C61AXRT-GR










J29

J28

J27

J26

P29

P28

P27

P26

J24

J25

J20

J21

J23

P20

P23

P25

P24

P21

P2

P1

J2

J1


















J7P7

J16

J17

J18

J10

J11

P10

P11

P17

P18

P8

P16

J8

J1P1

P6

P2

J6

J2

P2

P1

J2

J1


JACK NO

J2P2

P5

P3

P4

J5

J4

J3

PLUG NO

P1 J1





P32

P33

P31

P30

J33

J32

J31

J30


PC

ON

GN

D

PC

ON

PW

R

P7

CA

N S

HIE

LD

RS

23

2_

RX

D

RS

23

2_

TX

D

BO

OT

OU

T P

WR

EN

BL

HR

N R

LY C

NT

RL

CA

N+

CA

N-

RS

23

2_

GN

D

PW

R-P

CO

N E

ST

OP


P2

2

J3 10PIN

P1


J1 10PIN

P1

P1

P1

P1

P1

P1

STA

RT

AS

SIS

T

AC

GE

NE

RA

TO

R

AU

XIL

IAR

Y

HO

RN

STA

RT

J2 10PIN

P1

P1

P1

P2

P2

P2

P2

P2

P2

EN

GIN

E S

PE

ED

AX

LE

RE

TR

AC

T

DR

IVE

EN

AB

LE

1

SP

AR

E 1

CR

AB

ST

EE

R

FR

ON

T S

TE

ER

DR

IVE

SP

EE

D

RE

AR

ST

EE

R

AX

LE

EX

TE

ND

42 3 5 6

PCON MEMBRANE PANEL

P2

P2

P2

P2

FU

EL T

YP

E

CO

OR

D S

TE

ER

7 8 10

9

SP

AR

E 2

P1

-01

P1

-02

P1

-03

P1

-04

P1

-05

P1

-06

P1

-07

P1

-08

P1

-09

P1

-11

P1

-10

P1

-12

P1

-13

P1

-14

P1

-15

P1

-20

P1

-16

P1

-17

P1

-18

P1

-19

P1

-22

P1

-21

P1

-23

P5

2P

CO

N-W

H

GN

DP

CO

N-B

R

P5

6P

RV

-RD

S5

6P

RV

-RD

/WH

C4

7O

UT

-WH

/BK

P2

3P

CO

N-B

K

D8

1C

AN

- -G

R

D8

2C

AN

+ -

YL

C4

6H

N-W

H

5

87a

871

2 86

30 4

85

3

5

87a

871

2 86

30 4

85

3

P6R

P7R

P1

-23

P1

-21

P1

-22

P1

-19

P1

-18

P1

-17

P1

-16

P1

-20

P1

-15

P1

-14

P1

-13

P1

-12

P1

-10

P1

-11

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-03

P1

-02

P1

-01

P8

7P

TS

-RD

SA

FE

PL T

ILT

PW

R

SA

FE

PL T

ILT

GN

DP

TS

RE

T-B

R

PL T

ILT

SN

SR

PW

RP

85

PT

S-G

R

PL T

ILT

SN

SR

C8

4TA

Y-G

R/B

K

PL T

ILT

SN

SR

GN

DP

LA

TR

ET-B

R

FO

OT

SW

RT

NC

56

PT

S-R

D

FO

OT

SW

PW

RR

56

PT

S-R

D

SA

FE

PL T

ILT

OU

TC

88

PT

S-R

D/B

K

LO

AD

SN

SR

PW

R

LO

AD

SN

SR

OU

T

LO

AD

SN

SR

GN

D

PR

OX

KIL

L C

MD

C9

0P

XS

-RD

/BK

PR

OX

KIL

L G

ND

R9

0P

XS

-RD

/BK

C1

5P

LD

-OR

/BK

C1

4P

LU

-OR

C4

4JD

-GR

/BK

PR

OP

VLV

2_

AC

43

JU-G

R

ON

/OF

F V

LV3

_B

C1

8P

RR

-GR

/BK

ON

/OF

F V

LV3

_A

C1

7P

RL

-GR

VLV

RT

NV

LVR

ET-B

R

PR

OP

VLV

2_

B

PR

OP

VLV

1_

A

PR

OP

VLV

1_

B

PL

AT

RO

T C

CW

PL

AT

LE

VE

L D

N

PL

AT

LE

VE

L U

P

JIB

DO

WN

JIB

UP

PL

AT

RO

T C

W21

FOOTSWITCH

U2

0

9 10

7654 8321

321 654 987 10


GR

/YL

OR

BK

ASSEMBLY

PLATFORMTILT SENSOR

6P33-PCON MANIFOLD

J31-TILT SNSR

4321 5

FU

SE

5 A

K1

K2

P23PCON-BK

P52PCON-WH

GNDPCON-BR

C46HN-WH

P56PRV-RD

S56PRV-RD/WH

C47OUT-WH/BK

D82CAN+ -YL

D81CAN- -GR

GR

J8

J7

2

4

3

6

5

2

BL

YL

BR

OR

RD1

BK

WH1

2

6

5

4

3

2

1P7-LIMIT SW HARN

1P8-LIMIT SW HARN

P6R1

DCON PWR

DCON GND

P18

P11

P12

P9A

P7RWH

BK22

1P18

1

GR

YL

BL

66

5

44

5

P17

OR

BR

RD2 2

33

11

CCCAN SHIELD

B B

AP16

AYEL

GR

CAN HIGH

CAN LOWCC

B

A

B

AYEL

GR

P6-BOOM HARNJ6

(SLIP RING)

(SLIP RING)

D81CAN- -GR

D82CAN+ -YL

P57PBD-RD/WH

P21DCON-RD

C60AXEX-GR/WH

P53LS-WH/BK

P63LS-OR/RD

GNDDCON-BR

S56PRV-RD

C61AXRT-GR

PCON

PL

AT

SE

NS

OR

GN

D

TIL

T S

EN

SO

R S

IG O

UT

TIL

T S

EN

SO

R P

WR

TIL

T S

WIT

CH

GN

D

PW

R T

O T

ILT

SW

ITC

H

OU

T F

RM

TIL

T S

WIT

CH

LOAD SENSOR OPTION

88

88

88

88

88

88

88

88

88

88

88

Genie S-100/105(from serial number 810)

Genie S-120/125(from serial number 2710)

Electrical SchematicES0509C


NOT USED

61 2 3 4 5


JOYSTICK

P1

H1

_Y

OU

T

H1

_G

ND

H1

_X

OU

T

H1

_P

WR

P2

6532 41

JOYSTICK

BOOM EXT/RET

H2

_Y

OU

T

H2

_G

ND

H2

_P

WR

H3

_G

ND

H3

_P

WR

H3

_Y

OU

T41 2

P3

3 5 6 1P

4

6532 4

DRIVE & STEERINGJOYSTICK

H4

_G

ND

H4

_R

KO

UT

NO

T U

SE

D

H4

_X

OU

T

H4

_Y

OU

T

H4

_P

WR

TO HORN BUTTON

OUT PWR ENABLE

PWR TO TCON ESTOP

P_7

TCON MODE

P7R

P_22

P6R1

PCON POWER

P11

OP

ER

. R

EC

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ER

V.

OR

PLD

P1

5

S56PRV-RD

GNDDCON-BR


TO

MIC

RO

P1

5

P1

-23

P1

-22

P1

-21

P1

-20

BOOM HARNJ1 BLACK 23 PIN

TE

T E

ST

OP

RE

T

CA

N H

IGH

RS

23

2 G

ND

CA

N L

OW

NO

T U

SE

D

TE

T E

ST

OP

PW

R

LO

AD

SE

NS

OR

IN

PU

T

RS

23

2 T

XD

RS

23

2 R

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CA

N S

HIE

LD

FL

AS

HIN

G B

EA

CO

N

BO

OT

P1

-18

P1

-19

P1

-17

P1

-15

P1

-16

P1

-12

P1

-13

P1

-11

P1

-10

P1

-09

P1

-14

P_

7

P_

22

WO

RK

LT

PW

R-P

CO

N E

ST

OP

OU

T P

WR

EN

BL

TCON

PC

ON

GN

D

PC

ON

PO

WE

R

HO

RN

RE

LA

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OIL

P1

-07

P1

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P1

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P1

-05

P1

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P1

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P1

-02

P1

-03

D8

2C

AN

+ -

YL

D8

1C

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P9

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P2

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CO

N-B

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GN

DP

CO

N-B

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P5

2P

CO

N-W

H

C4

6H

N-W

H

C4

7O

UT

-WH

/BK

S5

6P

RV

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/WH

P5

6P

RV

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R4

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R11

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B-R

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P9

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ET-O

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J27-BOOM HARN







BM

DW

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PR

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GR

PK

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YL

BL

PR

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BR

WT

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OR

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PCON

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RUN

RECOVERY

SERV. BYPASS

1235 468 7910

P7

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P6

R1

P2

2

12

13

14

15

16

P7

P11

AL

AR

M P

WR

AL

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M G

ND

11O

PE

R.

RE

C.

RD

BK

LT B

L

YL

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PR GR

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TP

UT

PW

R E

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RV

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MO

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TC

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5 AF

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P21DCON-RD

C61AXRT-GR

P63LS-OR/RD

P57PBD-RD/WH

P53LS-WH/BK

C60AXEX-GR/WH

12 VOLT

TO FLASHING BEACON

TO WORK LIGHTS30

85

87

86

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30

85

87

86

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RV

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VLV

RE

T

LS

B4

EO

LS

B1

3A

O

LS

B1

4A

O

PR

I#1

LO

PR

I#2

LO

SN

SR

GN

D

AU

X H

YD

PR

ES

S S

IG

LS

B2

RO

LS

B3

RO

LS

B3

EO

FS

T1

S

LS

T1

0

LS

B1

DO

P_

14

P_

11

P_

12

P_

18

P_

9A

P_

7R

P_

6R

2

P_

9B

P_

10

OP

ER

SW

PW

R

DC

ON

EC

U G

ND

DC

ON

EC

U P

WR

P_

6R

1

TO

MIC

RO

TO

PL

D

TO

MIC

RO







1

2

3

4

5

6

7

8

9

10

11

12

13


2 WAY DEUTSCH LOAD SENSE LIMIT SWITCH TO BOOM HARNP157 J157

FU

SE

3-1

0A

C6

5L

OF

L-B

L/W

H

C6

4L

S-O

R/B

K

C6

6D

RE

N-B

L

C6

4L

S-O

R/B

K

1 213 2 4 42

C6

4L

S-O

R/B

K

P5

6P

RV

-RD

2 4 3 1

P

3 4 13

SJ3

-WH

C6

8P

BD

-BL

S6

2B

ST

O-O

RN

P5

3L

S-W

H/B

K

C6

0A

XE

X-G

N/W

H

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

C7

7A

S-W

H

3 1 24

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

P5

7P

BD

-RD

/WH

J2012 WAY

P2012 WAY

8 9 10 11 12

S5

6P

RV

-RD

SJ3

-WH

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

K

P5

7P

BD

-RD

/WH

13 4213 2 4

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

S6

2B

ST

O-O

R

C6

1A

XR

T-G

N

P5

7P

BD

-RD

/WH

P5

7P

BD

-RD

/WH

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

C7

0P

BE

-BL

/WH

P6

3L

S-O

R/R

D

SJ3

-WH

3 4 5 6 78 1 2

C6

1A

XR

T-G

N

S6

2B

ST

O-O

R

P6

3L

S-O

R/R

D

C7

0P

BE

-BL

/WH

P5

4E

NG

-BK

/WH

P5

3L

S-W

H/B

K

3 4 5 61 2J218 WAY

P218 WAY

P5

8L

S-R

D/B

K

7

P56PRV-RD

2 43 1

C6

4L

S-O

R/B

K

C7

1P

BE

-BL

/BK

431 2

PRESSURE SENSOR

OPTIONAL HYDRAULIC

C7

7A

S-W

H

SN

SR

GN

D-B

R

G11

9S

R-B

L

P5

7P

BD

-RD

/WH

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

S5

9C

NB

K-G

R/W

H

C6

0A

XE

X-G

R/W

H

C6

1A

XR

T-G

R

C6

8P

BD

-RD

C6

5L

OF

L-B

L/W

H

C6

6D

RE

N-B

L

C7

0P

BE

-BL

/WH

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

L

P6

3L

S-O

R/R

D

S6

2B

ST

O-O

R

S5

6P

RV

-RD

GN

DD

CO

N-B

R

P2

1D

CO

N-R

D

P5

3L

S-W

H/B

K

13 2 4

LS

B3R

O3' E

XT

LS

B3R

S

3.5

EX

T

LS

B4E

S

75.5

'

LS

B6S

C

HN

BR

K

LS

B3E

O

75' E

XT

LS

B8A

S50 D

EG

LS

B13A

O53 D

EG

LS

B7D

S11

DE

G

LS

B1D

O10 D

EG

LS

T1O

DR

VE

NA

BLE

FS

T1S

LO

WF

UE

L F

S

J2 BLACK 35 PINLIMIT SWITCH HARNESSP

2-3

3

P2

-32

P2

-34

P2

-35

P2

-23

P2

-28

P2

-24

P2

-25

P2

-27

P2

-26

P2

-29

P2

-30

P2

-31

P2

-16

P2

-14

P2

-15

P2

-17

P2

-18

P2

-19

P2

-20

P2

-22

P2

-21

P2

-06

P2

-05

P2

-04

P2

-07

P2

-08

P2

-11

P2

-09

P2

-10

P2

-12

P2

-13

P2

-01

P2

-02

P2

-03

LIMIT SWITCHESS-100/105

5 6

S7

PL

E1

-BL

/BK

S2

PL

D1

-BL

/RD

3 1 245 6

S2

PL

D1

-BL

/RD

P5

3L

S-W

H/B

K

3 1 42

BK

RD

WH

P1

-15

SA

FE

PL T

ILT

OU

T

P1

-16

FO

OT

SW

PW

R

3 1 42

PROXKILL

FOOTSWITCH

OPTIONAL PROXIMITY KILL WIRING

R5

6P

TS

-RD

C5

6P

TS

-RD

21

J157P157S132LDS-BL/WH

S132LDS-BL/WH

S1

32

LD

S-B

L/W

H

K6 K1

K4

K8

K5 K2

K7

K3

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87

86 30

85 87a87


K1 POWERS CKT P22R OR CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE)K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD, VALVES AUX RELAY, BOOM EXT/RET, TURNTABLE ROTATE VLV.K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WHK4 POWERS CIRCUIT P_6R1 OR VALVES: PRIMARY VALVES 1 & 2, THROTTLE (IGN), GLOW PLUG, STARTER RELAY, AC GENERATOR, BOOM RETRACT, MULTIFUNCTION VALVE, ROTATE CW, AND ROTATE CCW.K5 POWERS CIRCUIT P_7 AND THROTTLE RELAYK6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD. (FUEL ON/OFF SOLENOID AND ALT FIELD)K7 POWERS THROTTLE OR HI/LOW SOLENOID (CKT C35RPM-BK/RD)K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)

PROX KILL SW.

OPTIONAL







TO

PL

D

TO

MIC

RO

TO

PL

D

TO

PL

D

TO

MIC

RO

TO

PL

D

TO

MIC

RO

TO

MIC

RO

TO

PL

D

TO

PL

D

R4

9L

P -

WH

/BK

DR

IVE

LIG

HT

S R

EL

AY

TO

MIC

RO

TO

MIC

RO

VA

LVE

_R

TN

6

AU

X_

RE

LA

Y

VA

LVE

_R

TN

7

RO

TA

TE

_C

W_

VLV

MU

LTI_

FU

NC

T_

VLV

RO

TA

TE

_C

CW

_V

LV

TO DRIVELAMPS

12 VOLT

P4

-20

P4

-21

P4

-22

P4

-25

P4

-24

P4

-23

P4

-26

P4

-27

P4

-30

P4

-28

P4

-29

P4

-31

P4

-32

P4

-35

P4

-33

P4

-34

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

LS

B2

RS

MO

NIT

OR

IN

PU

T

LS

B9

AS

MO

NIT

OR

IN

PU

T

VA

LVE

_R

TN

4

BO

OM

_E

XT

/RE

T_

VLV

BO

OM

_U

P/D

OW

N_

VLV

BO

OM

_D

OW

N_

VLV

TU

RN

TA

BL

E_

RO

TA

TE

_V

LV

BO

OM

_U

P_

VLV

BO

OM

_E

XT

EN

D_

VLV

BO

OM

_R

ET

RA

CT

_V

LV

J4 WHITE 35 PIN

S2

PL

D2

-GR

/BK

S7

PL

E1

-BL

/BK

S2

PL

D1

-BL

/RD

P4

-03

P4

-02

P4

-01

P4

-13

P4

-08

P4

-04

P4

-05

P4

-06

P4

-07

P4

-09

P4

-10

P4

-11

P4

-12

P4

-14

P4

-15

P4

-16

P4

-17

P4

-18

MANIFOLD HARN

TO

MIC

RO

P4

-19

VA

LVE

RT

N7

VA

LVE

RT

N6

C2

7A

UX

-RD

C11

3M

FV

-OR

/RD

C0

5T

TL

-WH

C0

6T

TR

-WH

/BK

TO

AU

X H

YD

RE

LA

Y P

R1

TU

RN

TA

BL

E R

OT

CC

W V

LV

TU

RN

TA

BL

E R

OT

CW

VLV

MU

LTI

FU

NC

VLV

C0

6T

RF

-WH

/RD

VLV

RE

T4

-BR

C0

3P

BF

-RD

/WH

C0

9P

ER

F-B

K/R

D

C0

8P

BR

-BK

/WH

C0

7P

BE

-BK

C0

2P

BD

-RD

/BK

C0

1P

BU

-RD

P P P

BO

OM

RE

T V

LV

BO

OM

EX

T/R

ET

F.C

.

BO

OM

UP

VLV

BO

OM

EX

TE

ND

VLV

BO

OM

DW

N V

LV

BO

OM

UP

/DW

N F

.C.

TU

RN

TA

BL

E C

W/C

CW

F.C

.

5

87a

87

1

2 86

30 4

85

3

TO

MIC

RO

TCON MEMBRANE PANEL

JIB

DO

WN

PLT

FR

M C

W

BO

OM

CW

PLT

FR

M C

CW

JIB

UP

PLT

FR

M D

OW

N

PLT

FR

M U

P

34 2 19 8 7 6 5

SE

C.

DO

WN

BO

OM

EX

T

RA

BB

IT

TU

RT

LE

RO

OM

RE

T

BO

OM

DO

WN

14

13

12

11 10

1 P11

15

BO

OM

UP

EN

G S

PE

ED

+ B

UT

TO

N

GA

S/L

P

AU

XIL

IAR

Y

SE

C.

UP

6 5 4 3 210

9 8 7

J11

ST

RT

AS

ST

SC

RO

LL R

SC

RL F

/EN

T

- B

UT

TO

N

STA

RT

15

14

1113

12P10

J10

BO

OM

CC

W

TCON

ES0509C

S7

PL

E2

-GR

/WH

LS

B8

RS

MO

NIT

OR

IN

PU

T

LS

B4

ES

MO

NIT

OR

IN

PU

T

S7

PL

E1

-BL

/BK

S2

PL

D1

-BL

/RD

431 2

P2

34

WA

YJ2

34

WA

Y

S7PLE2-GR/WH

S7PLE1-BL/BK

FU

SE

3-1

0A

J2 BLACK 35 PINLIMIT SWITCH HARNESS

C6

5L

OF

L-B

L/W

H

C6

4L

S-O

R/B

K

C6

6D

RE

N-B

L

C6

4L

S-O

R/B

K

1 213 2 4

P27

42

C6

4L

S-O

R/B

K

P5

6P

RV

-RD

2 4 3 1

P

4

P

3 4 13

SJ3

-WH

C6

8P

BD

-BL

S6

2B

ST

O-O

R

P5

3L

S-W

H/B

K

C6

0A

XE

X-G

N/W

H

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

C7

7A

S-W

H

C6

4L

S-O

R/B

K

SJ1

-WH

/RD

SJ2

-BK

/RD

P5

8L

S-R

D/B

K

P5

7P

BD

-RD

/WH

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

SJ2

-BK

/RD

SJ1

-WH

/RD

J2012 WAY

P2012 WAY

8 9 10 11 12

S5

6P

RV

-RD

SJ3

-WH

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

K

P5

7P

BD

-RD

/WH

C7

8A

S-W

H/B

K

3

VLV

RE

T1

-BR

PR

I 1

LO

PR

I 2

LO

13 4213 2 4

S5

6P

RV

-RD

C6

4L

S-O

R/B

K

S6

2B

ST

O-O

R

C6

1A

XR

T-G

N

P5

7P

BD

-RD

/WH

P5

7P

BD

-RD

/WH

SJ1

-WH

/RD

SJ2

-BK

/RD

P5

8L

S-R

D/B

K

C7

0P

BE

-BL

/WH

P6

3L

S-O

R/R

D

SJ3

-WH

V7

5P

RL

O-R

D/W

H

V7

4P

RL

O-R

D

3 4 5 6 78 1 2

C6

1A

XR

T-G

N

S6

2B

ST

O-O

R

P6

3L

S-O

R/R

D

C7

0P

BE

-BL

/WH

C7

6P

BE

-BL

SJ2

-BK

/RD

SJ1

-WH

/RD

3 4 5 61 2J218 WAY

P218 WAY

S5

9C

NB

K-G

N/W

H

C6

9P

BE

-BK

P5

4E

NG

-BK

/WH

P5

3L

S-W

H/B

K

P5

8L

S-R

D/B

K

7

P56PRV-RD

43J264 WAY1

P264 WAY

2

2 43 1

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

C7

1P

BE

-BL

/BK

C7

6P

BE

-BL

SJ1

-WH

/RD

C6

9P

BE

-BK

SJ2

-BK

/RD

P5

4E

NG

-BK

/WH

P6

3L

S

S5

9C

NB

K

P5

3L

S-W

H/B

K


OPTIONAL HYDRAULIC

P2

-33

P2

-32

P2

-34

P2

-35

P2

-23

P2

-28

P2

-24

P2

-25

P2

-27

P2

-26

P2

-29

P2

-30

P2

-31

V7

4P

RL

O-R

D

VLV

RE

T1

-BR

C7

6P

BE

-BL

C7

7A

S-W

H

C7

8P

S-W

H/B

K

V7

5P

RL

O-R

D/W

H

SN

SR

GN

D-B

R

G11

9S

R-B

L

P2

-16

P2

-14

P2

-15

P2

-17

P2

-18

P2

-19

P2

-20

P2

-22

P2

-21

P2

-06

P2

-05

P2

-04

P2

-07

P2

-08

P2

-11

P2

-09

P2

-10

P2

-12

P2

-13

P5

7P

BD

-RD

/WH

P5

4E

NG

-BK

/WH

P5

8L

S-R

D/B

K

S5

9C

NB

K-G

R/W

H

C6

0A

XE

X-G

R/W

H

C6

1A

XR

T-G

R

C6

8P

BD

-RD

C6

5L

OF

L-B

L/W

H

C6

6D

RE

N-B

L

C7

0P

BE

-BL

/WH

C6

9P

BE

-BK

C7

1P

BE

-BL

/BK

C6

4L

S-O

R/B

L

P6

3L

S-O

R/R

D

S6

2B

ST

O-O

R

S5

6P

RV

-RD

P2

-01

P2

-02

P2

-03

GN

DD

CO

N-B

R

P2

1D

CO

N-R

D

P5

3L

S-W

H/B

K

13 2 413 2 413 2 4

LS

B3R

O3' E

XT

LS

B3R

S

3.5

EX

T

LS

B4E

S

75.5

'

LS

B6S

C

HN

BR

K

LS

B4E

O

100' E

XT

LS

B3E

O

75' E

XT

LS

B2R

S

101' LS

B2R

O

100'

LS

B8A

S50 D

EG

LS

B9A

S65 D

EG

LS

B14A

O68 D

EG

LS

B13A

O53 D

EG

LS

B7D

S11

DE

G

LS

B1D

O10 D

EG

LS

T1O

DR

VE

NA

BLE

FS

T1S

LO

WF

UE

L F

S

LIMIT SWITCHESS-120/125

3 1 245 6

3 1 245 6

S7

PL

E1

-BL

/BK

3 1 245 6

P5

3L

S-W

H/B

K

S7

PL

E2

-GR

/WH

P5

3L

S-W

H/B

K

S2

PL

D2

-GR

/BK

S2

PL

D1

-BL

/RD

S2

PL

D2

-GR

/BK

P5

3L

S-W

H/B

K

3 1 245 6

P5

3L

S-W

H/B

K

S2

PL

D1

-BL

/RD

GL

OW

PL

UG

WH-PULL

BR-COM

RD-HOLD

+AUX

+BAT


25

A

CB

4.5 DEGREETURNTABLE TILTSENSOR

RD

WH

BK

C83TAX-GR/WH

C84TAY-GR/BK

P85TTSR-GR

RET85TTSR-BR

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

C2

5P

SR

-WH

/BK

C2

6T

SR

-WH

/RD

R2

1IG

N-W

H

FUELSOLENOIDRELAY

BA

T G

ND

-BR

BA

T G

ND

-BR

P3

1-E

NG

H

AR

N

J31

-TIL

T

SN

SR

OIL

/WA

TE

R_

TE

MP

P3

-21

P3

-22

P3

-23

P3

-18

P3

-19

P3

-20

P3

-17

P3

-16

P3

-14

P3

-13

P3

-15

VA

LVE

_R

TN

3

ALT

_F

IEL

D_

WIR

E

TT

_T

ILT

_X

_A

XIS

AC

_G

EN

ER

AT

OR

TT

_T

ILT

_Y

_A

XIS

VA

LVE

_R

TN

2

TT

_T

ILT

_S

NS

R_

GN

D

TT

_T

ILT

_S

NS

R_

PW

R

ALT

EN

AT

OR

_R

PM

45

85

87

12

86

K8

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BAT.+

IND.

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EXCT.

AUX.PUMP

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RELAY ADDEDS100- S/N 865S120- S/N 2782

SEE GENERATOR OPTIONS

S2PLD2-GR/BK

S2PLD1-BL/RD

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PL

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PL

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Dis

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Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie ChinaPhone +86 21 53852570

Fax +86 21 53852569

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Fax +81 3 3453 6083

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Fax +31 183 581 566

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Fax +46 31 579020

Genie FrancePhone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Genie IbericaPhone +34 93 579 5042

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Genie GermanyPhone +49 (0)4202 88520

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Fax +52 55 5666 3241

California Proposition 65

WarningThe exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

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