Service Manual

Service Manual
Serial Number Range
S-100
S-105
from S100/105-136
to S10012/S10512-941
S-120
S-125
from S120/125-404
to S12012/S12512-3399
from S10011D-114
to S10015D-1000
from S10511D-133
to S10515D-1011
from S12011D-113
to S12015D-1011
from S12511D-134
to S12515D-983
Part No. 102916
Rev F
2FWRber 2015
October 2015
Introduction
Introduction
Important
Technical Publications
Read, understand and obey the safety rules and
operating instructions in the Genie S-100 and
Genie S-105 Operator's Manual or the Genie
S-120 and Genie S-125 Operator's Manual before
attempting any maintenance or repair procedure.
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills,
tools, lifting equipment and a suitable workshop.
In these instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Find a Manual for this Model
Go to http://www.genielift.com
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Use the links to locate Operator's, Parts or Service
Manuals.
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2001 by Terex Corporation
102916 Rev F September 2015
Second Edition, Sixth Printing
Genie is a registered trademark of Terex South Dakota, Inc.in
the U.S.A and many other countries.
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Part No. 102916
October 2015
INTRODUCTION
Serial Number Legend
Model: S-120
S12006-12345
Serial number:
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: Es0427
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg
Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 126 ft/ 38.6 m
Maximum platform reach : 75 ft/ 22.9 m
Gradeability: N/A
S120 06
D - 12345
Model
Country of manufacture: USA
This machine complies with:
ANSI A92.5
CAN B.354.4
Sequence
number
Model year
Facility code
(used only for model manufactured
in multiple facilities)
Terex South Dakota
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201
USA
Serial number
stamped on chassis
Part No. 102916
S-100 • S-105 • S-120 • S-125
Serial label
(located under cover)
iii
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This page intentionally left blank.
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Part No. 102916
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Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-100 & Genie S-105
Operator's Manual or the Genie S-120 & Genie
S-125 Operator's Manual will result in death or
serious injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 102916
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Section 1 - Safety Rules
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This manual and
the decals on the machine, use signal words to
identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of
a potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Used to indicate the presence of
a potentially hazardous situation
which, if not avoided, may result in
property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
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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
Specifications
Machine Specifications, S120 and S-125 Models....................................................2 - 1
Performance Specifications, S120 and S-125 Models.............................................2 - 2
Machine Specifications, S100 and S-105 Models....................................................2 - 3
Performance Specifications, S100 and S-105 Models.............................................2 - 5
Hydraulic Specifications...........................................................................................2 - 6
Hydraulic Component Specifications.......................................................................2 - 8
Deutz Engine F4L 913 Specifications....................................................................2 - 11
Deutz Engine BF4L 2011 Specifications................................................................2 - 12
Deutz Engine TD2011L04i Specifications..............................................................2 - 13
Deutz Engine TD 2.9 Specifications......................................................................2 - 14
Perkins Engine 1104D-44T Specifications.............................................................2 - 15
Perkins Engine 854F-34T Specifications...............................................................2 - 16
Perkins Engine 1004-42 Specifications.................................................................2 - 18
Perkins Engine 1104C-44 Specifications...............................................................2 - 19
Perkins Engine 804D-33T Specifications...............................................................2 - 20
Cummins Engine B3.3T Specifications..................................................................2 - 22
Cummins Engine B3.9L Specifications..................................................................2 - 23
Cummins Engine B4.5L Specifications..................................................................2 - 24
Machine Torque Specifications..............................................................................2 - 25
Manifold Plug Torque Specifications......................................................................2 - 25
Hydraulic Hose and Fitting Torque Specifications.................................................2 - 26
SAE and Metric Fasteners Torque Charts.............................................................2 - 26
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TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures
Introduction..............................................................................................................3 - 1
Pre-delivery Preparation..........................................................................................3 - 3
Maintenance Inspection Report...............................................................................3 - 5
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 - Deutz Models................................................3 - 9
A-6 Perform Engine Maintenance - Cummins Models........................................3 - 10
A-7 Check the Hydraulic Filter Condition Indicators...........................................3 - 10
A-8 Perform 30 Day Service...............................................................................3 - 12
A-9 Perform Engine Maintenance - Perkins Models...........................................3 - 12
A-10 Perform Engine Maintenance - Deutz Models..............................................3 - 13
A-11 Grease the Turntable Rotation Bearing and Rotate Gear............................3 - 14
A-12 Grease the Extendable Axles.......................................................................3 - 15
A-13 Replace the Drive Hub Oil............................................................................3 - 15
Checklist B Procedures
B-1 Inspect the Batteries.....................................................................................3 - 18
B-2 Inspect the Electrical Wiring.........................................................................3 - 19
B-3 Check the Engine Oil Cooler and Cooling Fins - Deutz Models...................3 - 21
B-4 Inspect the Engine Air Filter.........................................................................3 - 22
B-5 Perform Hydaulic Oil Analysis......................................................................3 - 23
B-6 Perform Engine Maintenance - Deutz Models..............................................3 - 23
B-7 Perform Engine Maintenance - Cummins Models........................................3 - 24
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TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued
Checklist B Procedures
B-8 Check the Exhaust System..........................................................................3 - 25
B-9 Inspect the Tires, Wheels and Lug Nut Torque............................................3 - 26
B-10 Check the Dirve Hub Oil Level and Fastener Torque...................................3 - 26
B-11 Confirm the Proper Brake Configuration......................................................3 - 28
B-12 Check and Adjust the Engine RPM..............................................................3 - 29
B-13 Test the Key Switches..................................................................................3 - 32
B-14 Test the Ground Control Override................................................................3 - 33
B-15 Test the Platform Self-leveling.....................................................................3 - 34
B-16 Test the Safety Envelope and Circuits.........................................................3 - 35
B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems........................3 - 41
B-18 Test the Engine Idle Select Operation..........................................................3 - 42
B-19 Test the Drive Brakes...................................................................................3 - 43
B-20 Test the Drive Speed - Stowed Position.......................................................3 - 43
B-21 Test the Drive Speed - Raised or Extended Position...................................3 - 44
B-22 Inspect the Boom Extend/Retract Cables....................................................3 - 45
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models..............................................3 - 46
C-2 Perform Engine Maintenance - Cummins Models........................................3 - 46
C-3 Perform Engine Maintenance - Perkins Models...........................................3 - 47
C-4 Perform Engine Maintenance - Perkins Models...........................................3 - 47
C-5 Replace the Engine Air Filter Element.........................................................3 - 48
C-6 Grease the Platform Overload Mechanism (if equipped).............................3 - 48
C-7 Test the Platform Overload System (if equipped)........................................3 - 49
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TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1 Check the Boom Wear Pads........................................................................3 - 51
D-2 Check the Extendable Axle Wear Pads.......................................................3 - 52
D-3 Check the Free-wheel Configuration............................................................3 - 53
D-4 Check the Turntable Rotation Bearing Bolts................................................3 - 54
D-5 Check the Turntable Rotation Gear Backlash..............................................3 - 55
D-6 Replace the Drive Hub Oil............................................................................3 - 57
D-7 Inspect for Turntable Bearing Wear.............................................................3 - 59
D-8 Perform Engine Maintenance - Deutz Models..............................................3 - 60
D-9 Perform Engine Maintenance - Perkins Models...........................................3 - 60
D-10 Perform Engine Maintenance - Perkins Models...........................................3 - 61
D-11 Perform Engine Maintenance - Cummins Models........................................3 - 61
D-12 Replace the Hydraulic Filter Elements.........................................................3 - 62
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil.................................................................3 - 64
E-2 Perform Engine Maintenance - Cummins Models........................................3 - 66
E-3 Perform Engine Maintenance - Perkins Models...........................................3 - 66
E-4 Perform Engine Maintenance - Deutz Models..............................................3 - 67
E-5 Perform Engine Maintenance - Perkins Models...........................................3 - 67
E-6 Perform Engine Maintenance - Deutz Models..............................................3 - 68
E-7 Perform Engine Maintenance - Perkins Models...........................................3 - 68
E-8 Perform Engine Maintenance - Deutz Models..............................................3 - 69
E-9 Perform Engine Maintenance - Perkins Models...........................................3 - 69
E-10 Replace the Boom Extend/Retract Cables...................................................3 - 70
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TABLE OF CONTENTS
Section 4
Repair Procedures
Introduction..............................................................................................................4 - 1
Display Module........................................................................................................4 - 2
Platform Controls
1-1 Circuit Boards.................................................................................................4 - 7
1-2 Membrane Decal............................................................................................4 - 8
1-3 Joystick Controllers........................................................................................4 - 9
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
2-6
Platform Overload Recovery Message (Software V3.14 and later)..............4 - 25
Jib Boom Components, S-105 and S-125 Models
3-1 Jib Boom, S-105 and S-125 Models.............................................................4 - 26
3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models.........................................4 - 28
Boom Components
4-1 Cable Track..................................................................................................4 - 30
4-2 Boom............................................................................................................4 - 33
4-3 Boom Lift Cylinder........................................................................................4 - 44
4-4 Extension Cylinders......................................................................................4 - 46
4-5 Boom Extend/Retract Cables.......................................................................4 - 50
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TABLE OF CONTENTS
Section 4
Repair Procedures, continued
Turntable Covers
5-1 Turntable Covers..........................................................................................4 - 54
Engines
6-1 RPM Adjustment..........................................................................................4 - 56
6-2 Flex Plate.....................................................................................................4 - 56
6-3 Oil Pressure and Coolant Temperature Sending Units,
Cummins and Perkins Models......................................................................4 - 58
6-4 Oil Pressure and Temperature Sending Units, Deutz Models......................4 - 58
Ground Controls
7-1 Circuit Boards...............................................................................................4 - 59
7-2 Membrane Decal..........................................................................................4 - 60
7-3 Control Relays..............................................................................................4 - 61
Limit Switches
8-1 Limit Switches..............................................................................................4 - 64
8-2 Limit Switch and Level Sensor Locations.....................................................4 - 67
8-3 Limit Switch Functions..................................................................................4 - 68
Hydraulic Pumps
9-1 Function Pumps...........................................................................................4 - 71
9-2 Drive Pump...................................................................................................4 - 72
9-3 Auxiliary Pump.............................................................................................4 - 75
Manifolds
10-1 Function Manifold Components, S-100 and S-105 Models
(serial number 136)......................................................................................4 - 77
10-2 Function Manifold Components, S-100 and S-105 Models
(after serial number 136)..............................................................................4 - 81
10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models..............4 - 85
10-4 Proportional Valves - Function Manifold.......................................................4 - 86
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TABLE OF CONTENTS
Section 4
Repair Procedures, continued
10-5 Function Manifold Components, S-120 and S-125 Models
(before serial number 431)...........................................................................4 - 87
10-6 Function Manifold Components, S-120 and S-125 Models
(from serial number 431 to 574)...................................................................4 - 91
10-7 Function Manifold Components, S-120 and S-125 Models
(after serial number 574)..............................................................................4 - 95
10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models..............4 - 99
10-9 Proportional Valves - Function Manifold.....................................................4 - 100
10-10Platform Manifold Components, S-100 and S-120 Models........................4 - 101
10-11Platform Manifold Components, S-105 and S-125 Models........................4 - 103
10-12Proportional Valves - Platform Manifolds...................................................4 - 105
10-13Platform Rotate Counterbalance Valve Manifold Components..................4 - 105
10-14Turntable Rotation Manifold Components..................................................4 - 106
10-15Steer and Axle Extend/Retract Manifold Components - View 1.................4 - 107
10-16Steer and Axle Extend/Retract Manifold Components - View 2.................4 - 109
10-17Valve Adjustments - Steer and Axle Extend/Retract Manifold...................4 - 113
10-18Traction Manifold Components
(S-100/105 before serial number 291)
(S-120/125 before serial number 1195).....................................................4 - 115
10-19Traction Manifold Components
(S-100/105 after serial number 290)
(S-120/125 after serial number 1194)........................................................4 - 119
10-20Valve Adjustments - Traction Manifold.......................................................4 - 123
10-21Valve Coils.................................................................................................4 - 123
Fuel and Hydraulic Tanks
11-1 Fuel Tank...................................................................................................4 - 126
11-2 Hydraulic Tank...........................................................................................4 - 127
Turntable Rotation Components
12-1 Turntable Rotation Hydraulic Motor and Drive Hub....................................4 - 129
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TABLE OF CONTENTS
Section 4
Repair Procedures, continued
Axle Components
13-1 Steer Sensors.............................................................................................4 - 133
13-2 Yoke and Hub.............................................................................................4 - 135
13-3 Drive Motor.................................................................................................4 - 137
13-4 Drive Hub...................................................................................................4 - 138
13-5 Steering Cylinders......................................................................................4 - 139
13-6 Extendable Axles........................................................................................4 - 140
Section 5
Diagnostic Codes
Introduction..............................................................................................................5 - 1
Diagnostic Code Chart.............................................................................................5 - 3
Control System Fault Codes....................................................................................5 - 9
Deutz TD 2.9 L4 Engine Fault Codes....................................................................5 - 13
Perkins 854F-34T Engine Fault Code....................................................................5 - 28
Software.................................................................................................................5 - 37
Section 6
Schematics
Introduction..............................................................................................................6 - 1
Circuit Numbering....................................................................................................6 - 2
Wire Color Legend...................................................................................................6 - 4
Limit Switches..........................................................................................................6 - 8
Relay Layout..........................................................................................................6 - 10
Drive Chassis Controller Pin Legend.....................................................................6 - 11
Platform Controller Pin Legend..............................................................................6 - 12
Turntable Controller Pin Legend............................................................................6 - 13
Engine Relay and Fuse Panel Legend Deutz TD2011 and Perkins 1104D Models..................................................6 - 14
Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models..............................6 - 15
Engine Relay and Fuse Panel Legend - Perkins 854F Models.............................6 - 16
Telematics Connector Pin Legend.........................................................................6 - 17
Electrical Symbols Legend.....................................................................................6 - 18
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TABLE OF CONTENTS
Section 6
Schematics
Hydraulic Symbols Legend....................................................................................6 - 19
Safety Circuit Schematic........................................................................................6 - 21
Engine Options- Perkins and Cummins
(S-100/105 before serial number 219)
(S-120/125 before serial number 933).........................................................6 - 23
Engine Options- Perkins
(S-100/105 from serial number 219 to 247)
(S-120/125 from serial number 933 to 984).................................................6 - 25
Engine Options- Perkins
(S-100/105 from serial number 248)
(S-120/125 from serial number 985)............................................................6 - 27
Engine Options- Perkins
(S-100/105/120/125 from serial number 874)..............................................6 - 29
Engine Options- Cummins
(S-100/105 from serial number 219 to 247)
(S-120/125 from serial number 933 to 984).................................................6 - 31
Engine Options- Cummins
(S-100/105 from serial number 248)
(S-120/125 from serial number 985)............................................................6 - 33
Electrical Schematic - Generator Options..............................................................6 - 35
Electrical Schematic - 12 kW Generator (welder option).......................................6 - 37
Electrical Schematic (ES105C, ES125G)
(S-100/105 before serial number 231)
(S-120/125 before serial number 921)...........................located at end of manual
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
Electrical Schematic (ES0509)
(S100/105 from serial number 810)
(S120/125 from serial number 2710)..............................located at end of manual
Perkins 1104D-44T Engine Electrical Schematic..................................................6 - 39
Perkins 854F-34T Engine Electrical Schematic.....................................................6 - 41
Perkins 854F-34T Engine Electrical Harness........................................................6 - 43
Deutz TD2.9 Engine Electrical Schematic.............................................................6 - 45
Part No. 102916
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TABLE OF CONTENTS
Section 6
Schematics,continued
Deutz TD2.9 Engine Electrical Harness.................................................................6 - 47
Hydraulic Schematic - 12 kW Generator (welder option)......................................6 - 49
Hydraulic Schematic, S-100 • S-105
(serial number 136)......................................................................................6 - 51
Hydraulic Schematic, S-100 • S-105
(from serial number 137 to 290)...................................................................6 - 53
Hydraulic Schematic, S-100 • S-105
(from serial number 291 to serial number 738)............................................6 - 55
Hydraulic Schematic, S-100 • S-105
(from serial number 739).6 - 57
Hydraulic Schematic, S-120 • S-125
(from serial number 404 to serial number 430)............................................6 - 59
Hydraulic Schematic, S-120 • S-125
(from serial number 431 to serial number 1194)..........................................6 - 61
Hydraulic Schematic, S-120 • S-125
(from serial number 1195 to serial number 2634)........................................6 - 63
Hydraulic Schematic, S-120 • S-125
(from serial number 2635 to serial number 3145)........................................6 - 65
Hydraulic Schematic, S-120 • S-125
(from serial number 3146 to serial number S12514D-921)..........................6 - 67
Hydraulic Schematic, S-120 • S-125
(from serial number S12514D-921)..............................................................6 - 69
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Section 2 • Specifications
Specifications
Machine Specifications,
S-120 and S-125 Models
Stowed dimensions
Turning radius, inside, axles retracted
S-120
S-125
39 ft 11 in
12.17 m
39 ft 11 in
12.17 m
42 ft 8 in
13 m
46 ft 9 in
14.25 m
Width, axles retracted
8 ft 2 in
249 cm
Width, axles extended
Length, transport position
Length, stowed
Turning radius, outside, axles extended
Turning radius, inside,
axles extended
13 ft 2 in
4.01 m
13 ft 2 in
4.01 m
18 ft 10 in
5.74 m
18 ft 10 in
5.74 m
8 ft 6 in
2.59 m
8 ft 6 in
2.59 m
Turntable rotation (degrees)
360° continuous
Platform rotation
160°
8 ft 2 in
249 cm
Maximum allowable
side force (ANSI and CSA)
150 lbs
667 N
11 ft
335 cm
11 ft
335 cm
Maximum allowable
side force (CE)
90 lbs
400 N
10 ft 1 in
308 cm
10 ft 1 in
308 cm
44,340 lbs
20,112 kg
44,640 lbs
20,248 kg
15 3/4 in
40 cm
15 3/4 in
40 cm
Platform height, maximum
120 ft
36.6 m
125 ft
38.1 m
Working height, maximum
126 ft 38.4 m
131 ft
39.9 m
Horizontal reach maximum
75 ft
22.9 m
80 ft
24.4 m
Maximum load capacity
750 lb
340 kg
500 lb
227 kg
Turntable tailswing,
axles retracted
66 in
168 cm
66 in
168 cm
Turntable tailswing
axles extended
48 in
122 cm
48 in
122 cm
Wheelbase
12 ft
366 cm
12 ft
366 cm
22 ft 2 in
6.75 m
22 ft 2 in
6.75 m
Height, stowed maximum
Weight
Ground clearance
Operational dimensions
Turning radius, outside,
axles retracted
Part No. 102916
Controls
12V DC proportional
Platform dimensions
Length
96 in
244 cm
Width
36 in
91 cm
Tires and wheels
Tire size
445/65D22.5, FF
Tire ply rating
18
Tire weight, new foam-filled (minimum)
815 lbs
370 kg
Overall tire diameter
46.5 in
118 cm
Wheel diameter
22.5 in
57 cm
Wheel width
13 in
33 cm
Wheel lugs
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
570 Nm
Lug nut torque, lubricated
320 ft-lbs
434 Nm
S-100 • S-105 • S-120 • S-125
2-1
October 2015
Section 2 • Specifications
SPECIFICATIONS
Fluid capacities
Hydraulic tank
55 gallons
208 liters
Hydraulic system
(including tank)
80 gallons
303 liters
Fuel tank
40 gallons
151 liters
Coolant capacity
20 quarts
18.9 liters
Drive hubs
47 oz
1.4 liters
Turntable rotation
drive hub
93 oz
2.8 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification GL5
For operational specifications, refer to the
Operator's Manual.
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, 32.6 - 36.6 sec 18 ft / 5.5 m
non-stowed > 80 ft
Braking distance, maximum
High range on paved surface
Gradeability (boom stowed)
4 to 6 ft
1.2 to 1.8 m
See Operators Manual
Boom function speeds, maximum
from 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
Boom extended to >4 ft / >1.2 m
(time between fully lowered and
a fully raised position)
80 to 88 seconds
100 to 110 seconds
Boom extended to >80 ft / >24.4 m
(time between 53° envelope
limit and a fully raised position)
50 to 55 seconds
Boom extended to >100 ft / >30.5 m
(time between 68° envelope
limit and a fully raised position)
24 to 28 seconds
Boom down
Boom fully retracted
Boom extended to >4 ft / >1.2 m
(time between fully raised and
a fully lowered position)
2 - 2
80 to 88 seconds
100 to 110 seconds
Boom extended to >80 ft / >24.4 m
(time between fully raised and
the 50° envelope limit)
50 to 55 seconds
Boom extended to >100 ft / >30.5 m
(time between fully raised and
the 65° envelope limit)
24 to 28 seconds
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Boom extend
vertical, 0 to 120 ft / 0 to 36.6 m
170 to 190 seconds
Boom retract
vertical, 120 ft to 0 / 36.6 m to 0
Machine Specifications,
S-100 and S-105 Models
170 to 190 seconds
Stowed dimensions
S-100
S-105
39 ft 11 in
12.17 m
39 ft 11 in
12.17 m
42 ft 8 in
13 m
46 ft
14 m
Width, axles retracted
8 ft 2 in
249 cm
8 ft 2 in
249 cm
Width, axles extended
11 ft
335 cm
11 ft
335 cm
10 ft 1 in
308 cm
10 ft 1 in
308 cm
39,700 lbs
18,007 kg
40,000 lbs
18,143 kg
151/2 in
39 cm
151/2 in
39 cm
Platform height, maximum
100 ft
30.5 m
105 ft
32 m
Working height, maximum
106 ft 32.3 m
111 ft
33.8 m
Horizontal reach maximum
75 ft
22.9 m
80 ft
24.4 m
Maximum load capacity
750 lb
340 kg
500 lb
227 kg
Turntable tailswing,
axles retracted
66 in
168 cm
66 in
168 cm
Turntable tailswing
axles extended
48 in
122 cm
48 in
122 cm
Wheelbase
12 ft
366 cm
12 ft
366 cm
Turning radius, outside,
axles retracted
21 ft 7 in
6.58 m
21 ft 7 in
6.58 m
Turning radius, inside, axles retracted
13 ft 7 in
4.14 m
13 ft 7 in
4.14 m
Length, transport position
Turntable rotate, 360°
boom horizontal and
fully retracted
170 to 190 seconds
Turntable rotate, 360°
boom horizontal and
extended >0 ft / >0 m
63 to 70 seconds
drive enable to drive enable
Turntable rotate, 360°
boom fully raised and
109 to 120 seconds
Length, stowed
Height, stowed maximum
Weight
Ground clearance
Operational dimensions
120 ft / 36.6 m
LSB9AS
65 O
LSB14AO
68 O
110 ft / 33.5 m
100 ft / 30.5 m
LSB2RS
101 ft (30.8 m)
LSB2RO
102 ft
(31.1 m)
90 ft / 27.4 m
LSB4EO
100 ft (30.5 m)
80 ft / 24.4 m
LSB13AO
53 O
70 ft / 21.3 m
LSB8AS
50 O
LSB4ES
75.5 ft
(23 m)
60 ft / 18.3 m
LSB3EO
75 ft
(22.9 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS
11 O
LSB1DO
10 O
20 ft / 6.1 m
10 ft / 3 m
LSB3RO
3 ft (0.9 m)
0 ft / 0 m
70 ft / 21.3 m
60 ft / 18.3 m
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
20 ft / 6.1 m
10 ft / 3 m
0 ft / 0 m
-10 ft / -3 m
Part No. 102916
LSB3RS
3.5 ft (1.1 m)
S-100 • S-105 • S-120 • S-125
2-3
October 2015
Section 2 • Specifications
SPECIFICATIONS
Turning radius, outside, axles extended
Turning radius, inside,
axles extended
19 ft 10 in
6.05 m
19 ft 10 in
6.05 m
9 ft
2.74 m
9 ft
2.74 m
Turntable rotation (degrees)
360° continuous
Platform rotation
160°
Maximum allowable
side force (ANSI and CSA)
150 lbs
667 N
Maximum allowable
side force (CE)
90 lbs
400 N
Controls
12V DC proportional
Platform dimensions
Length
96 in
244 cm
Width
36 in
91 cm
Tires and wheels
Tire size
IN385/65D22.5, FF
18
Tire ply rating
Tire weight, new foam-filled (minimum)
Hydraulic tank
55 gallons
208 liters
Hydraulic system
(including tank)
80 gallons
303 liters
Fuel tank
40 gallons
151 liters
Coolant capacity
20 quarts
18.9 liters
Drive hubs
47 oz
1.4 liters
Turntable rotation
drive hub
93 oz
2.8 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification GL5
For operational specifications, refer to the
Operator's Manual.
622 lbs
282 kg
Overall tire diameter
43.1 in
109.5 cm
22.5 in
57 cm
Wheel diameter
Wheel width
11.75 in
30 cm
10 @ 3/4 -16
Wheel lugs
Lug nut torque, dry
420 ft-lbs
570 Nm
Lug nut torque, lubricated
320 ft-lbs
434 Nm
2 - 4
Fluid capacities
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
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, 32.6 - 36.6 sec 18 ft / 5.5 m
non-stowed > 80 ft
Braking distance, maximum
High range on paved surface
Gradeability (boom stowed)
4 to 6 ft
1.2 to 1.8 m
See Operator's Manual
Boom function speeds, maximum
from platform controls
Jib boom up (S-105 models)
28 to 32 seconds
Jib boom down (S-105 models)
28 to 32 seconds
Boom extend, boom fully raised
0 to 100 ft / 0 to 30.5 m
120 to 140 seconds
Boom retract, boom fully raised
100 ft to 0 / 30.5 m to 0
120 to 140 seconds
Turntable rotate, 360°
boom horizontal and
fully retracted
170 to 190 seconds
Turntable rotate, 360°
boom horizontal and
extended >0 ft / >0 m
63 to 70 seconds
drive enable to drive enable
Turntable rotate, 360°
boom fully raised and
extended >80 ft / >24.4 m
109 to 120 seconds
drive enable to drive enable
18 to 22 seconds
Platform rotate, 160°
Boom up
Boom fully retracted
Boom extended to >4 ft / >1.2 m
(time between fully lowered and
a fully raised position)
Boom extended to >80 ft / >24.4 m
(time between 53° envelope
limit and a fully raised position)
80 to 88 seconds
100 to 110 seconds
120 ft / 36.6 m
50 to 55 seconds
100 ft / 30.5 m
Boom down
Boom fully retracted
Boom extended to >4 ft / >1.2 m
(time between fully raised and
a fully lowered position)
Boom extended to >80 ft / >24.4 m
(time between fully raised and
the 50° envelope limit)
110 ft / 33.5 m
90 ft / 27.4 m
80 to 88 seconds
100 to 110 seconds
LSB13AO
53
80 ft / 24.4 m
LSB8AS
50
70 ft / 21.3 m
50 to 55 seconds
LSB3EO
75 ft
(22.9 m)
60 ft / 18.3 m
LSB4ES
75.5 ft
(23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS
11
LSB1DO
10
20 ft / 6.1 m
10 ft / 3 m
LSB3RO
3 ft (0.9 m)
LSB3RS
3.5 ft (1.1 m)
0 ft / 0 m
70 ft / 21.3 m
60 ft / 18.3 m
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
20 ft / 6.1 m
10 ft / 3 m
S-100 • S-105 • S-120 • S-125
0 ft / 0 m
-10 ft / -3 m
Part No. 102916
2-5
October 2015
Section 2 • Specifications
SPECIFICATIONS
Hydraulic Specifications
Do not top off with incompatible
hydraulic fluids. Hydraulic
fluids may be incompatible
due to the differences in base
additive chemistry. When
incompatible fluids are mixed,
insoluble materials may form and
deposit in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level, minimum
ISO 15/13
250 ppm
Water content, maximum
Recommended Hydraulic Fluid
Hydraulic oil type
Note: Do not operate the machine when the ambient
air temperature is consistently above 120°F / 49°C.
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic fluids
Hydraulic Fluid Temperature
Range
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron 5606A
Biodegradable
Petro Canada Environ MV 46
2
UCON Hydrolube HP-5046
3
Fire resistant
Note: Genie specifications require additional
equipment and special installation instructions for the
approved optional fluids. Consult the Genie Product
Support before use.
1
4
-40 -22 -4 14 32
-40 -30 -20 -10 -0
Optional fluids may not have the
same hydraulic lifespan and may
result in component damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. if the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
50
10
68
20
86 104 122
30 40 50
F
C
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV
optional oil cooler may be required.
2 - 6
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
Chevron 5606A Hydraulic Oil
Fluid Properties
32
ISO Grade
15
Viscosity index
200
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @ -4°F / -20°C
cP @ -22°F / -30°C
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @ -40°F / -40°C
5.5
15.0
510
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: An hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C .
Flash point
180°F / 82°C
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil heating
system is used.
Note: Do not operate the machine when the ambient
temperature is below -20°F / -29°C with Rando HD
Premium MV.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2-7
October 2015
Section 2 • Specifications
SPECIFICATIONS
Petro-Canada Environ MV 46
Fluid Properties
Hydraulic Component
Specifications
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -45°C
Maximum continuous operating
temperature
180°F / 82°C
Drive pump
Type: bi-directional variable displacement piston pump
Displacement 0 to 2.8 cu in
0 to 46 cc
Flow rate @ 2350 rpm, maximum
28.5 gpm
108 L/min
Drive pressure, maximum
3625 psi
250 bar
Charge pump
Type:gerotor
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
Viscosity index
46
192
Displacement
0.85 cu in
13.9 cc
Flow rate @ 2350 rpm
9 gpm
34 L/min
Charge pressure @ 2350 rpm
Neutral position
315 psi
21.7 bar
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F / -18°C
22
46
1300
Function pump
Flash point
None
Front Section
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
189°F / 87°C
2 - 8
Type:
variable displacement piston pump
Displacement 0 to 1.71 cu in
0 to 28 cc
Flow rate @ 2350 rpm, maximum
S-100 • S-105 • S-120 • S-125
17.4 gpm
65.9 L/min
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Rear Section
Steer/Axle manifold
Displacement 0 to 1.1 cu in
0 to 18 cc
Axle extend relief pressure
Flow rate @ 2350 rpm, maximum
11.2 gpm
42.4 L/min
Drive manifold
Pressure, maximum continuous
3350 psi
231 bar
Standby pressure
250 psi
17 bar
Hot oil relief pressure:
S-100/105 before serial number 291
S-120/125 before serial number 1195
250 psi
17.2 bar
Hot oil relief pressure:
S-100/105 after serial number 290
S-120/125 after serial number 1194
280 psi
19.3 bar
Brakes
Auxiliary pumps
Type:
1800 psi
124 bar
fixed displacement gear pump
Displacement
0.15 cu in 2.47 cc
Function manifold
Function relief pressure
(measured at test port)
2600 psi
179.3 bar
Platform relief pressure
(measured at test port 2)
3000 psi
207 bar
Brake release pressure
174-189 psi
12-13 bar
Drive motors
Displacement per revolution,
high speed
0.8 cu in
13.3 cc
Displacement per revolution,
low speed
2.7 cu in
45 cc
Jib and platform manifolds
Platform rotate and platform level
flow regulator
0.3 gpm
1.14 L/min
Jib manifold flow regulator
2 gpm
7.6 L/min
Part No. 102916
S-100 • S-105 • S-120 • S-125
2-9
October 2015
Section 2 • Specifications
SPECIFICATIONS
Hydraulic filters
High pressure filter Beta 3 ≥ 200
High pressure filter
bypass pressure
102 psi
7 bar
Medium pressure filter Beta 3 ≥ 200
Medium pressure filter
bypass pressure
Hydraulic tank return filter
Drive motor case drain
return filter
2 - 10
25 psi
1.7 bar
10 micron with
25 psi / 1.7 bar bypass
Beta 10 ≥ 2
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz Engine F4L 913
Injection system
Displacement
Number of cylinders
Bore and stroke
Horsepower
249.3 cu in
4.086 liters
4
4.02 x 4.92 inches
102 x 125 mm
77 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
18:1
Compression pressure
pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle rpm
Frequency
1300 rpm
385.7 Hz
High idle rpm
Frequency
2350 rpm
570.4 Hz
Valve clearance, cold
Injection pump make
IMSA
Injection pump pressure
8702 psi
600 bar
Injector opening pressure
3626 psi
250 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Alternator output 55A, 12 VDC
3/8 to 1/2 inch
Fan belt deflection
9 to 12 mm
Battery - Engine starting
12V, Group 31
Type
Quantity1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
175 minutes
Battery - Control system
Intake
0.006 in
0.15 mm
Exhaust
0.006 in
0.15 mm
12V DC, Group 4D
Type
Quantity1
Cold cranking ampere
1020A
Reserve capacity @ 25A rate
300 minutes
Lubrication system
Oil pressure
Oil capacity
(including filter)
40 to 60 psi
2.75 to 4.14 bar
14.3 quarts
13.5 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 11
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz %NGINEBF4L 2011
Oil temperature switch
Displacement
Number of cylinders
Bore and stroke
189.6 cu in
3.1 liters
4
3.7 x 4.409 inches
94 x 112 mm
Horsepower
Continuous @ 2500 rpm
Net intermittent @ 2500 rpm
69.1
72.8
Firing order
1-3-4-2
Low idle rpm
Frequency
1500 rpm
382.5 Hz
High idle rpm
Frequency
2350 rpm
599.25 Hz
Compression ratio
17.5:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Governor
centrifugal mechanical
Valve clearance, cold
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
Lubrication system
40 to 60 psi
2.8 to 4.1 bar
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)
10.5 quarts
9.9 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
2 - 12
Torque
8-18 ft-lbs 11-24 Nm
Oil temperature switch point
275°F
135°C
Oil pressure switch
Torque
8-18 ft-lbs 11-24 Nm
Oil pressure switch point
7 psi 0.48 bar
Fuel injection system
Injection pump make
Bosch
Injection pump pressure, maximum
15,000 psi
1034 bar
Injector opening pressure
3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, normal load
140-200A
Cranking speed 200-250 rpm
Battery - Engine starting
12V, Group 31
Type
Quantity1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
175 minutes
Battery - Control system
12V DC, Group 4D
Type
Quantity1
Cold cranking ampere
1020A
Reserve capacity @ 25A rate
300 minutes
Alternator output
80A @ 14V DC
3/8 to 1/2 inch
Fan belt deflection
9 to 12 mm
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz %NGINETD2011L04i
Displacement
Number of cylinders
Bore and stroke
Oil temperature switch
220.9 cu in
3.62 liters
4
3.78 x 4.92 inches
96 x 125 mm
Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
275°F
135°C
Oil pressure switch
Installation torque
8-18 ft-lbs 11-24 Nm
Induction system turbocharged
Pressure switch point
22 psi 1.5 bar
Firing order
1-3-4-2
Fuel injection system
Low idle 1300 rpm
High idle
2450 rpm
Compression ratio
17.5:1
Horsepower net intermittent @
2400 rpm
74hp
55KW
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder.
Governor
centrifugal
mechanical
Injection pump pressure, maximum
15,000 psi
1034 bar
Injector opening pressure
3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
Valve Clearance, cold
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
Lubrication system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar
Oil capacity (including filter)
Motorpal
12.8 quarts
12.1 liters
140-200 A
Cranking speed 250-350 rpm
Battery - Engine starting and control system
Type
6V DC
Quantity2
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Alternator output
80A @ 14V DC
3/8 to 1/2 inch
Fan belt deflection
9 to 12 mm
Oil viscosity requirements
5W-30
-22°F to 86°F / -30°C to 30°C
(synthetic)
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to
the Engine Operator Manual for your engine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 13
October 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz %NGINETD 2.9
Oil temperature switch
Displacement
Number of cylinders
Bore and stroke
177 cu in
2.9 liters
4
3.6 x 4.3 inches
92 x 110 mm
Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
275°F
135°C
Oil pressure switch
Installation torque
8-18 ft-lbs 11-24 Nm
Induction system turbocharged
Pressure switch point
22 psi 1.5 bar
Firing order
1-3-4-2
Fuel injection system
Low idle 1000 rpm
High idle
2500 rpm
Compression ratio
17.4:1
Horsepower net intermittent @
2600 rpm
74.2hp
55KW
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder.
Governor
electronic
Motorpal
Injection pump pressure, maximum
15,000 psi
1034 bar
Injector opening pressure
3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Lubrication system
Starter motor
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar
Current draw, normal load
Oil capacity (including filter)
Battery - Engine starting and control system
9.4 quarts
8.9 liters
140-200 A
Cranking speed 250-350 rpm
-22°F to 86°F / -30°C to 30°C
5W-30
(synthetic)
Type
12V DC, Group 31
Quantity1
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
-4°F to 104°F / -20°C to 40°C
10W-40
Alternator output
Above 5°F / -15°C 15W-40
3/8 to 1/2 inch
Fan belt deflection
9 to 12 mm
Oil viscosity requirements
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
2 - 14
S-100 • S-105 • S-120 • S-125
95A @ 14V DC
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins %NGINE1104D-44T
Displacement
Oil temperature switch
268.5 cu in
4.4 liters
Installation torque
8-18 ft-lbs 11-24 Nm
8 psi
0.55 bar
Number of cylinders
4
Pressure switch point
Bore and stroke
4.13 x 5 inches
105 x 127 mm
Oil Sensor Settings
Horsepower net intermittent @
2200 rpm
68 ph / 50.7KW
74 hp / 55.2 KW
Induction system turbocharged
Firing order
1-3-4-2
Low idle 1300 rpm
High idle
2450 rpm
Compression ratio
18.2:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder.
Governor
centrifugal
mechanical
10 ohms
120 ohms
Fuel injection system
Motorpal
Transfer pump pressure
10-12 psi /
0.69-0.83 bar
Injector pressure
(4264+116 psi) /
(294+8 bar)
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
115 A
Cranking speed 200-250 rpm
Battery - Auxiliary power units
Valve Clearance, cold
Intake
0.008 in
0.2 mm
Exhaust
0.018 in
0.45 mm
Lubrication system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar
Oil capacity (including filter)
0 psi
50 psi
10.4 quarts
9.8 liters
6V DC
Type
Quantity2
Battery capacity, maximum
285AH
Reserve capacity @ 25A rate
745 Minutes
Battery - Engine starting and control system
12V DC, Group 31
Type
Quantity1
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Oil viscosity requirements
5W-20
-22°F to 86°F / -30°C to 30°C
(synthetic)
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 15
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins 1104D-44T
Perkins
Engine coolant
Capacity
(engine only)
Displacement
9.5 quarts
9 liters
Number of cylinders
Coolant temperature switch
Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F
110°C
Temperature Sensor Settings
%NGINE854F-34T
Bore and stroke
Horsepower net intermittent @
2500 rpm
4
3.89 x 4.33 inches
99 x 110 mm
74 hp / 55.2 KW
Induction system turbocharged
Firing order
215°F
37 ohms Standby
102°C speed Low idle 170°F
78 ohms
82°C
High idle
Alternator output
207 cu in
3.4 liters
1-3-4-2
1000 rpm
1500 rpm
2500 rpm
85A @ 12V DC
Compression ratio
3/8 to 1/2 in
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder.
Fan belt deflection
9 to 12 mm
Governor
17.0:1
Electronic
Lubrication system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar
Minimum oil pressure
Oil capacity (including filter)
12 psi
0.82 bar
7.7 quarts
7.3 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C
5W-20
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
2 - 16
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Oil temperature switch
Perkins 854F-34T cont.
Engine coolant
Installation torque
18.4 ft-lbs 25 Nm
Pressure switch point
12 psi
0.82 bar
Coolant temperature switch
0 psi
10 ohms
Installation torque
18.4 ft-lbs 25 Nm
50 psi
120 ohms
Maximum continuous temperature
226°F
108°C
Oil Sensor Settings
Fuel injection system
Transfer pump pressure
10-12 psi /
0.69-0.83 bar
Injector pressure
23000 psi /
(1600 bar)
Fuel requirement
16.5 quarts
15.6 liters
Temperature Sensor Settings
215°F
37 ohms 102°C
170°F
78 ohms
82°C
Alternator output
For fuel requirements, refer to the engine Operator
Manual for your engine.
120A @ 12V DC
3/8 to 1/2 in
Fan belt deflection
9 to 12 mm
Glow plugs
Initial load (0-10 sec)
Continuous load (>10 sec)
Capacity
(50/50 extended life)
80A
40A
Starter motor
Current draw, normal load
68 A
Cranking speed 130-200 rpm
Battery - Auxiliary power units
6V DC
Type
Quantity2
Battery capacity, maximum
285AH
Reserve capacity @ 25A rate
745 Minutes
Battery - Engine starting and control system
Type
12V DC, Group 31
Quantity1
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 17
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins Engine 1004-42
Injection system
Displacement
258 cu in
4.23 liters
Number of cylinders
4
Bore & stroke
4.06 x 5 inches
103.1 x 127 mm
Horsepower
81 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
18.5:1
Compression pressure
pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle rpm
Frequency
1300 rpm
303.3 Hz
High idle rpm
Frequency
2350 rpm
548.3 Hz
Valve clearance, cold
Intake
0.008 in
0.20 mm
Exhaust
0.018 in
0.45 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
51 psi
3.45 bar
8.9 quarts
8.4 liters
Injection pump make Zexel
Injector opening pressure
2204 psi
152 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Alternator output 55A, 12V DC
3/8 to 1/2 inch
Fan belt deflection
9 to 12 mm
Battery - System
Type
12V, Group 27TM
Quantity1
AH rating
109AH
Cold cranking ampere
630A
Reserve capacity @ 25A rate
160 minutes
Battery - Engine starting
12V, Group 4D
Type
Quantity1
AH rating
190AH
Cold cranking ampere
1020A
Reserve capacity @ 25A rate
325 minutes
Cooling system
Engine capacity
9.5 quarts
9 liters
System capacity
20 quarts
18.9 liters
Oil viscosity requirements
Unit ships with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
2 - 18
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins %NGINE1104C-44
Lubrication system
Displacement
268.5 cu in
4.4 liters
Oil pressure, hot 40 to 60 psi
(at 2000 rpm) 2.8 to 4.1 bar
Number of cylinders
4
Oil capacity
(including filter)
Bore and stroke
4.13 x 5 inches
105 x 127 mm
Oil viscosity requirements
Horsepower
Gross intermittent @ 2400 rpm
Net intermittent @ 2400 rpm
86
83
Firing order
1-3-4-2
Low idle rpm
Frequency
1300 rpm
316.3 Hz
Low Idle with belt-driven generator option
Frequency
1400 rpm
340.7 Hz
High idle rpm
Frequency
2350 rpm
571.8 Hz
Compression ratio
18.2:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Governor
centrifugal mechanical
Valve clearance, cold
Intake
0.008 in
0.2 mm
Exhaust
0.018 in
0.45 mm
Part No. 102916
7.3 quarts
6.9 liters
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Oil pressure sending unit
Torque
8-18 ft-lbs 11-24 Nm
Oil pressure switch point
8 psi 0.55 bar
Fuel injection system
Injection pump make
Bosch
Injector opening pressure
2200 psi
152 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
S-100 • S-105 • S-120 • S-125
2 - 19
October 2015
Section 2 • Specifications
SPECIFICATIONS
Battery - Engine starting
Type
12V, Group 31
Quantity1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
175 minutes
Battery - Control system
Type
12V DC, Group 4D
Quantity1
Cold cranking ampere
1020A
Reserve capacity @ 25A rate
300 minutes
Starter motor
Current draw, normal load
140-200A
Cranking speed 200-250 rpm
Engine coolant
Capacity
14 quarts
13.2 liters
Coolant temperature sending unit
Torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F
110°C
Alternator output
85A @ 13.8V DC
3/8 inch
Fan belt deflection
10 mm
Perkins %NGINE804D-33T
Displacement
Number of cylinders
Bore and stroke
203 cu in
3.33 liters
4
3.7 x 4.72 inches
94 x 120 mm
Horsepower
Gross intermittent @ 2500 rpm
83 / 62 kW
Induction system turbocharged
Firing order
1-3-4-2
Low idle
1300 rpm
316 Hz
High idle
2350 rpm
572 Hz
Compression ratio
19.5:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Governor
centrifugal mechanical
Valve clearance, cold
Intake
0.0098 in
0.25 mm
Exhaust
0.0098 in
0.25 mm
Lubrication system
Oil pressure, hot 40 to 60 psi
(at 2000 rpm) 2.8 to 4.1 bar
Oil capacity
(including filter)
2 - 20
S-100 • S-105 • S-120 • S-125
10.6 quarts
10 liters
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Oil viscosity requirements
Starter motor
Below 86°F / 30°C
5W-30
Current draw, normal load
200A
250 rpm
-4°F to 104°F / -20°C to 40°C
10W-30
Cranking speed
Above 14°F / -10°C
15W-40
Engine coolant
Units ship with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Oil pressure sending unit
Installation torque
8-18 ft-lbs 11-24 Nm
Oil pressure switch point
8 psi 0.55 bar
Fuel injection system
Injection pump make
Bosch
Injector opening pressure
2200 psi
152 bar
Capacity
12.5 quarts
11.8 liters
Coolant temperature sending unit
Installation torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F
110°C
Alternator output
90A @ 12V DC
3/8 to 1/2 in
Fan belt deflection
9 to 12 mm
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Battery - Auxiliary power units
Type
6V DC
Quantity2
AH rating
285AH
Reserve capacity @ 25A rate
745 minutes
Battery - Engine starting and control system
Type
12V DC, Group 31
Quantity1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
200 minutes
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 21
October 2015
Section 2 • Specifications
SPECIFICATIONS
Cummins %NGINEB3.3T
Fuel injection system
Displacement
Number of cylinders
Bore and stroke
Horsepower
199 cu in
3.26 liters
4
3.74 x 4.53 inches
95 x 115 mm
80 @ 2200 rpm
60 kW @ 2200 rpm
Firing order
1-2-4-3
Low idle
1300 rpm
368 Hz
High idle
2350 rpm
666 Hz
Compression ratio
17:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Valve clearance, cold
Intake
0.014 in
0.35 mm
Exhaust
0.020 in
0.5 mm
Lubrication system
Oil pressure, hot
(at 2000 rpm)
31 to 72 psi
2 to 5 bar
9 quarts
8.5 liters
Oil capacity
(including filter)
Injection pump make
Injection pressure
Zexel
12,000 psi
827 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Battery - Auxiliary power units
Type
6V DC
Quantity2
AH rating
285AH
Reserve capacity @ 25A rate
745 minutes
Battery - Engine starting and control system
Type
12V DC, Group 31
Quantity1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
200 minutes
Starter motor
Current draw, maximum
550A
Engine cranking speed, minimum
130 rpm
Engine coolant
Capacity
9.1 quarts
8.6 liters
Alternator output120A, 12V DC
3/8 to 1/2 inch
Fan belt deflection
10 to 12.5 mm
Oil viscosity requirements
Below 68°F / 20°C
5W-30
-10° to 68°F / -23° to 20°C
10W-30
Above 14°F / -10°C
15W-40
Units ship with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
2 - 22
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Cummins %NGINEB3.9L
Injection system
Displacement
Number of cylinders
Bore and stroke
Horsepower
238 cu in
3.9 liters
4
4.02 x 4.72 inches
102 x 120 mm
75 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
16.5:1
Compression pressure
pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle rpm
Frequency
1300 rpm
368.3 Hz
High idle rpm
Frequency
2350 rpm
665.8 Hz
Valve clearance, cold
Intake
0.010 in
0.254 mm
Exhaust
0.020 in
0.508 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
50 psi
3.45 bar
9.5 quarts
9 liters
Injection pump make
Bosch
Injection pump pressure
5500 psi
379.2 bar
Injector opening pressure
3480 psi
240 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Alternator output 63A, 12V DC
Battery - System
Type
12V, Group 27TM
Quantity1
AH rating
109AH
Cold cranking ampere
630A
Reserve capacity @ 25A rate
160 minutes
Battery - Engine starting
12V, Group 4D
Type
Quantity1
AH rating
190AH
Cold cranking ampere
1020A
Reserve capacity @ 25A rate
325 minutes
Cooling system
Engine capacity
8.8 quarts
8.3 liters
System capacity
20 quarts
18.9 liters
Oil viscosity requirements
Unit ships with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 23
October 2015
Section 2 • Specifications
SPECIFICATIONS
Cummins %NGINEB4.5L
Fuel injection system
Displacement
Number of cylinders
Bore and stroke
Horsepower
275 cu in
4.5 liters
4
4.02 x 5.42 inches
102 x 138 mm
80 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
18:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle rpm
Frequency
1300 rpm
368.3 Hz
High idle rpm
Frequency
2350 rpm
665.8 Hz
Valve clearance, cold
Intake
0.010 in
0.254 mm
Exhaust
0.020 in
0.508 mm
Lubrication system
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)
50 psi
3.45 bar
9.5 quarts
9 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Injection pump make
Injection pump pressure
Delphi
3480 to 3680 psi
240 to 254 bar
Injector opening pressure
3480 psi
240 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Battery - Engine starting
Type
12V, Group 31
Quantity1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
175 minutes
Battery - Control system
12V DC, Group 4D
Type
Quantity1
Cold cranking ampere
1020A
Reserve capacity @ 25A rate
300 minutes
Starter motor
Current draw, no load
125A
Brush length, minimum
0.72 in
18.3 mm
Engine coolant
Capacity
17 quarts
16 liters
Coolant temperature sending unit
Torque
8-18 ft-lbs 11-24 Nm
Temperature switch point
230°F
110°C
Alternator output 95A, 12V DC
3/8 to 1/2 inch
Fan belt deflection
10 to 12.5 mm
2 - 24
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Machine Torque Specifications
Platform rotator
Manifold Plug Torque
Specifications
1-8 center bolt, GR 5, dry
640 ft-lbs
868 Nm
Plug torque
1-8 center bolt, GR 5, lubricated
480 ft-lbs
651 Nm
SAE No. 4
14 ft-lbs / 18.9 Nm
3/8
35 ft-lbs*
47.5 Nm
SAE No. 6
23 ft-lbs / 31.2 Nm
SAE No. 8
36 ft-lbs / 48.8 Nm
Turntable rotate assembly
SAE No. 10
62 ft-lbs / 84.1 Nm
Rotate bearing mounting bolts, lubricated180 ft-lbs
244 Nm
SAE No. 12
84 ft-lbs / 113.9 Nm
-16 bolts, GR 8, lubricated
*use blue thread-locking compound
Rotate drive hub mounting bolts, dry
Rotate drive hub mounting bolts, lubricated
*use blue thread-locking compound
Rotate drive motor mounting bolts, dry
Rotate drive motor mounting bolts, lubricated
SAE No. 2
50 in-lbs / 6 Nm
380 ft-lbs
515 Nm
280 ft-lbs*
380 Nm
110 ft-lbs
149 Nm
80 ft-lbs
108 Nm
Drive motor and hubs
Drive hub mounting bolts, dry
269 ft-lbs
365 Nm
Drive hub mounting bolts, lubricated
202 ft-lbs
274 Nm
Drive motor mounting bolts, dry
110 ft-lbs
149 Nm
Drive motor mounting bolts, lubricated
80 ft-lbs
108 Nm
Drive hub oil plug, O-ring seal
13 ft-lbs
18 Nm
Part No. 102916
S-100 • S-105 • S-120 • S-125
2 - 25
October 2015
Section 2 • Specifications
SPECIFICATIONS
Hydraulic Hose and Fitting
Torque Specifications
SAE O-ring Boss Port
Your machine is equipped with Parker SealLokTM fittings and hose ends. Genie specifications
require that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
Seal-LokTM Fittings
(hose end - ORFS)
Torque
SAE Dash size
-4
10 ft-lbs / 13.6 Nm
-6
30 ft-lbs / 40.7 Nm
-8
40 ft-lbs / 54.2 Nm
-10
60 ft-lbs / 81.3 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
(tube fitting - installed into Aluminum)
(all types)
SAE Dash size
-4
14 ft-lbs / 19 Nm
-6
23 ft-lbs / 31.2 Nm
-8
36 ft-lbs / 54.2 Nm
-10
62 ft-lbs / 84 Nm
-12
84 ft-lbs / 114 Nm
-16
125 ft-lbs / 169.5 Nm
-20
151 ft-lbs / 204.7 Nm
-24
184 ft-lbs / 249.5 Nm
Adjustable Fitting
JIC 37° Fittings
Thread Size
Non-adjustable fitting
a jam nut
(swivel nut or hose connection)
SAE Dash Size
Torque
SAE O-ring Boss Port
Flats
-4
7/16-20
2
-6
9/16-18
1 1/4
-8
3/4-16
1
-10
7/8-14
1
-12
1 1/16-12
1
-16
1 5/16-12
1
-20
1 5/8-12
1
-24
1 7/8-12
1
(tube fitting - installed into Steel)
SAE Dash size
Torque
-4
ORFS / 37° (Adj)
ORFS / (Non-Adj)
37° (Non-Adj)
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
-6
ORFS / (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
-8
ORFS / (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm
-10 ORFS / 37° (Adj)
37° (Non-Adj)
100 ft-lbs / 135.6 Nm
85 ft-lbs / 115.3 Nm
-12 (All types)
135 ft-lbs / 183 Nm
-16 (All types)
200 ft-lbs / 271.2 Nm
-20 (All types)
250 ft-lbs / 339 Nm
-24 (All types)
305 ft-lbs / 413.5 Nm
2 - 26
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
Torque Procedure
JIC 37° fittings
Seal-LokTM fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
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 are
available in the O-ring field service kit (Genie part
number 49612).
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
approximately 30 in-lbs / 3.4Nm.
2 Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the hex
fitting. Refer to illistration 1.
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
Part No. 102916
Illustration 1
a hex nut
b reference mark
c body hex fitting
S-100 • S-105 • S-120 • S-125
2 - 27
October 2015
Section 2 • Specifications
SPECIFICATIONS
3 Working clockwise on the body hex fitting, make
a second mark with a permanent ink marker to
indicate the proper tightening position. Refer to
illustration 2.
Note: Using the JIC 37° Fitting table in this section
to determine the correct number of flats, for the
proper tightening position.
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect
the hose, fittings and related components to
confirm there are no leaks.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
a body hex fitting
b reference mark
c second mark
2 - 28
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 2 • Specifications
SPECIFICATIONS
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD
LUBED
in-lbs
20
28
1/4
DRY
Nm
80
90
in-lbs
9
10.1
100
120
LUBED
ft-lbs
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1
1 /4
1 1/2
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
LUBED
Nm
in-lbs
Nm
ft-lbs
11.3
13.5
110
120
DRY
Nm
ft-lbs
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
DRY
Nm
in-lbs
12.4
13.5
140
160
LUBED
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
Nm
in-lbs
Nm
ft-lbs
15.8
18
DRY
Nm
ft-lbs
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
Nm
130
140
14.7
15.8
LUBED
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
Nm
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size
(mm)
5
6
7
LUBED
in-lbs
16
19
45
Nm
1.8
3.05
5.12
LUBED
8
10
12
14
16
18
20
22
24
ft-lbs
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
Nm
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
Part No. 102916
Class 8.8
DRY
in-lbs
21
36
60
LUBED
Nm
in-lbs
Nm
ft-lbs
2.4
4.07
6.83
DRY
ft-lbs
7.2
14.4
25.1
40
62.5
86.2
121
166
210
41
69
116
Nm
4.63
7.87
13.2
LUBED
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
Nm
19.1
37.8
66
105
170
233
330
450
570
Class 10.9
DRY
in-lbs
54
93
155
LUBED
Nm
in-lbs
Nm
ft-lbs
6.18
10.5
17.6
DRY
ft-lbs
18.8
37.2
64.9
103
166
229
325
442
562
58
100
167
Nm
6.63
11.3
18.9
DRY
in-lbs
78
132
223
LUBED
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
Nm
27.3
54.1
94.5
150
235
323
458
622
791
Class 12.9
LUBED
Nm
in-lbs
Nm
ft-lbs
8.84
15
25.2
DRY
ft-lbs
26.9
53.2
92.2
147
230
317
450
612
778
S-100 • S-105 • S-120 • S-125
68
116
1.95
Nm
7.75
13.2
22.1
LUBED
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
Nm
32
63.3
110
175
274
377
535
727
925
DRY
in-lbs
91
155
260
Nm
10.3
17.6
29.4
DRY
ft-lbs
31.4
62.3
108
172
269
371
525
715
909
Nm
42.6
84.4
147
234
365
503
713
970
1233
2 - 29
October 2015
Section 2 • Specifications
SPECIFICATIONS
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2 - 30
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Maintenance inspections shall be completed
by a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, six months, annually
and every two years as specified on the
Maintenance Inspection Report.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial machine damage.
Used to indicate the presence of
a potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
With safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
Repair any machine damage or malfunction
before operating machine.
Use only Genie approved replacement parts.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
• 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
Part No. 102916
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
a potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-100 • S-105 • S-120 • S-125
3-1
October 2015
Section 3 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Pre-delivery Preparation Report
Note: The following symbols have been used
in this manual to help communicate the intent
of the instructions. When one or more of the
symbols appear at the beginning of a maintenance
procedure, it conveys the meaning below.
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two years.
The Scheduled Maintenance Procedures Section
and the Maintenance Inspection Report have
been divided into five subsections—A, B, C, D
and E. Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
InspectionChecklist
Daily or every 8 hours
Indicates that a warm engine will be
required to perform this procedure.
Quarterly or every 250 hours
Six months or every 500 hours
Annual or every 1000 hours
Indicates that dealer service will be
required to perform this procedure.
Two years or every 2000 hours
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental
regulations and requirements.
3 - 2
S-100 • S-105 • S-120 • S-125
Part No. 102916
Pre-Delivery Preparation
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Make copies of this form to use for each Pre-Delivery
Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to discover
if anything is apparently wrong with a machine before
it is put into service.
Use the operator’s manual on your machine.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
The Pre-delivery Preparation consists of completing
the Pre-operation Inspection, the Maintenance items
and the Function Tests.
Use this form to record the results. Place a check
in the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
Repairs to the machine may only be made by
a qualified service technician, according to the
manufacturer’s specifications.
If any inspection receives an N, remove the machine
from service, repair and re-inspect it. After repair,
place a check in the R box.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer’s specifications and the
requirements listed in the responsibilities manual.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Terex South Dakota, Inc USA
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201-6150
(605) 882-4000
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc.
Rev D
Inspector company
Y
N
R
Section 3 • Scheduled Maintenance Procedures
October 2015
This page intentionally left blank.
3 - 4
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s)
for the type of inspection to be
performed.
Checklist A YNR
A-1 Inspect the manuals
and decals
A-2 Pre-operation
inspection
A-3 Perform function tests
A-4 Engine maintenance Perkins models
A-5Engine maintenance Cummins models
A-6 Hydraulic filter
condition indicator
Perform after 40 hours:
A-7 30 Day Service
Perform every 50 hours:
A-8 Engine MaintenancePerkins models
Perform after 50 hours:
A-9 Engine MaintenanceDeutz models
Perform every 100 hours:
A-10 Grease rotation bearing
A-11 Grease axles
Perform after 150 hours:
A-12 Replace drive hub oil
Daily or 8 hour
Inspection:A
Quarterly or 250 hour
Inspection:A+B
Semi-annual or 500 hour
Inspection:A+B+C
Checklist B YNR
B-1Batteries
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 control
override
B-15 Platform self-leveling
B-16 Limit switches
B-17 Fuel and hydraulic tank
venting systems B-18 Engine idle select
operation
B-19 Test the drive brakes
B-20 Drive speed - stowed
position
B-21 Drive speed - raised
or extended position
B-22 Inspect the Boom
Extend/Retract Cables
Annual or 1000 hour
Inspection:A+B+C+D
2 Year or 2000 hour
Inspection:A+B+C+D+E
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
Comments
• If any inspection receives an “N”,
tag and remove the machine from
service, repair and re-inspect it.
After repair, place a check in the “R”
box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 102916
S-100 • S-105 • S-120 • S-125
3-5
Section 3 • Scheduled Maintenance Procedures
October 2015
MAINTENANCE INSPECTION REPORT
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s)
for the type of inspection to be
performed.
Daily or 8 hour
Inspection:A
Quarterly or 250 hour
Inspection:A+B
Semi-annual or 500 hour
Inspection:A+B+C
Checklist C
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 filter
element
C-5 Grease platform
overload (if equipped)
C-6 Test the platform
overload (if equipped)
Checklist D - Rev A
D-1 Boom wear pads
D-2 Extendable axle
wear pads
D-3Free-wheel
configuration
D-4 Turntable rotation
bearing 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-10Engine maintenance Cummins models
D-11Replace the hydraulic
filter elements
Checklist E
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
E-5 Engine maintenance Deutz models
Perform every 3000 hours:
E-6 Engine maintenance Perkins models
E-7 Engine maintenance Deutz models
Perform every 4000 hours:
E-8 Engine maintenance Perkins models
Perform every 6000 hours:
E-9 Engine maintenance Perkins models
E-10 Engine maintenance Deutz models
Perform every 12000 hours:
E-11 Engine maintenance Perkins models
E-12 Engine maintenance Deutz models
Perform every 10 years:
E-13 Replace the Boom
Extend/Retract cables
Annual or 1000 hour
Inspection:A+B+C+D
2 Year or 2000 hour
Inspection:A+B+C+D+E
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”,
tag and remove the machine from
service, repair and re-inspect it.
After repair, place a check in the “R”
box.
Comments
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3 - 6
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie requires that this procedure be performed
daily.
Maintaining the operator’s and safety manuals
in good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not appropriate
for the machine or all manuals are not in good
condition or is illegible. Remove the machine
from service until the manual is replaced.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3-7
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
Genie requires that this procedure be performed
daily.
Genie requires that this procedure be performed
daily.
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection
is designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The pre-operation inspection
also serves to determine if routine maintenance
procedures are required.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered,
the machine must be tagged and removed from
service.
Complete information to perform this procedure
is available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
3 - 8
Complete information to perform this procedure
is available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-4
Perform Engine Maintenance Perkins Models
A-5
Perform Engine Maintenance Deutz Models
Engine specifications require that this procedure
be performed every 8 hours or daily, whichever
comes first.
Engine specifications require that this procedure
be performed every 8 hours or daily, whichever
comes first.
All Models:
• Engine oil level - check
• Coolant level - check/add
• Engine oil level - check
• Fuel system filter/water separator - drain
• Fuel system filter/water separator - drain
• Alternator Belt - Inspect/Adjust/Replace
• Engine tightness - check for leaks
• Air filter discharge valve - clean
• Exhaust system - check for leaks
• Engine tightness - check for leaks
• Air filter discharge valve - clean
• Exhaust system - check for leaks
Required maintenance procedures and additional
engine information are available in the
Perkins 1004 User's Handbook
(Perkins part number TPD 1349E) OR the
Perkins 845F Operation and Maintenance Manual
(Perkins part number SEBU8726-00) OR the
Perkins 800D Series User's Handbook
(Perkins part number SEBU8324-00).
Perkins 1004 User's Handbook
Genie part number
Perkins 854 Series User's Handbook
Genie part number
Perkins 800D Series User's Handbook
Genie part number
Part No. 102916
61376
218708
None
TD 2.9 Models:
• Coolant level - check/add
Required maintenance procedures and additional
engine information are available in the Deutz
F4L913 Operation Manual (Deutz part number
0297-7341) OR the Deutz BF4L2011 Operation
Manual (Deutz part number 0297-9929) OR
the Deutz TD 2.9 Operation Manual (Deutz part
number 0312-3893) OR the Deutz TD 2011
Operation Manual (Deutz part number 0312-3547).
Deutz F4L913 Operation Manual
Genie part number
62446
Deutz BF4L2011 Operation Manual
Genie part number
84794
Deutz TD 2.9 Operation Manual
Genie part number
1251561
Deutz TD 2011 Operation Manual
Genie part number
139320
S-100 • S-105 • S-120 • S-125
3-9
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-6
Perform Engine Maintenance Cummins Models
A-7
Check the Hydraulic Filter
Condition Indicators
Engine specifications require that this procedure
be performed daily or every 8 hours, whichever
comes first.
Genie requires that this procedure be performed
daily.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Cummins B4.5 and B3.9L Operation and
Maintenance Manual (Cummins part number
4021389-01) OR the Cummins B3.3T Operation
and Maintenance Manual (Cummins part number
3666417-00).
Cummins B4.5 and B3.9L Operation and
Maintenance Manual
Genie part number
Cummins B3.3T Operation and
Maintenance Manual
Genie part number
3 - 10
107527
139324
Note: Perform this procedure after the machine
reaches operating temperature. The amount of
time this takes will vary, depending on ambient air
temperature.
Maintaining the hydraulic filters in good condition
is essential to good system performance and safe
machine operation. The filter condition indicators
will show when the hydraulic flow is bypassing
a clogged filter. If the filters are not frequently
checked and replaced, impurities will remain in the
hydraulic system and cause component damage.
Note: There are four hydraulic filters on the
machine: one tank return filter, one medium
pressure filter and two high pressure filters. All the
filters have condition indicators on them, except
the medium pressure filter.
1 Start the engine from the ground controls.
2 Press and release the engine idle select button
to change the engine rpm to high idle.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
Tank return filter
Medium and high pressure filters
Note: The tank return filter indicator needle may
operate in the red area when hydraulic oil is below
50° F / 10° C.
Note: The medium and high pressure filters are
mounted to the engine side bulkhead.
Note: If the return filter indicator needle is not
operating in the green area after performing
previous daily procedures, continue running engine
until hydraulic oil temperature is at least
50° F / 10° C.
3 Open the ground control side turntable cover
and inspect the filter condition indicator gauge.
4 Inspect the filter condition indicators.
b
a
c
a
a
b
c
a
filter condition indicator gauge
Result: The needle on the gauge should be
operating in the green area. If the needle is in
the red area, this indicates that the hydraulic
filter is being bypassed and the filter needs to
be replaced. See D-11, Replace the Hydraulic
Filter Elements.
Part No. 102916
high pressure filters
filter condition indicators
medium pressure filter
Result: The filter condition indicators should be
operating with the plungers in the green area.
If any of the indicators display the plunger in
the red area, this indicates that a hydraulic
filter is being bypassed and the filter needs to
be replaced. See D-11, Replace the Hydraulic
Filter Elements.
S-100 • S-105 • S-120 • S-125
3 - 11
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-8
Perform 30 Day Service
A-9
Perform Engine Maintenance Perkins Models
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after
the first 30 days or 40 hours of usage. After this
interval, refer to the maintenance checklists for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
• A-10
Grease the Turntable Rotation Bearing and Rotate Gear
• B-9
Inspect the Tires, Wheels,
and Lug Nut Torque
• B-10
Check the Drive Hub Oil Level
and Fastener Torque
• D-4 Check the Turntable Rotation Bearing Bolts
• D-11
Replace the Hydraulic Filter
Elements
Engine specifications require that this procedure
be performed every 50 hours or weekly, whichever
come first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Perkins 1004 User's Handbook
(Perkins part number TPD 1349E) OR the
Perkins 854 Series User's Handbook
(Perkins part number SEBU8726) OR the
Perkins 800D Series User's Handbook
(Perkins part number SEBU8324-00).
Perkins 1004 User's Handbook
Genie part number
61376
Perkins 854 Series User's Handbook
Genie part number
218708
Perkins 800D Series User's Handbook
Genie part number
None
3 - 12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
A-10
Perform Engine Maintenance Deutz Models
Engine specifications require that this one-time
procedure be performed after the first 50 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz F4L913 Operation Manual
(Deutz part number 0297-7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297-9929) OR the
Deutz TD 2.9 Operation Manual
(Deutz part number 0312-3893) OR the
Deutz TD 2011 Operation Manual
(Deutz part number 0312-3547).
Part No. 102916
Deutz F4L913 Operation Manual
Genie part number
62446
Deutz BF4L2011 Operation Manual
Genie part number
84794
Deutz TD 2.9 Operation Manual
Genie part number
1251561
Deutz TD 2011 Operation Manual
Genie part number
139320
S-100 • S-105 • S-120 • S-125
3 - 13
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
A-11
Grease the Turntable Rotation
Bearing and Rotate Gear
Genie specifications require that this procedure be
performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Remove the turntable rotation gear cover
retaining fasteners and remove the gear cover
from the machine.
2 Open the ground controls side turntable side
cover.
3 Locate the grease fitting below the ground
control box.
4 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5
inches (10 to 13 cm) at a time and repeat this
step 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 and
retaining fasteners onto the machine.
Bodily injury hazard. Contact
with the turntable rotation gear
could result in serious injury. Do
not operate the machine if the
turntable rotation gear cover is not
installed.
3 - 14
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Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-12
Grease the Extendable Axles
A-13
Replace the Drive Hub Oil
Genie specifications require that this procedure be
performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
Genie specifications require that this one-time
procedure be performed after the first 150 hours of
operation.
Frequent lubrication to the front and rear
extendable axles helps to ensure the smooth
operation of the axles over the lifetime of the
product. Two grease fittings are added at each
extending axle. One to direct grease to the top
sliding wear pad and one to direct grease to the
bottom sliding wear pad.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours
may cause the machine to perform poorly and
continued use may cause component damage.
Drive Hubs:
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
a
2 Remove both plugs and drain the oil into
a suitable container. Refer to capacity
specifications
3 Drive the machine to rotate the hub until the
plugs are located one at the side and the other
at the other side.
a
b
a
b
Top wear pad grease fitting
Side wear pad grease fitting
1 Locate the grease fittings on the extendable
axles covers.
2 Thoroughly pump grease into each grease
fitting. When grease is pumped into each fitting,
a hose directs this lubrication to the top or
bottom wear pad.
3 Cycle the extending axles in and out.
Genie recommends that the extending axles be
cycled in and out at least once a week.
Part No. 102916
a
drive hub plugs
4 Fill the hub with oil from either plug hole until
the oil level is even with the bottom of both plug
holes. Install the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
6 Check the torque of the drive hub mounting
bolts. Refer to Specifications, Machine Torque
Specifications.
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
Turntable Rotate Drive Hub:
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Machine
Torque Specifications.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
2 Remove the ground control side fixed turntable
cover. Refer to Repair Procedure, How to
Remove a Fixed Turntable Cover.
3 Tag, disconnect and plug the turntable rotate
drive motor hoses at the turntable rotate drive
motor and the turntable rotate drive brake
hoses at the turntable rotate drive brake. Cap
the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
5 Remove the plug from the side of the drive
hub. Drain the oil from the hub into a suitable
container.
6 Install the drive hub assembly onto the machine.
Lubricate and torque the drive hub mounting
bolts to specification. Refer to Specifications,
Machine Specifications.
7 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install
the plug. Refer to Specifications, Machine
Specifications.
8 Install the turntable rotate drive motor hoses
into the turntable rotate drive motor and install
the turntable rotate drive brake hose into the
turntable rotate drive brake.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
9 Adjust the turntable rotation gear backlash.
See D-5, Check the Turntable Rotation Gear
Backlash.
10Install the ground control side fixed turntable
cover onto the machine and tighten the
retaining fasteners
4 Remove the turntable rotate drive hub mounting
bolts and pivot bolt. Remove the turntable
rotate drive hub with a suitable lifting device of
ample capacity.
Crushing hazard. The turntable
rotate drive hub may become
unbalanced and fall when it is
removed from the machine if it is
not properly supported.
3 - 16
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Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
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Part No. 102916
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October 2015
Section 3 • Scheduled Maintenance Procedures
Checklist B Procedures
B-1
Inspect the Batteries
3 Be sure that the battery retainers and cable
connections are tight.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
5 Put on protective clothing and eye wear.
4 Fully charge the batteries. Allow the batteries to
rest 24 hours before performing this procedure
to allow the battery cells to equalize.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions. There are 2
batteries on the machine. One starts the engine
and the other powers the control system. The
batteries are charged by the alternator through a
battery separator.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Open the engine side cover.
2 Be sure that the battery cable connections are
free of corrosion.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
specific gravity of 1.277 +/- 0.007. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.269 or below. Proceed to
step 8.
8 Perform an equalizing charge OR fully charge
the batteries and allow the batteries to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 - 18
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
10Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
B-2
Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific gravity
of 1.277 +/- 0.007. The battery is fully charged.
Proceed to step 11.
Result: One or more battery cells display a
specific gravity from 1.269 to 1.218. The battery
is still useable, but at a lower performance so
will need to be recharged more often. Proceed
to step 11.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result
in unsafe operating conditions and may cause
component damage.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Result: One or more battery cells display a
specific gravity from 1.217 to 1.173. The battery
is approaching the end of its life. Proceed to
step 11.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is 1.172
or less. Replace the battery.
1 Open the engine side turntable cover.
2 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
11Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12Install the vent caps and neutralize any
electrolyte that may have spilled.
a
b
a
b
engine pivot plate anchor hole
engine pivot plate retaining fastener
3 Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
4 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
12Start the engine from the ground controls and
raise the boom above the turntable covers.
Component damage hazard. Be
sure the hydraulic supply hoses
to the function and drive pumps
are not kinked before starting the
engine.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
5 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
13Inspect the turntable area for burnt, chafed and
pinched cables.
· Engine wiring harness
· Battery area wiring
6 Open the ground controls side turntable cover.
14Lower the boom to the stowed position and turn
the engine off.
7 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
8
· Inside of the ground control box
· Hydraulic manifold wiring
· Battery area wiring
· Hydraulic oil cooler wiring
Inspect for a liberal coating of dielectric grease
in the following locations:
· All wire harness connectors to
ground control box
· Wire harness connectors
9 Open the hydraulic manifold box covers at both
sides of the drive chassis.
10Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Hydraulic manifold wiring
11Inspect for a liberal coating of dielectric grease
in the following location:
15Inspect 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
16Inspect for a liberal coating of dielectric grease
in the following location:
· All wire harness connectors to
platform control box
17Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor
hole at the pivot end of the engine pivot plate.
18Swing the engine pivot plate in towards the
machine.
19Install the bolt that was just removed into the
original hole to secure the engine pivot plate.
· Wire harness connectors to DCON module
3 - 20
S-100 • S-105 • S-120 • S-125
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-3
Check the Engine Oil Cooler and
Cooling Fins - Deutz Models (does
not include TD 2.9 models)
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
material.
Cooling and blower fins
5 Inspect the fan blower fins for physical damage.
6 Clean the fan blower fins of debris and foreign
material.
7 Using a flashlight, inspect the head cooling
passages and fins for physical damage or
foreign material.
8 If needed, clean the cylinder head cooling
passages and fins of debris and foreign
material.
9 Install the engine side cover and tighten the
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Burn hazard. Beware of hot
engine components. Contact with
hot engine components may result
in severe burns.
1 Open the engine side turntable cover.
Oil cooler
2 Remove the retaining fasteners from the engine
side cover. Remove the cover.
3 Inspect the oil cooler for leaks and physical
damage.
4 Clean the oil cooler of debris and foreign
Part No. 102916
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-4
Inspect the Engine Air Filter
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
Note: Perform this procedure with the engine off.
2 Release the latches from the end cap of the air
filter canister. Remove the end cap.
3 Remove the filter element.
4 Clean the inside of the canister and the canister
end cap with a damp cloth.
5 Inspect the filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or tap out dust, taking care not
to damage the element.
6 Install the filter element.
7 Install the end cap onto the canister. Secure the
clamps.
Note: Be sure the discharge slot is pointing down.
1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
a
b
c
aclamp
b cannister end cap
c dust discharge valve
3 - 22
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-5
Perform Hydraulic Oil Analysis
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
or hydraulic filters may cause the machine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require oil changes to be performed more
often.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels
of contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
See E-1, Test or Replace the Hydraulic Oil.
Part No. 102916
B-6
Perform Engine Maintenance Deutz Models
Engine specifications require that this procedure
be performed every 250 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz F4L913 Operation Manual
(Deutz part number 0297-7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297-9929) OR the
Deutz TD 2.9 Operation Manual
(Deutz part number 0312-3893) OR the
Deutz TD 2011 Operation Manual
(Deutz part number 0312-3547).
Deutz F4L913 Operation Manual
Genie part number
62446
Deutz BF4L2011 Operation Manual
Genie part number
84794
Deutz TD 2.9 Operation Manual
Genie part number
1251561
Deutz TD 2011 Operation Manual
Genie part number
139320
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
B-7
Perform Engine Maintenance Cummins Models
Engine specifications require that this procedure
be performed every 250 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Cummins B4.5 and B3.9L Operation and
Maintenance Manual (Cummins part number
4021389-01) OR the Cummins B3.3T Operation
and Maintenance Manual (Cummins part number
3666417-00).
Cummins B4.5 and B3.9L Operation and
Maintenance Manual
Genie part number
107527
Cummins B3.3T Operation and
Maintenance Manual
Genie part number
139324
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 24
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-8
Check the Exhaust System
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
a
b
a
b
engine pivot plate anchor hole
engine pivot plate retaining fastener
2 Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
3 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
4 Be sure that all fasteners are tight.
Cummins and Perkins models:
5 Inspect all welds for cracks.
1 Be sure that all fasteners are tight.
6 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
2 Inspect all welds for cracks.
3 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
Deutz models:
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
7 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor
hole at the pivot end of the engine pivot plate.
8 Swing the engine pivot plate in towards the
machine.
9 Install the bolt that was just removed into the
original hole to secure the engine pivot plate.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 25
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-9
Inspect the Tires, Wheels
and Lug Nut Torque
B-10
Check the Drive Hub Oil Level
and Fastener Torque
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Maintaining the tires and wheels in good
condition, including proper wheel fastener
torque, is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
Failure to maintain proper drive hub oil levels
may cause the machine to perform poorly and
continued use may cause component damage.
Note: The tires on these machines are foam filled
and do not need air added to them.
Drive hubs:
1 Drive the machine to rotate the hub until the
plugs are located one at the side and the other
at the other side.
a
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Specifications, Machine Torque Specifications.
a
drive hub plugs
2 Remove both plugs and check the oil level.
Result: The oil level should be even with the
bottom of the plug holes.
3 If necessary, add oil until the oil level is even
with the bottom of the plug holes.
4 Install the plugs in the drive hub.
5 Check the torque of the drive hub mounting
fasteners. Refer to Specifications, Machine
Torque Specifications.
6 Repeat this procedure for each drive hub.
3 - 26
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
Turntable Rotate Drive Hub:
1 Remove the fixed turntable cover at the ground
controls side of the machine.
2 Remove the power to platform plug panel
upper retaining fasteners and loosen the lower
retaining fasteners. Do not disconnect the
wiring.
a
c
b
3 Support the cover with a suitable lifting device.
Protect the cover from damage.
4 Remove the cover retaining fasteners. Remove
the cover from the machine.
Crushing hazard. The turntable
cover may become unbalanced
and fall when it is removed from
the machine if it is not properly
supporte
5 Remove the plug located on the top of the drive
brake and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
Part No. 102916
aplug
b turntable rotate drive hub
c drive brake
6 If necessary, add oil until the oil level is even
with the bottom of the plug hole.
7 Install the plug into the drive hub.
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-11
Confirm the Proper
Brake Configuration
2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
Note: The free-wheel valve is located on the drive
pump.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
b
d
Proper brake configuration is essential to safe
operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
operational.
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
disengaged position
c
a
a drive pump
bscrewdriver
c lift pump
d free-wheel valve
Note: The free-wheel valve should always remain
closed.
engaged position
3 - 28
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Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-12
Check and Adjust the
Engine RPM
Deutz models:
1 Start the engine from the ground controls.
2 Push one of the LCD screen buttons shown
until engine rpm is displayed.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Maintaining the engine rpm at the proper setting
for both low and high idle is essential to good
engine performance and service life. The machine
will not operate properly if the rpm is incorrect and
continued use may cause component damage.
Result: Refer to Specifications, Deutz Engine
Specification.
Skip to step 5 if the low idle rpm is correct.
3 Loosen the locknut on the low idle adjustment
screw.
Note: Does not apply to these models. The engine
RPM is controlled by the ECM and can only be
adjusted by re-programming the ECM. If RPM or
service is required, please contact Genie Product
Support.
Deutz TD 2.9 L4 model
Perkins 854F-34T model
Note: Use the following chart to identify the
description of each LCD screen control button
used in this procedure.
Plus
Minus
Previous
a
low idle adjustment screw
Part No. 102916
a
a
low idle adjustment screw
Enter
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
4 Adjust the low idle adjustment screw until low
idle is 1500 rpm. Tighten the locknut.
2 Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
5 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
3 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Result: Refer to Specifications, Deutz Engine
Specification.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
If the high idle is correct, disregard adjustment
step 6.
6 Loosen the yoke lock nut. Turn the high
idle adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
Cummins and Perkins models:
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
4 Start the engine from the ground controls.
Component damage hazard. Be
sure the hydraulic supply hoses
to the function and drive pumps
are not kinked before starting the
engine.
5 Push one of the LCD
screen buttons shown
until engine rpm is
displayed.
Result: Refer to Specifications, Perkins Engine
Specification.
a
a
b
a
b
engine pivot plate anchor hole
engine pivot plate retaining fastener
c
b
Perkins models
a low idle adjustment screw
b solenoid boot
c yoke lock nut
3 - 30
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Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
Skip to step 7 if the low idle rpm is correct.
6 Loosen the low idle lock nut. Turn the low idle
adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
7 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Result: Refer to Specifications, Cummins
Engine Specification.
If the high idle is correct, disregard adjustment
step 8.
8 Perkins models: Loosen the yoke lock nut.
Turn the high idle adjustment nut and solenoid
boot counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Cummins models: Turn the high idle solenoid
boot counterclockwise to increase the rpm or
clockwise to decrease the rpm. Recheck the
rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
9 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor
hole at the pivot end of the engine pivot plate.
10Swing the engine pivot plate in towards the
machine.
11Install the bolt that was just removed into the
original hole to secure the engine pivot plate.
a
b
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
c
Cummins models
a low idle adjustment screw
b solenoid cable
c rpm solenoid
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 31
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-13
Test the Key Switches
STOP
00000
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Proper key switch action and response is essential
to safe machine operation. Failure of either
key switch to function properly could cause a
hazardous operating situation.
There are two key switches on the machine - the
Main key switch and the Service Bypass/Recovery
key switch.
Run
Service
Bypass
Recovery
The Main key switch controls machine operation
from the ground or platform controls.
1 Open the ground controls side turntable side
cover.
When the Service Bypass/Recovery key switch is
turned to the service bypass position, the primary
boom can be raised while the axles are retracted.
This feature of the machine is especially helpful for
storage purposes or when loading the machine for
transport.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
Note: When the boom is raised with the axles
retracted, the boom cannot be rotated past either
circle-end wheel.
When the Service Bypass/Recovery key switch
is turned and held to the recovery position, the
auxiliary power units will turn on and fully retract
the boom and then lower the boom. This feature of
the machine is especially helpful if the operator in
the platform cannot lower the boom, if the platform
controls become inoperative or for returning
the machine to a safe position when the safety
switches have been tripped.
Note: Perform this procedure with the axles
retracted and the boom in the stowed position.
3 At the ground controls, turn the service
bypass/recovery key switch to the run position.
4 Turn the main key switch to ground control,
start the engine and then turn the key switch to
platform control.
5 Check any machine function from the ground
controls.
Result: The machine functions should not
operate.
6 Turn the main key switch to ground control.
7 Check any machine function from the platform
controls.
Result: The machine functions should not
operate.
8 Turn the main key switch to the off position.
Result: The engine should stop and no
functions should operate.
9 Turn the main key switch to ground control and
start the engine.
3 - 32
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
10Attempt to raise the primary boom.
Result: The boom should not raise.
Note: The primary boom will not raise until the
axles are fully extended.
11Remove the key from the main key switch and
insert the key into the service bypass/recovery
key switch.
Note: The main key switch should remain in the
ground control position.
12Turn the service bypass/recovery key switch to
the service bypass position.
13Raise the boom.
Result: The boom should raise.
14Remove the key from the service
bypass/recovery key switch and insert the key
into the main key switch.
15Turn the main key switch to the off position.
16Remove the key from the main key switch and
insert the key into the service bypass/recovery
key switch.
17Turn and hold the service bypass/recovery key
switch to the recovery position.
Result: The boom should return to the stowed
position.
B-14
Test the Ground Control Override
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the red Emergency
Stop button at the platform controls is in the on or
off position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the red Emergency Stop button at the
platform controls to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
Note: The boom will not raise past horizontal and
the boom will not extend more than
12 inches / 30.5 cm unless both axles are fully
extended.
18Turn the service bypass/recovery key switch to
the run position.
19Remove the key from the service
bypass/recovery key switch and insert the key
into the main key switch.
20Turn the main key switch to the off position.
21Close the turntable side cover.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 3 • Scheduled Maintenance Procedures
B-15
Test the Platform Self-leveling
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained level by the communication
between the platform level sensor and the
turntable level sensor. If the platform becomes
out of level, the computer at the ground controls
will open the appropriate solenoid valve(s) at the
platform manifold to maintain a level platform.
A platform self-leveling failure creates an unsafe
working condition for platform and ground
personnel.
1 Start the engine from the platform controls and
extend the axles.
2 Turn the key switch to ground controls.
5 Push and hold a function enable/speed select
button and fully raise the boom.
Result: The platform should remain level at
all times to within ±2 degrees.
Note: If the platform becomes out of level, the
tilt alarm will sound and the Platform Not Level
Indicator will flash at the ground controls. The
platform level up/down buttons will only work in
the direction that will level the platform. Level the
platform until the indicator light turns off.
6 Push and hold a function enable/speed select
button and fully lower the boom.
Result: The platform should remain level at
all times to within ±2 degrees.
Note: If the platform becomes out of level, the
tilt alarm will sound and the Platform Not Level
Indicator will flash at the ground controls. The
platform level up/down buttons will only work in
the direction that will level the platform. Level the
platform until the indicator light turns off.
3 Push and hold a function enable/speed select
button and fully retract the boom.
4 Push and hold a function enable/speed select
button and adjust the platform to a level position
using the platform level up/down buttons.
3 - 34
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-16
Test the Safety Envelope and
Circuits
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Testing the machine safety envelope is critical to
safe machine operation. If the boom is allowed to
operate when a safety switch is not functioning
correctly, the machine stability is compromised
and may tip over.
Note: Refer to Repair Procedure, Limit Switch and
Level Sensor Locations for diagram showing the
location of switches in this procedure.
1 Start the engine from the ground controls.
7 Pull out the red Emergency Stop button to the
on position and restart the engine.
8 Disconnect the 68° proximity switch LSB14AO
and install a wire jumper between pin 3 and pin
4 of the Deutsch connector.
Result: ">68 deg" should be present on the
display screen at the ground controls.
9 Activate the function enable/high RPM button
and extend the boom to 101 feet / 30.8 m.
Result: The engine should stop and the boom
extend function should be disabled.
Result: If the engine does not stop and the
boom continues to extend, the LSB2RS switch
is out of adjustment or the wiring circuit is faulty
and will need to be replaced or repaired. See
Repair Section.
Bodily injury hazard. If the boom
extends to more than 101 feet
/ 30.8 m without stopping the
engine, stop immediately and
retract the boom until the boom is
extended to less than 100 feet /
30.5 m. Failure to retract the boom
could result in death or serious
injury.
2 Raise the boom to approximately 60°.
Note: For S-100 or S-105 models, proceed to step
30.
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:
Machines after SN 2709:
10Using auxiliary power, retract the boom until the
boom is extended to approximately 95 feet
/ 29 m.
5 Push in the red Emergency Stop button to the
off position.
11Remove the wire jumper installed in step 8 and
connect the Deutsch connector to LSB14AO.
4 Proceed to step 8.
6 Plug in the LSB2RS test jumper between the
lower limit switch and the function manifold (J2
and J4 connectors on the ground control box).
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 35
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
S-100/105 models before SN 806:
20Measure the angle of the boom.
S-120/125 models before SN 2710:
Result: The angle of the boom should be
greater than 65°.
12Proceed to step 15.
21Using auxiliary power, raise the boom until the
boom angle is greater than 68°.
S-100/105 Models after SN 805:
S-120/125 Models after SN 2709:
13Push in the red Emergency Stop button to the
off position.
14Remove the LSB2RS test jumper between the
lower limit switch and the function manifold (J2
and J4 connectors on the ground control box).
15Pull out the red Emergency Stop button to the
on position and restart the engine.
65° Angle Safety Switch, LSB9AS:
16Raise the boom to the maximum angle.
17Fully extend the boom.
18Disconnect the 68° proximity switch LSB14AO
and install a wire jumper between pin 3 and pin
4 of the Deutsch connector.
19Activate the function enable/high RPM button
and lower the boom to 65°.
22Remove the wire jumper installed in step 18 and
connect the Deutsch connector to LSB14AO.
23With 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.
button until clear all safety switch
24Press the
faults appears.
25Select yes, then press the
26Press the
button.
button until exit appears.
27Select yes, then press the
button.
28Restart the engine.
50° Angle Safety Switch, LSB8AS:
29Lower the boom to approximately 60°.
Result: The engine should stop and the boom
down function should be disabled.
30Extend the boom to approximately
95 feet / 28.96 m.
Result: If the engine does not stop and the
boom continues to lower to less than 65°, the
LSB9AS switch is out of adjustment or the
wiring is faulty and will need to be replaced or
repaired. See Repair Section.
31Disconnect the 53° proximity switch LSB13AO
and install a wire jumper between pin 3 and pin
4 of the Deutsch connector.
Bodily injury hazard. If the
boom lowers to less than 65°
without stopping the engine, stop
immediately and raise the boom
until the boom is elevated to
greater than 68°. Failure to raise
the boom could result in death or
serious injury.
3 - 36
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
32Activate the function enable/high RPM button
and lower the boom to 50°.
Result: The engine should stop and the boom
down function should be disabled.
Result: If the engine does not stop and the
boom continues to lower to less than 50°,
the LSB8AS switch is out of adjustment or
the wiring circuit is faulty and will need to be
replaced or repaired. See Repair Section.
Bodily injury hazard. If the
boom lowers to less than 50°
without stopping the engine,
stop immediately and raise the
boom until the boom is elevated
togreater than 53°. Failure to raise
the boom could result in death or
serious injury.
33Measure the angle of the boom.
Result: the angle of the boom should be greater
than 50°.
34Using auxiliary power, raise the boom until the
boom angle is greater than 53°.
35Remove the wire jumper installed in step 31 and
connect the Deutsch connector to LSB13AO.
38Select yes, then press the
39Press the
button until exit appears.
40Select yes, then press the
button.
41Restart the engine, retract the boom so it is
extended less than 75 feet / 22.9 m and then
lower the boom sufficient to gain access to
LSB3EO.
Note: LSB3EO is located on top of boom tube
number 2 at the platform end of the machine.
76 feet / 23.2 m Length Safety Switch, LSB4ES:
42Disconnect the 75 feet / 22.9 m safety switch
LSB3EO.
43Start the engine and activate the function
enable/high RPM button and extend the boom
to 76 feet / 23.2 m.
Result: The engine should stop and the boom
extend function should be disabled.
Result: If the engine does not stop and the
boom continues to extend, the LSB4ES switch
is out of adjustment or the wiring circuit is faulty
and will need to be replaced or repaired. See
Repair Section.
36With 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.
button until clear all safety switch
37Press the
faults appears.
Part No. 102916
button.
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. If the boom
extends to more than 76 feet
/ 23.2 m without stopping the
engine, stop immediately and
retract the boom until the boom
is extended to less than 75 feet /
22.9 m. Failure to retract the boom
could result in death or serious
injury.
3 - 37
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
44Using auxiliary power, retract the boom until the
boom is extended to less than 75 feet / 22.9 m.
45Re-connect the harness plug to LSB3EO.
46With 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.
button until clear all safety switch
47Press the
faults appears.
48Select yes, then press the
49Press the
54Place the arm removed in step 53 back on
the LSB6S switch 180° opposite its original
position. Rotate the head of the switch 45°
clockwise and activate the function enable/high
RPM button and attempt to extend the boom.
Result: The boom extend function should be
disabled.
Result: If the boom extends, the LSB6S switch
or wiring circuit is faulty and will need to be
replaced or repaired. See Repair Section.
Bodily injury hazard. If the boom
extends at all, stop immediately
and retract the boom until the
boom is extended to less than
2 feet / 0.6 m. Failure to retract
the boom could result in death or
serious injury.
button.
button until exit appears.
50Select yes, then press the
button.
Cable Break Safety Switch, LSB6S:
51Start the engine and activate the function
enable/high RPM button and retract the boom
until the boom is extended to less than 2 feet / 0.6
m.
52Remove the boom end cover from the pivot end
of the boom.
53Remove the arm from the cable break limit
switch LSB6S.
55Activate the function enable/high RPM button
and attempt to retract the boom.
Result: The boom retract function should be
enabled.
Result: If the boom does not retract, the LSB6S
switch or wiring circuit is faulty and will need to
be replaced or repaired. See Repair Section.
Note: LSB6S is located at the end of the boom
tubes at the pivot end of the boom.
3 - 38
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
56Allow the switch to return to its neutral position,
then rotate the head of the switch 45° counter
clockwise and activate the function enable/high
RPM button and attempt to extend the boom.
Result: The boom extend function should be
disabled.
Result: If the boom extends, the LSB6S switch
or wiring circuit is faulty and will need to be
replaced or repaired. See Repair Section.
62Place a metal washer over the target area of
the axle extend proximity switch LSAX1EO and
place a metal washer over the target area of
the axle extend proximity switch LSAX2EO to
close the contacts.
Result: The axle extend indicator light at
the ground and platform controls should be
illuminated.
a
Bodily injury hazard. If the boom
extends at all, stop immediately
and retract the boom until the
boom is extended to less than
2 feet (0.6 m). Failure to retract
the boom could result in death or
serious injury.
57Reinstall the arm onto LSB6S in its original
position.
Axle Extend Safety Switch, LSAX1ES and
LSAX2ES and
3 feet / 0.9 m Safety Switch, LSB3RS and
11° Angle Safety Switch, LSB7DS:
58Fully retract and lower the boom to the stowed
position.
Proximity switch
a target area
63Activate the function enable/high RPM button
and attempt to extend the boom.
Result: The boom should not extend to more
than 3 feet / 0.9 m.
Result: If the boom extends to more than 3 feet
/ 0.9 m, the LSAX1ES or LSAX2ES switch are
out of adjustment or the wiring circuit is faulty
and will need to be replaced or repaired. See
Repair Section.
59Retract both axles approximately 1 foot / 0.3 m.
60Remove the access cover from each axle.
61Disconnect the square-end axle extend safety
switch LSAX1ES and install a wire jumper
between pin 3 and pin 4 of the deutsch
connector.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. If the boom
extends to more than 3 feet
/ 0.9 m, stop immediately and
retract the boom until the boom is
extended to less than 2 feet
/ 0.6 m. Failure to retract the boom
could result in death or serious
injury.
3 - 39
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
64Activate the function enable/high RPM button
and attempt to raise the boom.
67Activate the function enable/high RPM button
and attempt to extend the boom.
Result: The boom should not raise to more
than 11°.
Result: The boom should not extend to more
than 3 feet / 0.9 m.
Result: If the boom continues to raise, the
LSAX1ES or LSAX2ES switch are out of
adjustment or the wiring circuit is faulty and will
need to be replaced or repaired. See Repair
Section.
Result: If the boom extends to more than 3 feet
/ 0.9 m, the LSAX1ES or LSAX2ES switch are
out of adjustment or the wiring circuit is faulty
and will need to be replaced or repaired. See
Repair Section.
Bodily injury hazard. If the boom
raises to more than 11°, stop
immediately and lower the boom
until the boom is less than 11°.
See Repair Section. Failure to
retract the boom could result in
death or serious injury.
65Remove the wire jumper installed in step 61 and
connect the Deutsch connector to LSAX1ES.
66Disconnect the circle-end axle extend safety
switch LSAX2ES and install a wire jumper
between pin 3 and pin 4 of the Deutsch
connector.
Bodily injury hazard. If the boom
extends to more than 3 feet
/ 0.9 m, stop immediately and
retract the boom until the boom is
extended to less than 2 feet
/ 0.6 m. Failure to retract the boom
could result in death or serious
injury.
68Activate the function enable/high RPM button
and attempt to raise the boom.
Result: The boom should not raise to more
than 11°.
Result: If the boom continues to raise, the
LSAX1ES or LSAX2ES switch are out of
adjustment or the wiring circuit is faulty and will
need to be replaced or repaired. See Repair
Section.
Bodily injury hazard. If the boom
raises to more than 11°, stop
immediately and lower the boom
until the boom is less than 11°.
Failure to lower the boom could
result in death or serious injury.
69Remove the wire jumper installed in step 66 and
connect the Deutsch connector to LSAX2ES.
3 - 40
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-17
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the caps be inspected
more often.
Explosion and fire hazard.
Engine fuels are combustible.
Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Procced to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
3 Using a mild solvent, carefully wash the
cap venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air passes through the hydraulic tank
cap. 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
cap venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 6.
8 Install the breather cap onto the hydraulic tank.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 41
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-18
Test the Engine Idle Select
Operation
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
6 Turn the key switch to platform controls.
7 At the platform controls, press the engine idle
select button until high idle (rabbit symbol) is
selected.
Result: The engine should change to high idle.
a
b
c
A properly operating engine idle select function
is essential to good engine performance and safe
machine operation. There are three settings.
Low idle (turtle symbol) allows the operator
to control multiple boom and/or drive functions
simultaneously, though at reduced speed. This
setting maintains a consistent low idle.
d
High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive functions
simultaneously. This setting maintains a
consistent high idle.
Foot switch activated high idle (rabbit and
foot switch symbols) should be used for normal
machine operation. This selection activates high
idle only when the foot switch is pressed down.
1 Turn the key switch to ground controls.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Start the engine from the ground controls.
4 Push and release the rpm select button until
high rpm is selected (rabbit symbol).
a
b
c
d
foot switch activated high idle indicator light
low idle indicator light
high idle indicator light
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 foot
switch activated high idle (rabbit and foot switch
symbol) is selected.
Result: The engine should not change to
high idle.
10Press down the foot switch.
Result: The engine should change to high idle.
Result: The engine should change to high idle.
5 Push and release the rpm select button until
low rpm is selected (turtle symbol).
Result: The engine should return to low idle.
3 - 42
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-19
Test the Drive Brakes
B-20
Test the Drive Speed Stowed Position
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
Refer to Maintenance Procedure,
Confirm the Proper Brake
Configuration.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Proper drive function movement is essential
to safe machine operation. The drive function
should respond quickly and smoothly to operator
control. Drive performance should also be free
of hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Note: Select a test area that is firm, level and free
of obstructions.
Note: Perform this procedure with the boom in the
stowed position.
Note: Select a test area that is firm, level and free
of obstructions.
1 Create start and finish lines by marking two
lines on the ground 36 feet / 11 m apart.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the foot
switch activated high idle (rabbit and foot switch
symbol) is selected. then lower the boom into
the stowed position.
3 Press the engine rpm select button until the foot
switch activated high idle (rabbit and foot switch
symbol) is selected, then lower the boom into
the stowed position.
4 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use
when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive
controller when your reference point on the
machine crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Section Specifications, Machine Specifications.
Part No. 102916
4 Choose a point on the machine; i.e., contact
patch of a tire as a visual reference for use
when crossing the start and finish lines.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section Specifications, Machine
Specifications.
S-100 • S-105 • S-120 • S-125
3 - 43
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-21
Test the Drive Speed Raised or Extended Position
7 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section Specifications, Machine
Specification.
8 Lower the boom below horizontal.
9 Extend the boom approximately 4 feet (1.2 m).
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
10Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
Proper drive function movement is essential
to safe machine operation. The drive function
should respond quickly and smoothly to operator
control. Drive performance should also be free
of hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
11Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
Note: Select a test area that is firm, level and free
of obstructions.
1 Create start and finish lines by marking two
lines on the ground 36 feet (11 m) apart.
12Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section Specifications, Machine
Specification.
13Raise the boom to a horizontal position.
2 Start the engine from the platform controls.
14Extend the boom until the raise boom LED and
envelope alarm are activated.
3 Press the engine idle select button until the foot
switch activated high idle (rabbit and foot switch
symbol) is selected.
15Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
4 Raise the boom until the engine rpm switches
to low speed.
16Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
5 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
3 - 44
17Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section Specifications, Machine
Specification.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-22
Inspect the Boom Extend/Retract
Cables
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The boom extend/retract cables are responsible
for the extension and retraction of the number
3 boom tube on the S-100 and S-105, and the
numbers 2 and 3 boom tubes on the S-120 and
S-125. Inspecting for foreign objects, damage and/
or improper adjustment of the boom extend/retract
cables on a regular basis is essential to good
machine performance and safe machine operation.
The boom extend and retract functions should
operate smoothly and be free of hesitation, jerking
and unusual noise.
3 Visually inspect the cables and components
through 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 be
necessary to thoroughly inspect the above items.
Note: A pulley groove gauge should be used to
check the condition of the pulleys.
4 Replace the cables if any damage is found.
Note: Perform this procedure with the boom in the
stowed position and the engine off.
5 At the pivot end of the boom, visually inspect
for the following:
1 Remove the boom end cover from the pivot end
of the boom.
• The red locking bracket is securely installed over the cable adjustment bolts
6 Install the plastic cover at the pivot end of the
boom and access panels on the sides of the
boom.
a
b
7 Start the engine from the platform controls.
8 Extend the boom approximately 2 feet (0.6 m).
b
a
b
c
c
boom end cover
side access covers
cable ends (located
underneath the boom)
2 Remove the retaining fasteners from the access
covers located on the side of the boom at the
platform end of the machine. Remove the
covers.
Part No. 102916
9 Retract the boom. While retracting the boom,
visually inspect the number 2 and number 3
boom tubes.
Result: The number 2 should not move more
than 1/2 inch (13 mm) before the number 3
boom tube begins to retract.
Note: If the number 2 boom tube moves more than
inch (13 mm) before the number 3 boom tube
begins to retract, the boom extend/retract cables
need to be adjusted. See Repair Procedure 4-5,
How to Adjust the Boom Extend/Retract Cables.
1/2
S-100 • S-105 • S-120 • S-125
3 - 45
October 2015
Section 3 • Scheduled Maintenance Procedures
Checklist C Procedures
C-1
Perform Engine Maintenance Deutz Models
C-2
Perform Engine Maintenance Cummins Models
Engine specifications require that this procedure
be performed every 500 hours.
Engine specifications require that this procedure
be performed every 500 hours or 6 months,
whichever comes first.
All Models:
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
• Engine oil and filter - change
TD 2.9 Models:
• Primary fuel filter - replace
• V-belts - inspect/adjust/replace
• Air intake pipe - check
• Cooling system - check
TD 2011L04i Models:
• Valve clearance - check at first oil change
Required maintenance procedures and additional
engine information are available in the
Deutz F4L913 Operation Manual
(Deutz part number 0297-7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297-9929) OR the
Deutz TD 2.9 Operation Manual
(Deutz part number 0312-3893) OR the
Deutz TD 2011 Operation Manual
(Deutz part number 0312-3547).
Deutz F4L913 Operation Manual
Genie part number
62446
Deutz BF4L2011 Operation Manual
Genie part number
84794
Deutz TD 2.9 Operation Manual
Genie part number
1251561
Deutz TD 2011 Operation Manual
Genie part number
139320
3 - 46
Required maintenance procedures and additional
engine information are available in the
Cummins B4.5 and B3.9L Operation and
Maintenance Manual (Cummins part number
4021389-01) OR the Cummins B3.3T Operation
and Maintenance Manual (Cummins part number
3666417-00).
Cummins B4.5 and B3.9L Operation and
Maintenance Manual
Genie part number
107527
Cummins B3.3T Operation and
Maintenance Manual
Genie part number
139324
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
S-100 • S-105 • S-120 • S-125
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-3
Perform Engine Maintenance Perkins Models
C-4
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure
be performed every 500 hours.
Engine specifications require that this procedure
be performed every 500 hours or annually.
854F Models:
1104D Models:
• Engine oil and filter - change
• Engine oil and filter - change
• Fuel system primary filter (water separator)
• Fuel system primary filter (water separator)
element - replace
element - replace
• Fuel system secondary filter - replace
• Fuel system secondary filter - replace
• Fan clearance - check
• Hoses and clamps - inspect/replace
Required maintenance procedures and additional
engine information are available in the Perkins
854F Operation and Maintenance Manual (Perkins
part number SEBU8726-00) OR the Perkins 1004
Serial User's Handbook (Perkins part number
TPD 1349E) OR the Perkins 800D Serial User's
Handbook (Perkins part number TPD 1477).
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
Perkins 1004 Serial User's Handbook
Genie part number
61376
Perkins 800D Serial User's Handbook
Genie part number
None
Part No. 102916
• Radiator - clean
• V-belts - inspect/adjust/replace
Required maintenance procedures and additional
engine information are available in the Perkins
854F Operation and Maintenance Manual (Perkins
part number SEBU8726-00) OR the Perkins 1004
Serial User's Handbook (Perkins part number
TPD 1349E) OR the Perkins 800D Serial User's
Handbook (Perkins part number TPD 1477).
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
Perkins 1004 Serial User's Handbook
Genie part number
61376
Perkins 800D Serial User's Handbook
Genie part number
None
S-100 • S-105 • S-120 • S-125
3 - 47
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-5
Replace the Engine Air Filter
Element
C-6
Grease the Platform Overload
Mechanism (if equipped)
Engine specifications require that this procedure
be performed every 500 hours or 6 months,
whichever comes first.
Genie specifications require that this procedure be
performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Release the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
2 Remove the filter element.
3 Use a damp cloth to wipe the filter sealing
surface and the inside of the outlet tube. Make
sure that all contaminant is removed before the
filter is inserted.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting using a multipurpose grease.
4 Check new filter element gasket for damage
before 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.
3 - 48
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-7
Test the Platform Overload
System (if equipped)
Genie specifications require that this procedure be
performed every 500 hours or 6 months, whichever
comes first.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Turn the key switch to platform control. Start
the engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
4 Using a suitable lifting device, place an
appropriate test weight equal to that of the
maximum platform capacity in one of the
locations shown. Refer to Illustration 1.
Result: The platform overload indicator light
should be off at both the ground and platform
controls.
Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate
the platform overload system. Refer to Repair
Procedure, Calibrate the Platform Overload
System (if equipped).
5 Carefully move the test weight to each
remaining location.
Result: The platform overload indicator light
should be off at both the ground and platform
controls.
Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate
the platform overload system. Refer to Repair
Procedure, Calibrate the Platform Overload
System (if equipped).
6 Using a suitable lifting device, place an
additional weight onto the platform:
S-100 and S-120- 75 lbs / 34 kg
S-105 and S-125- 50 lbs / 22.7 kg.
Result: The alarm should sound.
The platform overload indicator light should be
flashing at the platform controls and
platform overload should be displayed on the
LCD screen at the ground controls.
Result: The alarm is not sounding and the
platform overload indicator light is not flashing
and platform overload is not displayed on the
LCD screen at the ground controls. Calibrate
the platform overload system. Refer to Repair
Procedure, Calibrate the Platform Overload
System (if equipped).
Note: There may be an approximate 2 second
delay before the overload indicator light turns on
and the alarm sounds.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 49
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
11Lift the test weights off the platform floor using
a suitable lifting device.
Result: The platform overload indicator light and
alarm should turn off at both the ground and
platform controls.
Illustration 1
7 Carefully move the test weights to each
remaining location in the platform.
Result: The alarm should sound.
The platform overload indicator light should be
flashing at the platform controls and
platform overload should be displayed on the
LCD screen at the ground controls.
Result: The alarm is not sounding and the
platform overload indicator light is not flashing
and platform overload is not displayed on the
LCD screen at the ground controls. Calibrate
the platform overload system. Refer to Repair
Procedure, Calibrate the Platform Overload
System (if equipped).
Note: There may be an approximate 2 second
delay before the overload indicator light turns on
and the alarm sounds.
Note: There may be an approximate 2 second
delay before the overload indicator light and alarm
turn off.
12Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
13Turn the key switch to platform control.
14Test all machine functions from the platform
controls.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, refer to Repair Procedure,
Calibrate the Platform Overload System (if
equipped).
8 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
9 Turn the key switch to ground control.
10Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
Note: Machine functions should still operate with
auxiliary power at the ground controls.
3 - 50
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
Checklist D Procedures
D-1
Check the Boom Wear Pads
6 Remove the boom end cover retaining
fasteners at the pivot end of the boom. Remove
the boom end cover from the machine.
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
7 Remove the boom side inspection cover
retaining fasteners from the boom at the pivot
end of the boom. Remove the boom inspection
cover from the machine to access boom 3 wear
pads.
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide
a low friction, replaceable wear pad between
moving parts. Improperly shimmed wear pads or
continued use of worn out wear pads may result
in component damage and unsafe operating
conditions.
1 Start the engine from the ground controls.
2 Raise the end of the boom to a comfortable
working height (chest high). Stop the engine.
3 Remove the protective covers from the platform
end of each boom tube.
4 Measure each wear pad.
Boom wear pad specifications
Minimum thickness
1/2
inch
12.7 mm
8 Measure each wear pad at the pivot end of the
boom.
Boom wear pad specifications
Minimum thickness
1/2
inch
12.7 mm
9 Replace any wear pad if it is less than
specification. If a wear pad is not less than
specification, shim as necessary to obtain
minimum clearance with zero binding.
10Extend and retract the boom through the entire
range of motion to check for tight spots that
may cause binding of the boom tubes.
Note: Always maintain squareness between the
outer and inner boom tubes.
5 Replace any wear pad if it is less than
specification. If a wear pad is not less than
specification, shim as necessary to obtain
minimum clearance with zero binding.
Note: The minimum shim clearance for the boom
wear pads is .030 in / .76 mm and the maximum
allowable shim clearance is .090 in / 2.29 mm.
Note: If the wear pads are still within specification,
refer to Repair Procedure, How to Shim the Boom.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 51
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-2
Check the Extendable Axle
Wear Pads
3 Replace any wear pad if it is less than
specification. If a wear pad is not less than
specification, shim as necessary to obtain
minimum clearance and no drag.
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
Maintaining the axle wear pads in good condition
is essential to safe machine operation. Wear
pads are placed on axle tube surfaces to provide
a low friction, replaceable wear pad between
moving parts. Improperly shimmed wear pads or
continued use of worn out wear pads may result
in component damage and unsafe operating
conditions.
Note: If the wear pads are still within specification.
Refer to Repair Procedure, How to Shim the
Extendable Axles.
Note: Keep axle lubricated. See A-11, Grease the
Extendable Axles.
4 Extend and retract the axles through the entire
range of motion to check for tight spots that
may cause binding or scraping of the axle
tubes.
Note: Always maintain squareness between the
outer and inner axle tubes.
Note: Be sure that the axles are fully extended
before attempting this procedure.
1 Start the engine from the platform controls and
extend the axles.
2 Measure each wear pad.
Extendable axle wear pad specifications
Minimum thickness
3 - 52
7/16
inch
11.1 mm
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-3
Check the Free-wheel
Configuration
5 Manually rotate each wheel at the square-end
of the machine.
Result: Each wheel at the square-end of the
machine should rotate with minimum effort.
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
Proper use of the free-wheel configuration is
essential to safe machine operation. The
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious
injury and property damage.
Collision hazard. Select a work
site that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
1 Chock both of the wheels at the circle-end
of the machine to prevent the machine from
rolling.
2 Place a lifting jack of ample capacity
(35,000 lbs / 16000 kg) under each of the steer
yokes at the square-end of the machine.
3 Lift the wheels off the ground and place blocks
under the drive chassis for support.
6 Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks. Lower the
machine.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury
and property damage.
7 Chock both of the wheels at the square-end
of the machine to prevent the machine from
rolling.
8 Place a lifting jack of ample capacity
(35,000 lbs / 16000 kg) under each of the steer
yokes at the circle-end of the machine.
9 Lift the wheels off the ground and place blocks
under the drive chassis for support.
10Disengage the drive hubs by turning over the
drive hub disconnect caps on each wheel hub
at the circle-end of the machine.
11Manually rotate each wheel at the circle-end of
the machine.
Result: Each wheel at the circle-end of the
machine should rotate with minimum effort.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each wheel hub
at the square-end of the machine.
disengaged position
engaged position
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 53
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-4
Check the Turntable Rotation
Bearing Bolts
12Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks. Lower the
machine.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury
and property damage.
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
All models:
13Be sure the free-wheel valve on the drive pump
is closed (clockwise).
Note: The free-wheel valve is located on the drive
pump, and should always remain closed.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the boom to a horizontal position.
2 Install a safety chock onto the hydraulic lift
cylinder extension rod. Carefully lower the
boom onto the lift cylinder safety chock.
Crushing hazard. Keep hands
away from the cylinder and all
moving parts when lowering the
boom.
b
c
a
d
Note: The lift cylinder safety chock is available
through Genie (Genie part number 75097).
a drive pump
bscrewdriver
c lift pump
d free-wheel valve
3 - 54
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
3 Be sure that each turntable rotation bearing
mounting bolt above the turntable is torqued
in sequence. Refer to Specifications, Machine
Torque Specifications.
18
23 28
1 6
11
16
13
3
30
21
26
4
9
25
20
15
10
14
19
24
29
8
5
D-5
Check the Turntable Rotation
Gear Backlash
27 22
7
17 12
2
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
Properly adjusted turntable rotation gear backlash
is essential for good machine performance and
service life. Improperly adjusted turntable rotation
gear backlash will cause the machine to perform
poorly and continued use will cause component
damage. The turntable rotation drive hub is
mounted on the swing chassis behind the fixed
side cover at the ground controls side.
Note: Be sure to check the backlash with the
machine fully stowed and the counterweight at the
square end of the machine.
Note: Select a test area that is firm, level and free
of obstructions.
Bolt torque sequence
4 Raise the boom to a horizontal position.
5 Remove the safety chock and lower the boom
to the stowed position.
6 Be sure that each turntable rotation bearing
mounting bolt under the drive chassis is
torqued in sequence. Refer to Specifications,
Machine Torque Specifications.
1 Rotate the turntable until the boom is centered
between the circle end wheels.
2 Apply approximately 20 lbs / 89 N of side force
to the platform, moving the platform to one side
as far as it will go.
Note: The turntable rotation bearing bolt torque
sequence is the same from above the turntable
and below the drive chassis.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 55
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
3 Using a feeler guage, measure the gap
between the swing hub pinion gear and the
turntable rotation bearing at the center tooth.
The gap should be meaured on one side of the
pinion gear on the center tooth.
5 Apply approximately 20 lbs / 89 N of side force
to the platform, moving the rotator to the left as
far as it will go. Move the tape measure so the
straight edge on the rotator measures
0 inches / 0 m.
Note: The pinion gear can be accessed on the
outside of the chassis under the pinion gear guard.
6 Apply approximately 20 lbs / 89 N of side force
to the platform, moving the rotator to the right
as far as it will go.
Result: The gap is between .010 inch / .254 mm
and .022 inch / .559 mm. The backlash is within
tolerance.
Result: The gap is less than .010 inch / .254
mm or more than .022 inch / .559 mm. The
backlash needs to be adjusted. Refer to Repair
Procedure, Turntable Rotation Hydraulic Motor
and Drive Hub.
4 After the backlash has been set, place a tape
measure approximately two feet long / 0.6 m,
perpendicular to the boom, on the ground under
the rotator.
7 Note the distance on the tape measure the
rotator has moved.
Result: The rotator movement does not exceed
2 inches / 51 mm. The backlash is in tolerence.
Result: The side-to-side rotator movement
exceeds 2 inches / 51 mm. The turntable
drive hub may need service. Contact Genie
Industries Service Department.
Note: Fasten a straight edge on the side of the
rotator using tape so one end is just above the
tape measure.
3 - 56
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-6
Replace the Drive Hub Oil
4 Fill the hub with oil from either plug hole until
the oil level is even with the bottom of both plug
holes. Install the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
6 Check the torque of the drive hub mounting
bolts. Refer to Specifications, Machine Torque
Specifications.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure
to replace the drive hub oil at yearly intervals
may cause the machine to perform poorly and
continued use may cause component damage.
Turntable Rotate Drive Hub:
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Machine
Torque Specifications.
Drive Hubs:
1 Secure the turntable from rotating with the
turntable rotation lock pin.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove the ground control side fixed turntable
cover. Refer to Repair Procedure, How to
Remove a Fixed Turntable Cover.
2 Remove both plugs and drain the oil into
a suitable container. Refer to capacity
specifications
3 Drive the machine to rotate the hub until the
plugs are located one at the side and the other
at the other side.
3 Tag, disconnect and plug the turntable rotate
drive motor hoses at the turntable rotate drive
motor and the turntable rotate drive brake
hoses at the turntable rotate drive brake. Cap
the fittings.
a
a
Part No. 102916
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
drive hub plugs
S-100 • S-105 • S-120 • S-125
3 - 57
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
a
b
c
h
d
f
e
g
f
a
b
c
d
e
f
g
h
drive motor
brake drain plug
drive hub drain plug
drive hub
pivot bolt
mounting bolt
adjustment bolt with lock nut
drive brake
7 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install
the plug. Refer to Specifications, Machine
Specifications.
8 Install the turntable rotate drive motor hoses
into the turntable rotate drive motor and install
the turntable rotate drive brake hose into the
turntable rotate drive brake.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
9 Adjust the turntable rotation gear backlash.
See D-5, Check the Turntable Rotation Gear
Backlash.
10Install the ground control side fixed turntable
cover onto the machine and tighten the
4 Remove the turntable rotate drive hub mounting
bolts and pivot bolt. Remove the turntable
rotate drive hub with a suitable lifting device of
ample capacity.
Crushing hazard. The turntable
rotate drive hub may become
unbalanced and fall when it is
removed from the machine if it is
not properly supported.
5 Remove the plug from the side of the drive
hub. Drain the oil from the hub into a suitable
container.
6 Install the drive hub assembly onto the machine.
Lubricate and torque the drive hub mounting
bolts to specification. Refer to Specifications,
Machine Torque Specifications.
3 - 58
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-7
Inspect for Turntable Bearing
Wear
a
b
Genie specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of
a worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
Note: Perform this procedure with the machine on
a firm, level surface and the boom in the stowed
position.
1 Grease the turntable bearing. Refer to
maintenance procedure, Grease the Turntable
Bearing and Rotate Gear.
2 Torque the turntable bearing bolts to
specification. Refer to maintenance procedure,
Check the Turntable Rotation Bearing Bolts.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
boom.
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more
than 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.
c
d
aturntable
b dial indicator
c drive chassis
d turntable rotation bearing
5 Adjust the dial indicator needle to "zero"
position.
6 Lower the primary boom and jib to the
horizontal position and fully extend the boom.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.118 inch / 3.0 mm. The bearing is good.
Result: The measurement is more than
0.118 inch / 3.0 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the boom. Fully raise the boom and
jib. Visually inspect the dial indicator to be sure
the needle returns to the "zero" position.
9 Remove the dial indicator and rotate the
turntable 90°.
10Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
11Lower the boom to the stowed position and turn
the machine off.
12Remove the dial indicator from the machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 59
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-8
Perform Engine Maintenance Deutz Models
D-9
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
Engine specifications require that this procedure
be performed every 1000 hours.
All Models:
• Fuel system primary filter (water separator)
element - replace
• Engine valve lash - inspect/adjust
854F Models:
• Water pump - inspect
• Fuel system secondary filter - replace
Required maintenance procedures and additional
engine information are available in the Perkins
854F Operation and Maintenance Manual (Perkins
part number SEBU8726-00) OR the Perkins 1004
Serial User's Handbook (Perkins part number
TPD 1349E) OR the Perkins 800D Serial User's
Handbook (Perkins part number TPD 1477).
• Hoses and clamps - inspect/replace
• Glow plugs - check
• V-belts - re-tension/renew
TD 2011L04i Models:
• Engine valve lash - inspect/adjust
Required maintenance procedures and additional
engine information are available in the
Deutz F4L913 Operation Manual
(Deutz part number 0297-7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297-9929) OR the
Deutz TD 2.9 Operation Manual
(Deutz part number 0312-3893) OR the
Deutz TD 2011 Operation Manual
(Deutz part number 0312-3547).
Deutz F4L913 Operation Manual
Genie part number
62446
Deutz BF4L2011 Operation Manual
Genie part number
84794
Deutz TD 2.9 Operation Manual
Genie part number
1251561
Deutz TD 2011 Operation Manual
Genie part number
139320
3 - 60
1104D Models:
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
Perkins 1004 Serial User's Handbook
Genie part number
61376
Perkins 800D Serial User's Handbook
Genie part number
None
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-10
Perform Engine Maintenance Perkins Models
D-11
Perform Engine Maintenance Cummins Models
Engine specifications require that this procedure
be performed every 1500 hours.
Engine specifications require that this procedure
be performed every 1000 hours or annually,
whichever comes first.
854F Models:
• Engine crankcase breather - replace
Required maintenance procedures and additional
engine information are available in the Perkins
854F Operation and Maintenance Manual (Perkins
part number SEBU8726-00) OR the Perkins 1004
Serial User's Handbook (Perkins part number
TPD 1349E) OR the Perkins 800D Serial User's
Handbook (Perkins part number TPD 1477).
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
Perkins 1004 Serial User's Handbook
Genie part number
Perkins 800D Serial User's Handbook
Genie part number
61376
None
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Cummins B4.5 and B3.9L Operation and
Maintenance Manual (Cummins part number
4021389-01) OR the Cummins B3.3T Operation
and Maintenance Manual (Cummins part number
3666417-00).
Cummins B4.5 and B3.9L Operation and
Maintenance Manual
Genie part number
107527
Cummins B3.3T Operation and
Maintenance Manual
Genie part number
139324
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 61
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-12
Replace the Hydraulic Filter
Elements
Genie requires that this procedure be performed
every 1000 hours or annually, whichever comes
first.
Replacement of the hydraulic tank return filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause
the machine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
3 Remove each filter with an oil filter wrench.
4 Apply a thin layer of clean oil to the new oil filter
gaskets.
5 Install the new hydraulic return filter element
and tighten it securely by hand. Clean up any
oil that may have spilled during the installation
procedure.
6 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filters.
7 Start the engine from the ground controls.
8 Inspect the filters and related components to
be sure that there are no leaks.
Tank Return Filter:
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
Note: Perform this procedure with the engine off.
1 Open the ground controls side turntable side
cover and locate the tank return filters.
2 Place a suitable container under the hydraulic
tank return filters.
3 - 62
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
Medium and High Pressure Hydraulic Filters:
4 Remove the filter element from the housing.
5 Inspect the housing seal and replace it if
necessary.
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
Note: The medium pressure filter is for the charge
pump and the high pressure filters are for the drive
circuit.
Note: Perform this procedure with the engine off.
1 Open the engine side turntable cover and locate
the three filters mounted to the bulkhead.
6 Install the new medium pressure filter element
into the housing and tighten it securely.
7 Install the new high pressure filter elements into
the housings and tighten them securely.
8 Clean up any oil that may have spilled during
the installation procedure.
9 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housings.
10Start the engine from the ground controls.
11Inspect the filter housings and related
components to be sure that there are no leaks.
a
b
a
b
high pressure filters
medium pressure filter
2 Place a suitable container under the filters.
3 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housing.
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 63
October 2015
Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
2 Close the two hydraulic shut-off valves located
at the hydraulic tank.
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of
the condition.
Genie specifications require that this procedure be
performed every 2000 hours or 2 years, whichever
comes first.
Replacement or testing of the hydraulic oil
is essential for good machine performance
and service life. Dirty oil and suction strainers
may cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more frequently.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels
of contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
Note: Perform this procedure with the boom in the
stowed position and the axles extended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Remove the ground controls side turntable
side cover. Refer to Repair Procedure, How to
Remove a Hinged Turntable Cover.
3 Remove the drain plug from the hydraulic tank
and allow all of the oil from the tank to drain into
a suitable container. Refer to Specifications,
Hydraulic Specifications.
4 Remove the ground controls support bracket
retaining fasteners and remove the ground
control box assembly from the machine.
Component damage hazard.
Be sure to properly support the
ground control box. Do not allow
the ground control box to hang by
the wiring or cables.
5 Tag and disconnect the wires from the horn.
Remove the horn retaining fasteners and
remove the horn from the machine.
6 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank shut-off
valves. Cap the fittings.
7 Tag, disconnect and plug the supply hose for
the auxiliary power unit. Cap the fitting on the
hydraulic tank.
8 Tag, disconnect and plug the case drain hose
at the return filter. Cap the fitting on the return
filter head.
9 Disconnect and plug the T-fitting located at the
return filter with the 2 hoses connected to it.
Cap the fitting on the return filter head.
open
3 - 64
closed
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
10Remove the hydraulic tank breather filter from
the tank.
11Remove the hydraulic tank strap retaining
fasteners and remove the hydraulic tank straps
from the machine.
12Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.
13Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if it is not properly
supported and secured to the
overhead crane when it is
removed from the machine.
24Install the two suction hoses and the supply
hose for the auxiliary power unit onto the
machine.
25Install the case drain hose onto the return filter
head.
26Install the T-fitting and 2 hoses connected to it
to the hydraulic tank return filter head.
27Fill the tank with hydraulic oil until the level
is within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
28Apply pipe thread sealant to the threads of the
hydraulic tank filter mount.
29Install a new tank breather filter onto the filter
mount and tighten it securely by hand.
14Remove the hydraulic tank return filter from the
hydraulic tank return filter head.
30Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
15Remove the case drain filter from the case
drain filter head.
31Install a new tank case drain return filter onto
the filter mount and tighten it securely by hand.
16Remove the suction strainers from the tank and
clean them using a mild solvent.
32Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
17Rinse out the inside of the tank using a mild
solvent.
18Install the suction strainers using pipe thread
sealant on the pipe threads.
19Install the drain plug using pipe thread sealant
on the pipe threads.
Note: Always use pipe thread sealant on all pipe
threads.
20Install the hydraulic tank onto the machine.
33Install a new tank return filter onto the filter
mount and tighten it securely by hand.
34Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
35Clean up any oil that may have spilled during
the procedure.
36 Open the hydraulic tank shut-off valves.
Component damage hazard.
Be sure to open the two hydraulic
tank shutoff valves and prime the
pump after installing the hydraulic
tank. Refer to Repair Procedure,
How to Prime the Pumps.
21Install the hydraulic tank retaining straps and
install the hydraulic tank retaining fasteners.
22Install the horn and horn retaining fasteners
onto the machine. Connect the wiring.
23Install the ground control box assembly and
assembly retaining fasteners onto the machine.
Part No. 102916
37Install the turntable side cover.
S-100 • S-105 • S-120 • S-125
3 - 65
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-2
Perform Engine Maintenance Cummins Models
E-3
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure
be performed every 2000 hours or 2 years,
whichever comes first.
Engine specifications require that this procedure
be performed every 2000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Cummins B4.5 and B3.9L Operation and
Maintenance Manual (Cummins part number
4021389-01) OR the Cummins B3.3T Operation
and Maintenance Manual (Cummins part number
3666417-00).
Cummins B4.5 and B3.9L Operation and
Maintenance Manual
Genie part number
107527
Cummins B3.3T Operation and
Maintenance Manual
Genie part number
139324
All Models:
• Aftercooler core - inspect
• Alternator - inspect
• Engine mounts - inspect
• Starting Motor - inspect
• Turbocharger - inspect
1104D Models:
• Water pump - inspect
Required maintenance procedures and additional
engine information are available in the
Perkins 854F Operation and Maintenance Manual
(Perkins part number SEBU8726-00) OR the
Perkins 1004 Serial User's Handbook (Perkins
part number TPD 1349E) OR the Perkins 800D
Serial User's Handbook (Perkins part number TPD
1477).
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Perkins 1004 Serial User's Handbook
Genie part number
61376
Perkins 800D Serial User's Handbook
Genie part number
None
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 66
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-4
Perform Engine Maintenance Deutz Models
E-5
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure
be performed every 2 years.
Engine specifications require that this procedure
be performed every 3000 hours.
All Models:
1104D Models:
• Extended Life Coolant (ELC) - replace
• Fuel Injector - test/change
TD 2011L04i Models:
854F Models:
• Alternator belt - replace
• Diesel Particulate Filter - clean
• Glow plugs - replace
• Radiator cap - inspect/replace
Required maintenance procedures and additional
engine information are available in the Deutz TD
2011 Series Operation Manual (Deutz part number
0312-3547) OR the Deutz TD 2.9 Series Operation
Manual (Deutz part number 0312-3893) OR the
Deutz F4L913 Series Operation Manual (Deutz
part number 0297-7341) OR the Deutz B4L2011
Series Operation Manual (Deutz part number
0297-9929).
• Alternator Belt - Inspect/Adjust/Replace
Required maintenance procedures and additional
engine information are available in the
Perkins 854F Operation and Maintenance Manual
(Perkins part number SEBU8726-00) OR the
Perkins 1004 Serial User's Handbook (Perkins
part number TPD 1349E) OR the Perkins 800D
Serial User's Handbook (Perkins part number TPD
1477).
Deutz TD 2011 Series Operation Manual
Genie part number
139320
Deutz TD 2.9 Series Operation Manual
Genie part number
1251561
Deutz F4L913 Series Operation Manual
Genie part number
Perkins 1004 Serial User's Handbook
Genie part number
61376
62446
Deutz B4L2011 Series Operation Manual
Genie part number
Perkins 800D Serial User's Handbook
Genie part number
None
84794
Part No. 102916
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
S-100 • S-105 • S-120 • S-125
3 - 67
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-6
Perform Engine Maintenance Deutz Models
E-7
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure
be performed every 3000 hours.
Engine specifications require that this procedure
be performed every 4000 hours.
TD 2011L04i Models:
All Models:
• Injection valve - replace
• Aftercooler core - clean/test
• Aftercooler Core - clean/test
Required maintenance procedures and additional
engine information are available in the
Perkins 854F Operation and Maintenance Manual
(Perkins part number SEBU8726-00) OR the
Perkins 1004 Serial User's Handbook (Perkins
part number TPD 1349E) OR the Perkins 800D
Serial User's Handbook (Perkins part number TPD
1477).
• Charge air cooler entry - drain lube oil/
condensate
• Turbocharge compressor outlet - clean
TD 2.9 Models:
• V-belt and tensioning pulley - replace
Required maintenance procedures and additional
engine information are available in the Deutz TD
2011 Series Operation Manual (Deutz part number
0312-3547) OR the Deutz TD 2.9 Series Operation
Manual (Deutz part number 0312-3893) OR the
Deutz F4L913 Series Operation Manual (Deutz
part number 0297-7341) OR the Deutz B4L2011
Series Operation Manual (Deutz part number
0297-9929).
Deutz TD 2011 Series Operation Manual
Genie part number
139320
Deutz TD 2.9 Series Operation Manual
Genie part number
1251561
Deutz F4L913 Series Operation Manual
Genie part number
62446
Deutz B4L2011 Series Operation Manual
Genie part number
84794
3 - 68
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
Perkins 1004 Serial User's Handbook
Genie part number
61376
Perkins 800D Serial User's Handbook
Genie part number
None
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-8
Perform Engine Maintenance Deutz Models
E-9
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure
be performed every 6000 hours.
Engine specifications require that this procedure
be performed every 12000 hours or 6 years,
whichever come first.
TD 2011L04i Models:
All Models:
• Toothed belt - replace
• Extended Life Coolant (ELC) - replace
Required maintenance procedures and additional
engine information are available in the Deutz TD
2011 Series Operation Manual (Deutz part number
0312-3547) OR the Deutz TD 2.9 Series Operation
Manual (Deutz part number 0312-3893) OR the
Deutz F4L913 Series Operation Manual (Deutz
part number 0297-7341) OR the Deutz B4L2011
Series Operation Manual (Deutz part number
0297-9929).
Required maintenance procedures and additional
engine information are available in the
Perkins 854F Operation and Maintenance Manual
(Perkins part number SEBU8726-00) OR the
Perkins 1004 Serial User's Handbook (Perkins
part number TPD 1349E) OR the Perkins 800D
Serial User's Handbook (Perkins part number TPD
1477).
Deutz TD 2011 Series Operation Manual
Genie part number
139320
Perkins 854F Operation and Maintenance Manual
Genie part number
1263971
Deutz TD 2.9 Series Operation Manual
Genie part number
1251561
Perkins 1004 Serial User's Handbook
Genie part number
61376
Deutz F4L913 Series Operation Manual
Genie part number
62446
Perkins 800D Serial User's Handbook
Genie part number
None
Deutz BF4L2011 Series Operation Manual
Genie part number
84794
Part No. 102916
S-100 • S-105 • S-120 • S-125
3 - 69
Section 3 • Scheduled Maintenance Procedures
October 2015
CHECKLIST E PROCEDURES
E-10
Replace the Boom Extend/Retract
Cables
Genie specifications require that this procedure be
performed every 10 years.
The boom extend/retract cables are responsible
for the extension and retraction of the number
3 boom tube on the S-100 and S-105, and the
numbers 2 and 3 boom tubes on the S-120 and
S-125. Replacement of the boom extend/retract
cables is essential to good machine performance
and safe machine operation. The boom extend/
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Replace the boom extend cables. Refer to
Repair Procedure, How to Replace the Boom
Extend/Retract Cables.
3 - 70
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of
this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the Genie S-100 &
Genie S-105 Operator’s Manual and the
Genie S-120 & Genie S-125 Operator’s Manual.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Be sure that all necessary tools and parts are
available and ready for use.
Used to indicate the presence of
a potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
With safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Use only Genie approved replacement parts.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Boom in the stowed position
• Turntable rotated with the boom between
the circle-end wheels
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
• 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
Part No. 102916
Used to indicate the presence of
a potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-100 • S-105 • S-120 • S-125
4-1
October 2015
Section 4 • Repair Procedures
Display Module
This table lists the various screens and menu options of the operating software. Some display menus are
for 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.
button (to increase) or the
button (to decrease) or to select
To change parameter values, use the
a setting. Press the
button to save the new value to memory. An audible beep will indicate a save to
memory.
You must exit the programming mode for the changes to take effect.
To Exit Programming Mode:
se the scroll button
U
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 or
Menu
Operator
Machine
Status
Unit of
Measure
and
Language
4 - 2
Procedure
Default
Hour meter (on power up)
Engine speed
Engine oil pressure PSI (English)
Engine oil pressure kPa (metric)
Engine temperature °F (English)
Engine temperature °C (metric)
Primary boom angle sensor
Turntable level sensor X°
Turntable level sensor Y°
Platform angle
Battery voltage
With key switch
on,
press the
and at
same time.
Description
the
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Range or Selection
Engine temperature is not
displayed until engine is
above 100°F / 38°C
Hydraulic pressure PSI (English)
Hydraulic pressure kPa (metric)
Boom angle
Axle status
Metric/English measurements
Use +/- buttons to change
Language selection
English, German, French,
Spanish, Portuguese, Italian,
Dutch and Swedish.
Deutz 2.9L Turbo (D2.9T)
Deutz TD2011L0.4i (DL04i)
Perkins 1104D-44T (P1104)
Perkins 854F (P854T)
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
DISPLAY MODULE
Screen or
Menu
Drive
Functions
Procedure
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
.
Description
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
Boom
Function
Speeds
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and
press
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 %
Part No. 102916
S-100 • S-105 • S-120 • S-125
Range or Selection
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)
4-3
October 2015
Section 4 • Repair Procedures
DISPLAY MODULE
Screen or
Menu
Procedure
Description
Range or Selection
Lift
Function
Ramp
Settings
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Boom up/down
ramp acceleration %
Boom up/down
ramp deceleration %
Boom extend/retract
ramp acceleration %
Turntable rotate
ramp acceleration %
Turntable rotate
ramp deceleration %
Jib up/down ramp
deceleration %
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)
Valve
Calibration
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Reset drive valve defaults
(yes/no)
Reset boom up/down
valve defaults
Reset boom extend/retract
valve defaults
Reset turntable rotate
valve defaults
Allow boom up/down
speed calibration
Allow turntable rotate
speed calibration
Reset drive joystick
defaults
Reset boom up/down
joystick defaults
Reset boom extend/retract
joystick defaults
reset turntable rotate
joystick defaults
Reset steer joystick
defaults
(yes/no)
Set unit level to gravity
Turntable Y-axis millivolts
per degree
Turntable X-axis millivolts
per degree
Platform level to gravity
Platform millivolts per degree
(yes/no)
Level
Sensor
Calibration
4 - 4
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
S-100 • S-105 • S-120 • S-125
(yes/no)
(yes/no)
(yes/no)
(yes/no)
(yes/no)
(yes/no)
(yes/no)
(yes/no)
(yes/no)
(yes/no)
Part No. 102916
October 2015
Section 4 • Repair Procedures
DISPLAY MODULE
Screen or
Menu
Default
Reset
Procedure
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Description
Range or Selection
Reset drive functions
(yes/no)
Reset boom function speeds
(yes/no)
Reset lift function ramps
(yes/no)
Reset all (Contact Genie Industries
(yes/no)
Service Department before using this
option)
Clear all safety switch faults
(yes/no)
Overload
Recovery
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Clear Overload Recovery
A passcode is required to clear
the message
Options
With key switch
off, press and
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Limit boom height to 100 ft / 80 ft
AC generator
Alarm
(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)
Lift / drive cutouts
Auxiliary drive
Proximity kill switch
Platform overload sensing
Work lights
Flashing beacon
Drive lights
Disable steer mode change
while driving
Rocker joystick steering
Generator off delay (0-10 sec)
(yes/no)
(o to 10 seconds, 2 is the default.
shown only when hyd gen is selected)
Part No. 102916
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October 2015
Section 4 • Repair Procedures
Platform Controls
The platform controls contains two printed circuit
boards:
The membrane circuit board is mounted to the
underside of the control box lid which contains
the LEDs and touch-sensitive buttons for machine
functions. The membrane circuit board sends the
input from the operator to the platform controls
ECM circuit board. The ECM circuit board sends
the data to the turntable control box for processing.
b
a
c
e
The platform controls ECM circuit board
communicates with the turntable controls. The
joystick controllers at the platform controls utilize
Hall Effect technology and require no adjustment.
The operating parameters of the joysticks are
stored in memory at the turntable controls. If a
joystick controller error occurs or if a joystick is
replaced, it will need to be calibrated before that
particular machine function will operate. See 1-3,
How to Calibrate a Joystick Controller.
d
a platform ECM circuit board
b boom extend/retract
joystick controller
c drive/steer joystick controller
d membrane circuit board
e boom up/down and turntable rotate left/right joystick controller
Each joystick controller should operate smoothly
and provide proportional speed control over its
entire range of motion.
4 - 6
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Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
1-1
Circuit Boards
7 Locate the ECM circuit board mounted to the
inside of the platform control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: When an ECM circuit board is replaced, the
joystick controllers will need to be calibrated. See
1-3, How to Calibrate a Joystick Controller.
How to Remove the ECM
Circuit Board
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
1 Push in the Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the platform control box mounting
fasteners. Remove the platform control box
from the machine.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
8 Remove the ECM circuit board mounting
fasteners.
9 Carefully remove the ECM circuit board from
the platform control box.
3 Locate the cables that connect to the bottom
of the control box. Number each cable and its location at the control box.
How to Remove the Membrane
Circuit Board
4 Disconnect the cables from the bottom of the
platform control box.
1 Push in the Emergency Stop button to the
off position at both the ground and platform
controls.
5 Remove the control cable plug retaining
fasteners from the bottom of the platform
control box.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
6 Remove the platform control box lid retaining
fasteners. Open the control box lid.
Part No. 102916
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October 2015
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
3 Locate the membrane circuit board mounted to
the inside of the platform control box lid.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: Component damage hazard. Electrostatic
discharge (ESD) can damage printed circuit board
components. Maintain firm contact with a metal
part of the machine that is grounded at all times
when handling printed circuit boards OR use a
grounded wrist strap.
4 Carefully disconnect the two ribbon cables from
the membrane circuit board.
5 Remove the membrane circuit board retaining
fasteners.
6 Carefully remove the membrane circuit board
from the platform control box lid.
1-2
Membrane Decal
How to Replace the Membrane
Decal
The membrane decal is a special decal that
consists of a decal with an electronic membrane
on the backside. The membrane contains touch
sensitive areas that, when pushed, activates the
machine functions. The membrane buttons activate
machine functions similar to toggle switches, but
do not have any moving parts.
1 Push in the Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Carefully disconnect the two ribbon cables from
the membrane circuit board.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: Component damage hazard. Electrostatic
discharge (ESD) can damage printed circuit board
components. Maintain firm contact with a metal
part of the machine that is grounded at all times
when handling printed circuit boards OR use a
grounded wrist strap.
4 - 8
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Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
4 Close the control box lid.
5 Remove the decal from the platform control
box.
6 Carefully remove the membrane decal from the
platform control box while guiding the ribbon
cables out of the control box lid.
7 Remove any decal adhesive from the control
box lid with a mild solvent.
Note: Do not allow any solvent to come in contact
with the membrane circuit board.
8 Install the new membrane decal while guiding
the ribbon cables through the control box lid.
Note: Be sure that all LED locations on the
membrane decal align with the LED's on the
membrane circuit board.
9 Install a new platform controls decal over the
membrane decal.
10Open the control box lid and carefuly connect
the ribbon cables from the membrane decal to
the membrane circuit board.
1-3
Joysticks
How to Calibrate a Joystick
The joystick controllers on this machine utilize
digital Hall Effect technology for proportional
control. If a joystick controller is disconnected
or replaced, it must be calibrated before that
particular machine function will operate.
Note: The joystick must be calibrated before the
threshold, max-out or ramp rate can be set.
Note: It is possible to reset multiple joystick
defaults before exiting the programming mode.
Note: After each joystick is calibrated, check the
display at the ground control box. There should
be no calibration faults shown on the display. If
calibration faults exist, repeat steps 1 through 8 for
that joystick controlled function.
Note: Contact Genie Product Support Department
before using the reset all joystick default option.
Note: Perform this procedure with the engine off.
The calibration procedure for each joystick begins
on the next page.
Part No. 102916
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October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
Drive functions:
Steer functions:
Note: If the calibration fault is already displayed at
the ground box begin with step 6.
Note: If the calibration fault is already displayed at
the ground box begin with step 6.
1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform
and ground controls is in the on position.
1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform
and ground controls is in the on position.
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to platform controls. Hold the enter
button for approximately 5 seconds.
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to platform controls. Hold the enter
button for approximately 5 seconds.
3 Press the minus button
enter button twice.
3 Press the minus button
enter button
twice.
twice, then press the
twice, then press the
to scroll through the
4 Use the scroll button
menu until reset drive joystick defaults is
displayed. Press the
button to select yes,
then press the
button.
4 Use the scroll button
to scroll through the
menu until reset steer joystick defaults is
displayed. Press the
button to select yes,
then press the
button.
5 Exit programming mode.
5 Exit programming mode.
Note: To exit programming mode, use the scroll
button
to scroll through the menu until the
screen displays exit, then press the plus button
once, change the NO to YES, and press the enter
button .
Note: To exit programming mode, use the scroll
button
to scroll through the menu until the
screen displays exit, then press the plus button
once, change the NO to YES, and press the enter
button
.
6 Do not start the engine.
6 Do not start the engine.
7 Locate the drive/steer joystick.
7 Locate the drive/steer joystick.
8 Move the drive/steer joystick full stroke in the
forward direction and hold for 5 seconds, then
return to the center or neutral position.
8 Move the drive/steer joystick full stroke in the
left direction and hold for 5 seconds, then return
to the center or neutral position.
9 Move the drive/steer joystick full stroke in the
reverse direction and hold for 5 seconds, then
return to the center or neutral position.
9 Move the drive/steer joystick full stroke in the
right direction and hold for 5 seconds, then
return to the center or neutral position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
4 - 10
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Part No. 102916
October 2015
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
Primary boom extend/retract functions:
Primary boom up/down functions:
Note: If the calibration fault is already displayed at
the ground box begin with step 6.
Note: If the calibration fault is already displayed at
the ground box begin with step 6.
1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform
and ground controls is in the on position.
1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform
and ground controls is in the on position.
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to platform controls. Hold the enter
button for approximately 5 seconds.
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to platform controls. Hold the enter
button for approximately 5 seconds.
3 Press the minus button
enter button
twice.
twice, then press the
3 Press the minus button
enter button
twice.
twice, then press the
4 Use the scroll button
to scroll through the
menu until reset primary boom extend/retract
joystick defaults is displayed. Press the
button to select yes, then press the
button.
4 Use the scroll button
to scroll through the
menu until reset primary boom up/down joystick
defaults is displayed. Press the
button to
select yes, then press the
button.
5 Exit programming mode.
5 Exit programming mode.
Note: To exit programming mode, use the scroll
button
to scroll through the menu until the
screen displays exit, then press the plus button
once, change the NO to YES, and press the enter
button
.
Note: To exit programming mode, use the scroll
button
to scroll through the menu until the
screen displays exit, then press the plus button
once, change the NO to YES, and press the enter
button
.
6 Do not start the engine.
6 Do not start the engine.
7 Locate the primary boom/turntable rotate
joystick.
7 Locate the primary boom/turntable rotate
joystick.
8 Move the primary boom extend/retract joystick
full stroke in the extend direction and hold for
5 seconds, then return to the center or neutral
position.
8 Move the boom/turntable rotate joystick
full stroke in the up direction and hold for 5
seconds, then return to the center or neutral
position.
9 Move the primary boom extend/retract joystick
full stroke in the retract direction and hold for
5 seconds, then return to the center or neutral
position.
9 Move the boom/turntable rotate joystick full
stroke in the down direction and hold for 5
seconds, then return to the center or neutral
position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
Part No. 102916
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October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
Turntable rotate functions:
Note: If the calibration fault is already displayed at
the ground box begin with step 6.
1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform
and ground controls is in the on position.
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to platform controls. Hold the enter
button for approximately 5 seconds.
3 Press the minus button
enter button
twice.
twice, then press the
4 Use the scroll button
to scroll through the
menu until reset turntable rotate joystick
defaults is displayed. Press the
button to
select yes, then press the
button.
5 Exit programming mode.
Note: To exit programming mode, use the scroll
button
to scroll through the menu until the
screen displays exit, then press the plus button
once, change the NO to YES, and press the enter
button
.
6 Do not start the engine.
7 Locate the primary boom/turntable rotate
joystick.
8 Move the boom/turntable joystick full stroke in
the left direction and hold for 5 seconds, then
return to the center or neutral position.
9 Move the boom/turntable joystick full stroke in
the right direction and hold for 5 seconds, then
return to the center or neutral position.
How to Reset a Proportional
Valve Coil Default
Note: Use this procedure for any software version
other than 2.00. For software version 2.00 refer to
the following procedure.
Note: This procedure only needs to be performed
if a proportional valve has been replaced.
Note: After the valve coil defaults have been set,
each machine function threshold and default
function speed must be set. See How to Set the
Function Thresholds and Default Function Speeds.
1 Turn the key switch to the off position.
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to platform controls. Hold the enter
button for approximately 5 seconds.
3 Press the minus button
enter button
twice.
twice, then press the
4 Use the scroll button
to scroll through the
menu until the function valve that needs to be
reset is displayed. Press the
button to
select yes, then press the
button to save the
setting.
Note: Choices are: Propel (drive) valve reset;
Boom up/down valve reset; Boom extend/retract
valve reset; or TT rotate valve reset.
5 Push one of the LCD
screen buttons shown
until exit is displayed.
6 Press the plus
button or minus button
select yes and then press the enter button
to
.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
4 - 12
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Part No. 102916
October 2015
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
How to Reset a Proportional
Valve Coil Default
(software version 2.00)
Note: Software version 2.00 requires the use of
Web GPI to perform this procedure.
Refer to Diagnostic Code, Software.
Note: This procedure only needs to be performed
if a proportional valve has been replaced.
Note: After the valve coil defaults have been set,
each machine function threshold and default
function speed must be set. See How to Set the
Function Thresholds and Default Function Speeds.
1 Open Web GPI and connect to the TCON.
2 Select the valve screen of the proportional
valve you want to reset.
Note: Choices are: Propel (drive) valve reset;
Boom up/down valve reset; Boom extend/retract
valve reset; or TT rotate valve reset.
3 Press "set Defaults" and enter the level
2 password (obtained from field service
personnel).
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 with
calibration.
How to Set the Function
Thresholds and Function Speeds
Note: Before the threshold and default function
speeds can be set, the boom function proportional
valve coil defaults must be set first.
See How to Reset a Proportional Valve Coil
Default.
Note: If a boom function proportional valve coil
has not been replaced and just want to reset the
function speed to original factory settings, begin
with step 10.
1 Start the engine from the platform controls.
2 Press down the foot switch.
Note: Be sure the engine rpm is set to foot switch
activated high idle.
Function threshold:
3 Select a joystick controlled function that needs
to have the threshold set.
4 Slowly move the joystick off center in either
direction just until the machine function starts
to move, then move the joystick very slowly
towards the neutral or center position just
before the machine function stops.
Do not let go of the joystick.
5 While holding the joystick in position, press the
engine start button
at the platform controls
to set the joystick controller threshold.
6 Slowly move the joystick off center in the
opposite direction just until the machine
function starts to move, then move the joystick
very slowly towards the neutral or center
position just before the machine function stops.
Do not let go of the joystick.
Part No. 102916
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October 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV B
7 While holding the joystick in position, press the
engine start button
at the platform controls
to set the joystick controller threshold.
8 Repeat steps 3 through 7 for each joystick
controlled machine function (boom up/down
and turntable rotate left/right, boom extend/
retract, and drive forward/reverse).
9 Once all the joystick controllers have been
calibrated, push in the Emergency Stop button
at the platform controls to save the settings in
memory.
Note: The red Emergency Stop button at the
platform controls must be pushed in to the off
position following calibration of the joystick
controllers to save the settings in memory.
10At the ground controls, turn the key switch to
the off position, wait a moment and then turn
the key switch to platform controls.
11Check the display at the ground controls to be
sure there are no calibration faults.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat this
procedure.
Function speeds:
Note: Be sure the machine is in the stowed
position and the boom is rotated between the circle
end tires.
Note: Perform this procedure with the machine
parked on a firm, level surface which is free of
obstructions.
12Start the engine from the platform controls.
13Select a boom function that needs the function
speed set.
14Boom up/down functions: Starting in the
stowed position, move the joystick full stroke
in the up direction. When the alarm sounds,
move the joystick in the opposite direction full
stroke until the alarm sounds again. Return the
joystick to center.
4 - 14
Boom extend/retract functions: Raise the
boom until the low-speed drive function is
enabled. Move the joystick full stroke in the
extend direction. When the alarm sounds,
move the joystick in the opposite direction full
stroke until the alarm sounds again. Return the
joystick to center.
Turntable rotate functions: Raise the boom
until the low-speed drive function is enabled.
Move the joystick full stroke to the left (cw) until
the drive enable light turns on. Then move the
joystick full stroke to the right (ccw). When the
alarm sounds, move the joystick in the opposite
direction full stroke until the alarm sounds
again. Return the joystick to center.
15Once all the joystick controllers have been
calibrated, push in the red Emergency Stop
button at the platform controls to save the
settings in memory.
Note: The red Emergency Stop button at the
platform controls must be pushed in to the off
position following calibration of the joystick
controllers to save the settings in memory.
16At the ground controls, turn the key switch to
the off position, wait a moment and then turn
the key switch to platform controls.
17Check the display at the ground controls to be
sure there are no calibration faults.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat this
procedure.
How to Adjust the Function
Speeds
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
REV B
PLATFORM CONTROLS
2 Press and hold the enter button
on the
ground control panel while turning the key
switch to ground controls. Hold the enter
button for approximately 5 seconds.
3 Press the plus button
minus button
twice.
twice, then press the
4 Press the scroll button
until the function to
be adjusted is displayed.
5 Press the plus button
to increase the speed
to decrease the
or press the minus button
speed.
6 Press the enter button
memory.
to save the setting in
ground control panel while turning the key
switch to ground controls. Hold the enter
button for approximately 5 seconds.
3 Press the plus button
scroll button
twice.
twice, then press the
4 Press the scroll button
until the function to
be adjusted is displayed.
5 Press the plus button
to increase the ramp
rate or press the minus button
to decrease
the ramp rate.
6 Press the enter button
memory.
to save the setting in
7 Push one of the LCD screen buttons shown
until exit is displayed.
7 Push one of the LCD
screen buttons shown
until exit is displayed.
8 Press the plus
button to select yes and then
press the enter button
.
8 Press the plus
button to select yes and
then press the enter button
.
9 Continue to perform this procedure until the
machine function speed meets specification.
Refer to Specifications for function speeds.
Specifications
How to Adjust the Function
Ramp Rate Setting
Turntable rotate
accelerate
2 seconds
decelerate 0.25 second
The ramp rate setting of a joystick controls the time
at which it takes for the joystick to reach maximum
output, when moved out of the neutral position.
The ramp rate settings of a joystick can be
changed to compensate for hydraulic pump wear
to maintain peak performance from the machine.
Note: Perform this procedure with the boom in the
stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Press and hold the enter button
Part No. 102916
Ramp rate (factory settings)
Primary boom up/down
accelerate
decelerate
3 seconds
0..25 second
Primary boom extend/retract
accelerate
decelerate
2 seconds
0.25 second
Jib boom up/down
accelerate
decelerate
2 seconds
0.25 second
Drive
accelerate
2 seconds
on the
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
Platform Components
2-1
Platform
2-2
Platform Leveling Cylinder
How to Remove the Platform
The platform leveling cylinder keeps the platform
level through the entire range of boom motion.
The platform is maintained level to the turntable.
The ECM at the ground controls compares the
difference in readings between the platform angle
sensor and the turntable level sensor. The ECM at
the ground controls sends a signal to the platform
controls to open or close the appropriate platform
level proportional valve on the platform manifold
to maintain a level platform. The platform leveling
cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
failure.
1 Separate the foot switch quick disconnect plug.
2 Support the platform with an appropriate lifting
device.
3 Locate the cables that connect to the bottom
of the control box. Number each cable and its
location at the platform control box.
4 Disconnect the cables from the bottom of the
platform control box.
5 Remove the platform control box mounting
fasteners. Remove the platform control box and
set it aside.
6 Remove the air line to platform bracket retaining
fasteners (if equipped).
7 Remove the weld cables from the platform
(if equipped).
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
8 Remove the platform mounting fasteners and
remove the platform from the machine.
Crushing hazard. The platform
may become unbalanced and
fall when it is removed from
the machine if it is not properly
supported.
4 - 16
How to Remove the Platform
Leveling Cylinder
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Extend the boom until the platform leveling
cylinder barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks under
the platform.
3 Lower the boom until the platform is resting on
the blocks just enough to support the platform.
Note: Do not rest the entire weight of the boom on
the blocks.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
4 Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder at the
bulkhead fittings located inside the boom tube
at the platform end and connect them together
using a connector. Cap the bulkhead fittings on
the boom tube.
8 Use a soft metal drift to remove the rod-end
pivot pin.
Crushing hazard. The platform
(S-100 and S-120 models) or
jib boom (S-105 and S-125
models) will fall when the platform
leveling cylinder rod-end pivot
pin is removed if it is not properly
supported.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Crushing hazard. The platform
leveling cylinder will fall if it is not
properly supported when the rodend pivot pin is removed.
5 Remove the pin retaining fastener from
the platform leveling cylinder rod-end pivot pin.
Do not remove the pin.
6 Remove the external snap ring from the barrelend pivot pin. Do not remove the pin.
7 Support the platform leveling cylinder with a
suitable lifting device. Protect the cylinder rod
from damage.
Component damage hazard. The
platform leveling cylinder rod can
become damaged if it is allowed to
fall.
9 Use a soft metal drift to remove the barrel-end
pivot pin.
10Carefully pull the platform leveling cylinder out
of the boom.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 17
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
How to Bleed the Platform
Leveling Cylinder
2-3
Platform Rotator
Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure.
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
Note: The boom must remain below 10° to properly
perform this procedure.
1 Raise the boom to a horizontal position.
2 Activate auxiliary power.
How to Remove the
Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal.
If a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way
to the left and then installing the
platform mounting weldment all
the way in the left position.
3 Push the platform level up and down buttons
through two complete platform leveling cycles
to remove any air that might be in the system.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Remove the platform. See Repair Procedure,
How to Remove the Platform.
2 Disconnect the electrical connector from the
platform angle sensor.
4 - 18
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
3 Tag, disconnect and plug the hydraulic hoses
from the "V1" and "V2" ports on platform rotator
manifold. Cap the fittings on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 Remove the platform manifold mounting
fasteners. Lay the platform manifold to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
5 Remove the power to platform cover plate from
the electrical outlet box. Do not disconnect the
wiring.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
8 Support the platform mounting weldment, but
do not apply any lifting pressure.
9 Remove the eight mounting bolts from the
platform mounting weldment.
10 Remove the center bolt and slide the platform
mounting weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment may become
unbalanced and fall if it is not
properly supported.
11Support the platform rotator. Do not apply
any lifting pressure.
S-100 and S-120 models:
12Support the rod end of the platform leveling
cylinder. Protect the cylinder rod from damage.
13Remove the pin retaining fastener from the
platform level cylinder rod-end connecting link
pivot pin and the platform rotator pivot pin. Do
not remove the pins.
14Use a soft metal drift to remove both pins and
remove the platform rotator from the machine.
6 Remove the power to platform electrical outlet
box from the platform and lay it to the side.
7 Remove the weld cable from the platform
(if equipped).
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Crushing hazard. The platform
rotator may become unbalanced
and fall if it is not properly
supported.
Component damage hazard. The
platform angle sensor is a very
sensitive instrument. It can be
damaged internally if the platform
rotator is dropped or sustains
any physical shock, even if the
damage is not visible.
4 - 19
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
S-105 and S-125 models:
12Remove the pin retaining fasteners from the jib
boom and jib boom leveling arms to platform
rotator pivot pins. Do not remove the pins.
13Support the jib boom leveling arms with a
suitable lifting device.
2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
to collect any drainage. Secure the container to
the boom.
3 Slowly open the top bleed valve on the rotator.
Do not remove the bleed valve from the
platform rotator.
14Use a soft metal drift to remove both pins and
remove the platform rotator from the machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Crushing hazard. The jib boom
leveling arms may fall if they are
not properly supported when the
jib boom leveling arm pivot pin is
removed.
Component damage hazard. The
platform angle sensor is a very
sensitive instrument. It can be
damaged internally if the platform
rotator is dropped or sustains
any physical shock, even if the
damage is not visible.
a
How to Bleed the Platform
Rotator
Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure.
d
S-105 (Before serial number 251) and
S-125 models (Before serial number 999):
1 At the ground controls, simultaneously hold the
auxiliary power button and the platform rotate
right button until the platform is fully rotated to
the right.
4 - 20
S-100 • S-105 • S-120 • S-125
c
b
a top bleed valve
b bottom bleed valve
c clear hose
dcontainer
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
4 Hold the platform rotate left button until the
platform is fully rotated. Continue holding the
button until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
5 Connect the clear hose to the bottom bleed
valve and slowly open the valve. Do not remove
the bleed valve.
6 Hold the platform rotate right button until the
platform is fully rotated. Continue holding the
button until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform full right then left and
inspect the bleed valves for leaks.
9 Clean up any oil that may have spilled during
this procedure.
S-100, S-120, S-105 (after serial number 250) and
S-125 models (after serial number 998):
1. Rotate the platform full right, then full left until
air is completely out of the rotator. Bleeding the
valve is not necessary.
2-4
Platform Level Sensor
The platform level sensor is mounted to the side
of the platform rotator. The platform level sensor
is monitored by the control system to maintain a
level platform throughout boom range of motion.
If a platform level sensor is replaced, it must be
calibrated prior to machine operation.
How to Calibrate the
Platform Level Sensor
Note: Perform this procedure with the machine on
a firm, level surface and in the stowed position.
1 Secure a digital level to one of the side railings
of the platform.
2 Start the machine and level the platform to
gravity. Push the red Emergency stop button in
to stop the engine.
3 Press and hold the enter button
on the
ground control panel while pulling out the red
Emergency Stop button.
4 Press the plus button
, then press the enter
button
twice before again pressing the plus
button
.
5 Press the enter button
three timees until
Platform Level to Gravity is displayed on the
LCD screen.
6 Press the plus button
7 Press the enter button
memory.
once.
to save the setting in
8 Push one of the LCD
screen buttons shown
until platform level sensor
mv per degree is displayed.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 21
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
9 Confirm that the number shown on the display
is the same as that shown on the data sheet
supplied with the new platform level sensor.
Result: If the number shown on the display
is the same as that shown on the data sheet
supplied with the new platform level sensor,
continue to step 10.
Result: If the number shown on the display is
not the same as that shown on the data sheet
supplied with the new platform level sensor,
continue to step 9.
button or the minus
10Press the plus
button to correct the display to match the data
sheet. Then press the enter button
to save
the setting in memory.
11Push one of the LCD
screen buttons shown
until exit is displayed.
11Press the plus
button to select yes and then
press the enter button
.
2-5
Platform Overload System
The platform overload system is designed to
prevent the machine from continuing to operate
when the load in the platform exceeds maximum
rated capacity. Refer to the machine serial label
for maximum capacity information.
If maximum platform capacity is exceeded, the
alarm will sound at the platform controls and the
platform overload indicator lights will flash at both
the ground and platform controls. The ground and
platform controls will become disabled. Before
normal machine operation can continue, the
excess load will need to be removed from the
platform.
If the excess load cannot be removed or if the
operator at the platform controls is unable to
correct the overloaded condition, another person
at the ground controls can operate the machine
using auxiliary power. There will be limited control
of boom functions from the ground controls when
using auxiliary power. Auxiliary power can be
used to correct the overloaded platform condition
in order to resume normal, safe operation of the
machine.
How to Calibrate the Platform
Overload System (if equipped)
Calibration of the platform overload system is
essential to safe machine operation. Continued
use of an improperly calibrated platform overload
system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Turn the key switch to platform control. Start
the engine and level the platform.
4 - 22
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the enter of the platform floor.
5 Move the platform up and down by hand, so
it bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Proceed to step 6.
Result: The alarm is sounding. The
platform overload indicator light is flashing
at the platform controls and “PLATFORM
OVERLOAD” should be displayed on the LCD
screen at the ground controls. Slowly tighten
the load spring adjustment nut in a clockwise
direction in 10° increments until the overload
indicator light turns off, and the alarm does not
sound. Proceed to step 8.
6 Move the platform up and down by hand, so
it bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no
error message on the LCD display at the
ground controls. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds. Proceed to
step 7.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at the platform controls and “PLATFORM
OVERLOAD” should be displayed on the LCD
screen at the ground controls. Repeat this
procedure beginning with step 5.
Note: The platform will need to be moved up
and down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before
the platform overload indicator lights and alarm
responds.
Note: The platform will need to be moved up
and down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before
the platform overload indicator light and alarm
responds.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 23
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
7 Move the platform up and down by hand, so
it bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Proceed to step 8.
Result: The overload indicator lights are flashing
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure
beginning with step 5.
Note: There may be a 2 second delay before
the platform overload indicator light and alarm
responds.
8 Add an additional test weight to the platform.
S-105 and S-125- 10 lb / 4.5 kg
S-100 and S-120- 12 lb / 5.4 kg.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at the platform controls and “PLATFORM
OVERLOAD” should be displayed on the LCD
screen at the ground controls. Proceed to step 9.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Remove the additional 10 lb / 4.5 kg
test weight. Repeat this procedure beginning
with step 6.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
10Turn the key switch to ground control.
11Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
12Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
13Test all machine functions from the ground
controls.
Result: All ground control functions should operate normally.
14Turn the key switch to platform control.
15Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.
Note: There may be a 2 second delay before
the platform overload indicator light and alarm
responds.
4 - 24
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
2-6
Platform Overload Recovery
Message (software V3.14 and
later)
If the ground controls LCD screen displays
OVERLOAD RECOVERY, the emergency lowering
system has been used while the platform was
overloaded.
How to Clear the Platform
Overload Recovery Message
Note: This message shall be cleared by a person
trained and qualified on the troubleshooting and
repair of this machine.
Note: Use the following chart to identify the
description of each LCD screen control button
used in this procedure.
3 Press the buttons on the ground
controls in the following sequence: (plus)(minus)(minus)(plus).
4 Press the enter or previous button on the LCD
screen until CLEAR OVERLOAD RECOVERY
is displayed.
5 Press the plus button or minus
button to select YES. Then press
the buttons in following sequence: (plus)(plus)(plus)(minus) and press the enter
button to accept.
Note: The passcode buttons (plus)(plus)(plus)(minus) must be entered in
the proper sequence before the enter button is
pressed.
6 Press the enter or previous button on the LCD
screen until EXIT is displayed.
7 Press the plus button or minus button to select
YES and then press the enter button.
8 Turn the key switch to the off position.
Plus
Minus
Previous
Enter
1 Turn the key switch to platform control. Start
the engine and level the platform.
2 Press and hold the enter button on the ground
sontrol panel while turning the key switch to
ground controls. Hold the enter button for
approximately 5 seconds.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 25
October 2015
Section 4 • Repair Procedures
Jib Boom Components, S-105 / S-125 Models
3-1
Jib Boom,
S-105 and S-125 Models
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Jib Boom
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Remove the platform. See Repair Procedure,
How to Remove the Platform.
2 Remove the platform mounting weldment
and the platform rotator. See Repair Procedure,
How to Remove the Platform Rotator.
3 Remove the hose and cable cover retaining
fasteners from the jib boom leveling arm.
Remove the hose and cable cover from the
machine.
6 Support the barrel end of the cylinder with a
suitable lifting device.
7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
8 Use a soft metal drift to remove the pin and let
the cylinder hang down.
9 Attach a lifting strap from an overhead crane to
the jib boom.
10Remove the pin retaining fastener from the jib
boom pivot pin.
11Use a soft metal drift to remove the pin and
remove the jib boom from the primary boom.
4 Support the jib boom with a suitable lifting
device.
4 - 26
S-100 • S-105 • S-120 • S-125
Crushing hazard. The jib boom
may become unbalanced and
fall when it is removed from
the machine if it is not properly
supported.
Part No. 102916
October 2015
Section 4 • Repair Procedures
JIB BOOM COMPONENTS, S-105 AND S-125 MODELS
12Remove the pin retaining fasteners from the
jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.
13Slide both of the jib boom leveling arms off of
the jib boom pivot pin and lay them off to the
side.
18Remove the pin retaining fastener from the
platform leveling cylinder rod-end pivot pin.
19Use a soft metal drift to remove the platform
leveling cylinder rod-end pivot pin.
Crushing hazard. The platform
leveling cylinder may fall if it is not
properly supported when the rodend pivot pin is removed.
14Attach a lifting strap from an overhead crane
to the lug on the rod end of the jib boom lift
cylinder.
Crushing hazard. The jib boom
bellcrank may fall if it is not
properly supported when the
platform leveling cylinder rod-end
pivot pin is removed.
15Use a soft metal drift to remove the jib boom
lift cylinder rod-end pivot pin. Remove the jib
boom lift cylinder from the jib boom bellcrank.
Crushing hazard. The jib boom lift
cylinder may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported.
16Attach a lifting strap from an overhead crane to
the jib boom bellcrank.
20Remove the pin retaining fastener from the jib
boom bellcrank pivot pin.
21Use a soft metal drift to remove the jib boom
bellcrank pivot pin. Remove the jib boom
bellcrank from the machine.
17Support the rod end of the platform leveling
cylinder with a suitable lifting device. Protect
the cylinder rod from damage.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Crushing hazard. The jib boom
bellcrank may become unbalanced
and fall if it is not properly
supported when it is removed from
the machine.
4 - 27
October 2015
Section 4 • Repair Procedures
JIB BOOM COMPONENTS, S-105 AND S-125 MODELS
3-2
Jib Boom Lift Cylinder,
S-105 and S-125 Models
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Jib Boom
Lift Cylinder
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Lower
the jib boom until the platform is resting on the
blocks just enough to support the platform.
Note: Do not rest the entire weight of the boom on
the blocks.
3 Remove the hose and cable cover retaining
fasteners from the jib boom leveling arm.
Remove the hose and cable cover from the
machine.
4 Remove the pin retaining fasteners from the
jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.
5 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out and
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
6 Support the jib boom lift cylinder with a suitable
lifting device.
7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin.
8 Use a soft metal drift to remove the jib boom
lift cylinder rod-end pivot pin. Remove the jib
boom lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported.
4 - 28
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Boom Components
S-100 and S-105 Models
Pivot end
a
b
c
a
b
c
Number 1
Number 2
Number 3
Platform end
S-120 and S-125 Models
Pivot end
a
b
c
d
a
b
c
d
Part No. 102916
Platform end
Number 0
Number 1
Number 2
Number 3
S-100 • S-105 • S-120 • S-125
4 - 29
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
4-1
Cable Track
4 Tag and disconnect the black electrical
connector from the bottom of the control box.
The cable track and boom cable tube guides
cables and hoses running up the boom. The
cable track can be repaired link by link without
removing the cables and hoses that run through
it. Removing the entire cable track assembly may
be necessary when performing major repairs that
involve removing the boom.
6 Remove the cable track mounting fasteners
from the cable track support at the engine side
of the machine.
How to Remove the Boom
Cable Track
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
Note: Perform this procedure with the boom fully
stowed.
1 Remove the hose and cable cover retaining
fasteners from the jib boom leveling arm.
Remove the hose and cable cover from the
machine.
2 Remove the protective coil sleeve from the
hose and cable bundle at the platform end of
the boom cable tube.
3 Tag, disconnect and plug all hydraulic hoses
from the boom cable tube to the platform
manifold.
Note: If your machine is equipped with an airline
to platform option and/or weld cable option, the
airline and/or cable must be disconnected from the
platform before the cable track is removed.
4 - 30
5 Remove the platform-end boom cable tube
mounting fasteners at the engine side of the
machine.
7 Remove the wear pad mounting weldment from
the cable track support bracket at the engine
side of the machine.
8 Remove the hose and cable clamp from the
cable track support bracket at the engine side
of the machine.
9 Place blocks between the cable track and the
boom cable tube for support.
10Strap together the boom cable tube, blocks of
wood, and the cable track at the engine side of
the machine.
Component damage hazard.
Cables, hoses, boom cable tube
and cable track can be damaged if
they are kinked or pinched.
11Remove the limit switch cover retaining
fasteners from the top of the number 2 boom
tube at the platform end of the machine.
Remove the limit switch cover.
12Tag and disconnect the wiring connectors from
the proximity and limit switches on top of the
number 2 boom tube at the platform end of the
machine.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
13Remove the cable track roller guide mounting
fasteners from the ground controls side of the
machine at the platform end.
14Remove the roller guide from the cable
track guide bracket at the engine side of the
machine.
If not removing the boom from the machine,
proceed to step 19.
18Tag, disconnect and plug the primary extension
cylinder hydraulic hoses on the side of the
number 2 boom tube at the ground controls
side of the machine. Cap the fittings.
15Tag, disconnect and plug the hydraulic hoses
from the bottom of the bulkhead fittings on the
cable track support at the ground controls side
of the machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
16 Remove the bulkhead fitting locknuts from the
bulkhead fittings on the cable track support
at the ground controls side of the machine.
Remove and cap the fittings.
17Tag and disconnect the wiring connectors.
Note: The wiring connectors that need to be
disconnected are located next to the hose fittings
that were removed in step 16.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
19Remove the cable track mounting fasteners
from the cable track support at the ground
controls side of the machine.
20Remove the side panels from the boom cable
tube located under the cable track at the
ground controls side of the machine.
21Remove the hose and cable cover mounting
fasteners from the pivot end of the boom at the
ground controls side of the machine. Remove
the cover.
22Remove the hose and cable clamps from the
hoses and cables located below the boom pivot
on the inside of the turntable riser at the ground
controls side of the machine.
23Tag and disconnect the electrical cables from
the cable track to the ground controls side of
the machine.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 31
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
If not removing the boom from the machine,
proceed to step 25.
24Pull the hydraulic hoses from the boom cable
tube located under the cable track at the
ground controls side of the machine.
28Attach a lifting strap from an overhead crane to
each end of the cable track assembly. Carefully
lift the assembly from the boom and set it on a
structure capable of supporting it.
Crushing hazard. If the cable
track assemblies are not properly
secured together, the cable
track assemblies may become
unbalanced and fall when it is
removed from the machine.
25Place blocks between the cable track and the
cable track tube at the ground controls side of
the machine. Secure the cable track and the
cable track tube together.
Component damage hazard.
Cables, hoses, boom cable tube
and cable track can be damaged if
they are kinked or pinched.
26Attach a lifting strap from an overhead crane
to the cable track assembly at the engine side
of the boom. Lift the cable track assembly over
the boom and carefully set the assembly on top
of the longer boom cable tube at the ground
controls side of the machine.
Crushing hazard. If the cable
track assemblies are not properly
secured together, the cable track
may become unbalanced and
fall when it is removed from the
machine.
27Strap both cable track assemblies together.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Component damage hazard.
Cable tracks can be damaged if
they are twisted.
4 - 32
Component damage hazard.
Cables, hoses, boom cable tube
and cable track can be damaged if
they are kinked or pinched.
Component damage hazard. The
boom cable tube and cable tracks
can be damaged if they are
twisted.
How to Repair the Boom
Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
Note: A cable track repair kit is available through
the Genie Service Parts Department.
Before serial number 881 (S-120/125) and
210 (S-100/105):
Use part number 62320 which includes a 1-link
section of cable track. If the cable track has been
replaced using cable track kit, Genie part number
102054, use part number 102214. If unsure which
cable track is on the machine, contact Genie
Industries Service Department.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
After serial number 880 (S-120/125) and
209 (S-100/105):
Use part number 102214 which includes a 3-link
section of cable track.
1 Visually inspect the cable track and determine
which section needs to be replaced.
2 Remove the snap-on cable track spacers.
3 Remove the external snap rings from the pivot
pins at each end of the 3-link section to be
removed.
4 Lift up the hoses and cables and carefully
remove the damaged 3-link section of cable
track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
5 Remove the snap-on spacers from the
replacement section of cable track.
6 Lift up the hoses and cables and carefully insert
the new 3-link section of cable track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
7 Connect the ends of the replacement cable
track section to the existing cable track using
the pivot pins and external snap rings.
Note: Be sure that the pivot pins are installed from
the inside out so the external snap rings are on the
outside of the cable track.
8 Install the cable track snap-on spacers.
4-2
Boom
How to Shim the Boom
1 Measure each upper, side and lower wear pad.
1
Boom wear pad specifications
/2 inch
12.7 mm
Minimum thickness
Note: If a wear pad is not less than specification,
perform the following procedure.
2 Remove the retaining fasteners from the
appropriate black plastic boom tube cover at
the platform end of the boom. Remove the
cover.
3 Extend the boom until the wear pads are
accessible.
4 Loosen the 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
fasteners at the pivot end of the boom. Remove
the boom end cover from the machine.
8 Remove the boom side inspection cover
retaining fasteners from the boom at the pivot
end of the boom. Remove the boom inspection
cover from the machine to access boom 3 wear
pads.
9 Loosen the wear pad mounting fasteners.
10Fit as many shims as can be installed by hand.
11Tighten the mounting fasteners.
12Replace the covers.
13Extend and retract the boom through an entire
cycle. Check for tight spots that may cause binding of the boom.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 33
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
How to Remove the Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death
or serious injury and significant
component damage. Dealer
service is strongly recommended.
8 Remove the boom storage area cover retaining
fasteners. Remove the cover from the machine.
9 Place support blocks under the boom lift
cylinder.
10Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The boom lift
cylinder may fall when the rod-end
pivot pin is removed if the boom lift
cylinder is not properly supported
by the overhead crane.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
Crushing hazard. The boom
may fall when the rod-end pivot
pin is removed if the boom is
not properly supported by the
overhead crane.
1 Remove the platform. See Repair Procedure,
How to Remove the Platform.
2 Remove the platform rotator. See Repair
Procedure, How to Remove the Platform
Rotator.
11Carefully raise the boom with the overhead
crane until the rod end of the boom lift cylinder
can be removed.
3 S-105 and S-125 models: Remove the Jib
Boom. See 3-1, How to Remove the Jib Boom.
12Carefully lower the rod end of the boom lift
cylinder down onto the support blocks.
4 Remove the cable track. See Repair Procedure,
How to Remove the Boom Cable Track.
13Lower the boom with the overhead crane to a
horizontal position.
5 Raise the boom approximately 4 feet / 1.2 m.
14Remove the boom end cover retaining fasteners
from the pivot end of the boom. Remove the
cover.
6 Attach a lifting strap from an overhead crane to
the rod end of the boom lift cylinder.
7 Attach an overhead 10 ton / 10,000 kg crane to
the platform end of the boom for support. Do
not lift the boom.
4 - 34
15Locate the cable break limit switch above the
primary boom extension cylinder at the pivot
end of the boom.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
16Tag and disconnect the wiring connector from
the cable break limit switch.
17Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder. Cap
the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
18Attach a second overhead 10 ton / 10,000 kg
crane to the pivot end of the boom for support.
Do not apply any lifting pressure.
19Remove the pin retaining fastener from the
boom pivot pin. Do not remove the pin.
How to Disassemble the Boom,
S-120 and S-125 Models
Note: Complete disassembly of the boom is only
necessary if the outer or inner boom tubes must
be replaced. The primary boom extension cylinder
can be removed without completely disassembling
the boom. See 4-4, How to Remove the Primary
Extension Cylinder.
1 Remove the boom. See 4-2,
How to Remove the Boom.
2 Remove the retaining fasteners from the access
covers on both sides of the boom at the pivot
end. Remove the access covers.
a
20Use a soft metal drift to remove the boom pivot
pin.
Component damage hazard. Be
careful not to damage the boom
envelope limit switch(s) located
on the inside of the engine side
turntable riser when removing
the boom assembly. The boom
envelope switch(s) can be
damaged even if the damage is
not visible.
21Carefully remove the boom assembly from the
machine and place it on a structure capable of
supporting it.
a
side access covers
3 Secure the number 2 and number 3 boom
tubes together with a strap or chain to prevent
them from moving.
4 Remove the cable clamp from the cable break
limit switch wiring.
Crushing hazard. The boom may
become unbalanced and fall when
it is removed from the machine if
it is not properly supported by the
overhead cranes.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 35
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
10Remove the pulley pivot pins, cable guards and
pulleys.
a
Note: When installing the pulleys, be sure that the
side of the pulley with the taller flange is facing the
center of the boom tube.
11Locate the number 3 boom tube extension
cable clevis pins on both sides of the number 2
boom tube at the pivot end of the boom.
b
12Remove the cotter pin and clevis pin from both
cables.
Note: When installing a clevis pin, always replace
the cotter pin with a new one.
a
b
cable break limit switch
cable pulley
13Remove the lower external snap ring and
washer from the cable break limit switch
actuator pivot pin.
5 Disconnect the wiring connector from the cable
break limit switch.
14Remove the cable break actuator mounting
plate retaining fasteners. Remove the lower
plate from the machine.
6 Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder. Cap
the fittings on the cylinder.
15Remove the upper plate and actuator pivot pin.
Do not remove the cable break limit switch from
the mounting plate.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
16Push the cable break actuator and cables
towards the platform end of the boom
approximately 18 inches / 46 cm.
17Remove the red cable adjustment locking
bracket retaining fasteners. Remove the red
locking bracket from the machine.
7 Remove the fasteners from the inner cable
track mounting bracket at the primary boom
extension cylinder.
8 Lay the inner cable track and hoses down and
out of the way.
Bodily injury hazard. Failure to
install the red cable adjustment
locking bracket will allow the cable
mounting bolts to loosen and fall
out which could result in death or
serious injury.
9 Remove the pulley pivot pin retaining fasteners
from the number 2 boom tube at the pivot end
of the boom.
4 - 36
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
24Support and slide the primary boom extension
cylinder out of the boom assembly while
guiding the cables out of the boom and place it
on a structure capable of supporting it.
Crushing hazard. The primary
boom extension cylinder may
become unbalanced and fall when
it is removed from the boom if
it is not properly supported and
attached to the overhead crane.
a
a
red cable adjustment
locking bracket
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
18Remove the two cable adjustment bolts.
25Remove the retaining fasteners from the limit
switch cover on top of the number 2 boom tube
at the platform end of the machine.
19Remove the cable-end block mounting plate
fasteners. Remove the cable-end block
mounting plate from the machine.
26Carefully remove the cover with proximity and
limit switches from the top of the number 2
boom tube at the platform end of the boom.
20Remove the trunnion pin retaining fasteners.
Tip-over hazard. Failure to install
the correct proximity and/or limit
switches in the correct location will
result in the machine tipping over,
resulting in death or serious injury.
21Use a slide hammer to remove the trunnion
pins from the primary boom extension cylinder.
22Remove the primary boom extension cylinder
hold down brackets at the pivot end of the
boom.
23Attach a lifting strap from an overhead crane to
the lifting eye on the primary boom extension
cylinder.
Part No. 102916
27Tag and disconnect the wiring connectors from
the proximity and limit switches at the top of
the number 2 boom tube at the platform end of
the boom. Do not remove the proximity or limit
switches.
S-100 • S-105 • S-120 • S-125
4 - 37
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
28Remove the retaining fasteners from the limit
switch cover on the side of the number 0 boom
tube at the platform end of the boom.
34Attach a lifting strap from an overhead crane to
the number 3 boom tube at the platform end of
the boom.
29Carefully remove the cover with proximity and
limit switches from the number 0 boom tube at
the platform end of the boom.
35Support and slide the number 3 boom tube out
of the number 2 boom tube. When the number
3 boom tube is approximately halfway removed,
remove the bottom wear pads from the number
2 boom tube at the platform end of the boom.
Tip-over hazard. Failure to install
the correct proximity and/or limit
switches in the correct location will
result in the machine tipping over,
resulting in death or serious injury.
30Tag and disconnect the wiring connectors from
the proximity and limit switches at the ground
controls side of the number 0 boom tube at the
platform end of the boom. Do not remove the
proximity or limit switches.
31Remove the retaining fasteners from each black
plastic boom tube cover at the platform end of
the machine. Remove the covers.
32Remove and label the top and side wear pads
of the number 3 boom tube at the pivot end
of the boom. Do not remove the bottom wear
pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
33Remove and label the top and side wear pads
from the number 2 boom tube at the platform
end of the boom. Do not remove the bottom
wear pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
4 - 38
Crushing hazard. The number
3 boom tube may become
unbalanced and fall when it is
removed from the number 2 boom
tube if it is not properly supported
and attached to the overhead
crane.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
36Remove and label the top and side wear pads
from the number 2 boom tube at the pivot end
of the boom. Do not remove the bottom wear
pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
37Remove and label the top and side wear pads
from the number 1 boom tube at the platform
end of the boom. Do not remove the bottom
wear pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
38Attach a lifting strap from an overhead crane to
the number 2 boom tube at the platform end of
the boom.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
39Support and slide the number 2 boom tube out
of the number 1 boom tube. When the number
2 boom tube is approximately halfway removed,
remove the bottom wear pads from the number
1 boom tube at the platform end of the boom.
Crushing hazard. The number
2 boom tube may become
unbalanced and fall when it is
removed from the number 1 boom
tube if it is not properly supported
and attached to the overhead
crane.
42Support the secondary boom extension cylinder
with an overhead crane or other suitable lifting
device.
43Remove the pin retaining fasteners from both
the rod-end and barrel-end pivot pins. Do not
remove the pins.
44Use a soft metal drift to remove both pivot pins
and remove the secondary boom extension
cylinder from the machine while guiding the
barrel end of the cylinder out of the boom.
Crushing hazard. The secondary
boom extension cylinder may
become unbalanced and fall if it is
not properly supported when it is
removed from the machine.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
40Remove the secondary boom extend cylinder
cover retaining fasteners. Remove the covers.
Bodily injury hazard. Do not
operate the machine unless the
secondary extend cylinder covers
are properly installed. Operating
the machine with the covers
removed could result in death or
serious injury.
41Tag, disconnect and plug the secondary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 102916
Component damage hazard.
The boom lift cylinder rod can
become damaged if the barrel end
of the secondary boom extension
cylinder is allowed to come in
contact with it.
45Remove and label the top and side wear pads
from the number 1 boom tube at the pivot end
of the boom. Do not remove the bottom wear
pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
S-100 • S-105 • S-120 • S-125
4 - 39
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
46Remove and label the top and side wear pads
from the number 0 boom tube at the platform
end of the boom. Do not remove the bottom
wear pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
47Attach a lifting strap from an overhead crane to
the number 1 boom tube at the platform end of
the boom.
48Support and slide the number 1 boom tube out
of the number 0 boom tube. When the number
1 boom tube is approximately halfway removed,
remove the bottom wear pads from the number
0 boom tube at the platform end of the boom.
Crushing hazard. The number
1 boom tube may become
unbalanced and fall when it is
removed from the number 0 boom
tube if it is not properly supported
and attached to the overhead
crane.
How to Disassemble the Boom,
S-100 and S-105 Models
Note: Complete disassembly of the boom is only
necessary
if the outer or inner boom tubes must be replaced.
The primary boom extension cylinder can be
removed without completely disassembling the
boom. See 4-4, How to Remove the Primary
Extension Cylinder.
1 Remove the boom. See 4-2,
How to Remove the Boom.
2 Remove the retaining fasteners from the access
covers on both sides of the boom at the pivot
end. Remove the access covers.
a
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
a
side access covers
3 Secure the number 2 and number 3 boom
tubes together with a strap or chain to prevent
them from moving.
4 Remove the cable clamp from the cable break
limit switch wiring.
4 - 40
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
10Remove the cotter pin and clevis pin from both
cables.
a
Note: When installing a clevis pin, always replace
the cotter pin with a new one.
11Remove the lower external snap ring and
washer from the cable break limit switch
actuator pivot pin.
b
12Remove the cable break actuator mounting
plate retaining fasteners. Remove the lower
plate from the machine.
13Remove the upper plate and actuator pivot pin.
Do not remove the cable break limit switch from
the mounting plate.
a
b
cable break limit switch
cable pulley
5 Disconnect the wiring connector from the cable
break limit switch.
6 Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder. Cap
the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Remove the pulley pivot pin retaining fasteners
from the number 2 boom tube at the pivot end
of the boom.
8 Remove the pulley pivot pins, cable guards and
pulleys.
14Push the cable break actuator and cables
towards the platform end of the boom
approximately 18 inches / 46 cm.
15Remove the red cable adjustment locking
bracket retaining fasteners. Remove the red
locking bracket from the machine.
Bodily injury hazard. Failure to
install the red cable adjustment
locking bracket will allow the cable
mounting bolts to loosen and fall
out which could result in death or
serious injury.
16Remove the two cable adjustment bolts.
17Remove the cable-end block mounting plate
fasteners. Remove the cable-end block
mounting plate from the machine.
18Remove the trunnion pin retaining fasteners.
19Use a slide hammer to remove the trunnion
pins from the primary boom extension cylinder.
Note: When installing the pulleys, be sure that the
side of the pulley with the taller flange is facing the
center of the boom tube.
9 Locate the number 3 boom tube extension
cable clevis pins on both sides of the number 2
boom tube at the pivot end of the boom.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 41
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
23Remove the retaining fasteners from the limit
switch cover on top of the number 2 boom tube
at the platform end of the machine.
24Carefully remove the cover with proximity and
limit switches from the top of the number 2
boom tube at the platform end of the boom.
Tip-over hazard. Failure to install
the correct proximity and/or limit
switches in the correct location will
result in the machine tipping over,
resulting in death or serious injury.
a
a
red cable adjustment
locking bracket
20Remove the primary boom extension cylinder
hold down brackets at the pivot end of the
boom.
21Attach a lifting strap from an overhead crane to
the lifting eye on the primary boom extension
cylinder.
22Support and slide the primary boom extension
cylinder out of the boom assembly while
guiding the cables out of the boom and place it
on a structure capable of supporting it.
Crushing hazard. The primary
boom extension cylinder may
become unbalanced and fall when
it is removed from the boom if
it is not properly supported and
attached to the overhead crane.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
25Tag and disconnect the wiring connectors from
the proximity and limit switches at the top of
the number 2 boom tube at the platform end of
the boom. Do not remove the proximity or limit
switches.
26Remove the retaining fasteners from the limit
switch cover on the side of the number 1 boom
tube at the platform end of the boom.
27Carefully remove the cover with proximity and
limit switches from the number 1 boom tube at
the platform end of the boom.
Tip-over hazard. Failure to install
the correct proximity and/or limit
switches in the correct location will
result in the machine tipping over,
resulting in death or serious injury.
28Tag and disconnect the wiring connectors from
the proximity and limit switches at the ground
controls side of the number 1 boom tube at the
platform end of the boom. Do not remove the
proximity or limit switches.
29Remove the retaining fasteners from each black
plastic boom tube cover at the platform end of
the machine. Remove the covers.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
4 - 42
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
30Remove and label the top and side wear pads
of the number 3 boom tube at the pivot end
of the boom. Do not remove the bottom wear
pads.
34Remove and label the top and side wear pads
from the number 2 boom tube at the pivot end
of the boom. Do not remove the bottom wear
pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
31Remove and label the top and side wear pads
from the number 2 boom tube at the platform
end of the boom. Do not remove the bottom
wear pads.
35Remove and label the top and side wear pads
from the number 1 boom tube at the platform
end of the boom. Do not remove the bottom
wear pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
32Attach a lifting strap from an overhead crane to
the number 3 boom tube at the platform end of
the boom.
36Attach a lifting strap from an overhead crane to
the number 2 boom tube at the platform end of
the boom.
33Support and slide the number 3 boom tube out
of the number 2 boom tube. When the number
3 boom tube is approximately halfway removed,
remove the bottom wear pads from the number
2 boom tube at the platform end of the boom.
37Support and slide the number 2 boom tube out
of the number 1 boom tube. When the number
2 boom tube is approximately halfway removed,
remove the bottom wear pads from the number
1 boom tube at the platform end of the boom.
Crushing hazard. The number
3 boom tube may become
unbalanced and fall when it is
removed from the number 2 boom
tube if it is not properly supported
and attached to the overhead
crane.
Crushing hazard. The number
2 boom tube may become
unbalanced and fall when it is
removed from the number 1 boom
tube if it is not properly supported
and attached to the overhead
crane.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
Part No. 102916
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
S-100 • S-105 • S-120 • S-125
4 - 43
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
4-3
Boom Lift Cylinder
5 Place support blocks under the boom lift
cylinder.
How to Remove the Boom
Lift Cylinder
6 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a
soft metal drift to remove the pin. Protect the
cylinder rod from damage.
Crushing hazard. The boom lift
cylinder may fall when the rod-end
pivot pin is removed if the boom lift
cylinder is not properly supported
by the overhead crane.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death
or serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
1 Raise the boom until there is approximately
4 feet / 1.2 m between the turntable and boom
rest pad.
2 Attach a lifting strap from an overhead crane or
other suitable lifting device to the rod end of the
the boom lift cylinder.
Crushing hazard. The boom
may fall when the rod-end pivot
pin is removed if the boom is
not properly supported by the
overhead crane.
7 Carefully raise the boom with the overhead
crane until the rod end of the boom lift cylinder
can be removed.
8 Carefully lower the rod end of the boom lift
cylinder down onto the support blocks.
9 Carefully raise the boom with the overhead
crane until the barrel end of the boom lift
cylinder is accessible.
10Tag, disconnect and plug the boom lift cylinder
hydraulic hoses. Cap the fittings on the cylinder.
3 Attach an overhead 10 ton / 9071 kg crane to
the platform end of the boom for support. Do
not lift the boom.
4 Remove the boom storage area cover retaining
fasteners. Remove the cover from the machine.
4 - 44
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
11Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
17With the boom lift cylinder being supported by
the overhead crane, pull the boom lift cylinder
toward the platform until it is out.
Crushing hazard. The boom lift
cylinder may become unbalanced
and fall if it is not properly
supported when it is removed from
the machine.
a
b
a
b
engine pivot plate anchor hole
engine pivot plate retaining fastener
12Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
13Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Component damage hazard.
Be careful not to damage the
proximity and/or limit switches
when removing the boom lift
cylinder.
Component damage hazard. The cables and hydraulic hoses can be
damaged if the boom lift cylinder
is pulled across them.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
anchor hole to secure it from
moving could result in death or
serious injury.
14Remove the pin retaining fastener from the
barrel-end pivot pin. Do not remove the pin.
15Support the boom lift cylinder with an overhead
crane.
16Use a slide hammer to remove the boom lift
cylinder barrel-end pivot pin through the access
hole in the engine side turntable riser.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 45
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
4-4
Extension Cylinders
3 Remove the access cover retaining fasteners
from both sides of the boom. Remove the
access covers.
The primary boom extension cylinder is located
inside the boom assembly and incorporates cables
and pulleys that are responsible for extending the
number 2 and 3 boom tubes. The secondary boom
extension cylinder (S-120 and S-125 models) is
located underneath the number 0 boom tube and
is responsible for extending the number 1 boom
tube. The extension cylinders are equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
4 Secure the number 2 and number 3 boom
tubes together with a strap or chain to prevent
them from moving.
5 Remove the cable clamp from the cable break
limit switch wiring.
a
How to Remove the Primary
Boom Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death
or serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
a
6 Disconnect the wiring connector from the cable
break limit switch.
7 Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder. Cap
the fittings on the cylinder.
1 Raise the boom to a horizontal position.
2 Remove the retaining fasteners from the
boom end cover at the pivot end of the boom.
Remove the cover from the machine.
4 - 46
cable break limit switch
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
8 S-120 and S-125 models: Remove the
fasteners from the inner cable track mounting
bracket at the primary boom extension cylinder.
17Push the cable break actuator and cables
towards the platform end of the boom
approximately 18 inches / 46 cm.
9 S-120 and S-125 models: Lay the inner cable
track and hoses down and out of the way.
18Remove the retaining fasteners from the red
cable adjustment locking bracket. Remove the
red locking bracket.
10Remove the pulley pivot pin retaining fasteners
from the number 2 boom tube at the pivot end
of the boom.
11Remove the pulley pivot pins, cable guards and
pulleys.
Note: When installing the pulleys, be sure that the
side of the pulley with the shorter flange is facing
the inside of the boom tube.
Bodily injury hazard. Failure to
install the red cable adjustment
locking bracket would allow the
cable mounting bolts to loosen
and fall out which could result in
death or serious injury.
12Locate the number 3 boom tube extension
cable clevis pins on both sides of the number 2
boom tube at the pivot end of the boom.
13Remove the cotter pin and clevis pin from both
cables.
Note: When installing a clevis pin, always replace
the cotter pin with a new one.
14Remove the lower external snap ring and
washer from the cable break limit switch
actuator pivot pin.
a
15Remove the cable break actuator mounting
plate retaining fasteners. Remove the lower
plate.
16Remove the upper plate and actuator pivot pin.
Do not remove the cable break limit switch from
the mounting plate.
Part No. 102916
S-100 • S-105 • S-120 • S-125
a
red cable adjustment
locking bracket
4 - 47
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
19Remove the two cable adjustment bolts.
20Remove the cable-end block mounting plate
fasteners. Remove the cable-end block
mounting plate.
How to Remove the Secondary
Boom Extension Cylinder,
S-120 and S-125 Models
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death
or serious injury and significant
component damage. Dealer
service is strongly recommended.
21Remove the trunnion pin retaining fasteners.
22Use a slide hammer to remove the trunnion
pins from the primary boom extension cylinder.
Note: Use a 1/2 -13 bolt thread on each end of the
slide hammer.
23Attach a lifting strap from an overhead crane to
the lifting eye on the primary boom extension
cylinder.
24Support and slide the primary boom extension
cylinder out of the boom assembly while
guiding the cables out of the boom and place it
on a structure capable of supporting it.
Crushing hazard. The primary
boom extension cylinder may
become unbalanced and fall when
it is removed from the boom if
it is not properly supported and
attached to the overhead crane.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
1 Raise the boom until the secondary boom
extension cylinder barrel-end pivot pin is above
the turntable covers.
2 Remove the secondary boom extend cylinder
cover retaining fasteners. Remove the covers.
Component damage hazard.
Cables can be damaged if they
are kinked, pinched or snagged
during removal.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
4 - 48
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. Do not
operate the machine unless the
secondary extend cylinder covers
are properly installed. Operating
the machine with the covers
removed could result in death or
serious injury.
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
3 Tag, disconnect and plug the secondary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 Support the secondary boom extension cylinder
with an overhead crane or other suitable lifing
device.
5 Remove the pin retaining fasteners from both
the rod-end and barrel-end pivot pins. Do not
remove 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
cylinder from the machine while guiding the
barrel end of the cylinder out of the boom.
Crushing hazard. The secondary
boom extension cylinder may
become unbalanced and fall if it is
not properly supported when it is
removed from the machine.
Component damage hazard.
The boom lift cylinder rod can
become damaged if the barrel end
of the secondary boom extension
cylinder is allowed to come in
contact with it.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 49
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
4-5
Boom Extend/Retract Cables
a
How to Adjust the Boom Extend/
Retract Cables
d
Properly adjusted extend/retract cables are
essential to safe machine operation. Failure to
maintain proper adjustment of the cables could
result in unsafe operating conditions and may
cause component damage. The boom extend and
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
Note: A flashlight may be necessary to be able to
see the extend/retract cables inside of the boom
assembly.
Note: Perform this procedure with the boom fully
retracted.
b
c
a
b
c
d
Illustration 1
1 Start the engine from the ground controls.
2 Raise the boom to a horizontal position.
3 Stop the engine.
4 Remove the boom end cover from the pivot end
of the machine.
5 Locate the red locking bracket (c) covering the
cable adjustment bolts at the pivot end of the
boom (illustration 1).
6 Remove the retaining fastener from the red
locking bracket and remove the bracket from
the machine.
7 Locate the retract cable equalizer bolt under the
number 1 boom tube at the platform end of the
boom assembly (illustration 3).
8 Loosen the nylock (g) and jam nut (h) on the
cable tension equalizer bracket. Do not remove
the nuts.
4 - 50
limit switch
extend cable adjustment bolts
red cable adjustment locking bracket
boom tube distance
9 At the pivot end of the boom (illustration 1),
turn the cable adjustment bolts (b) clockwise
to obtain 63/4 inches / 17 cm between the end
of the number 3 boom tube and the end of the
number 2 boom tube (d). As a guide (Illustration
2), the end of the extension cable coupling (i)
should be approximately mid-point (k) between
the guide plate (l) and the cable retainer
bracket (j). Illustration 2 is visible by removing
the boom side covers.
Note: Adjust the cable adjustment bolts evenly so
the cable break limit switch (a) stays centered in
the limit switch actuator (Illustration 1).
Note: If the distance is greater than 63/4 inches /
17 cm, loosen the extend cable adjustment bolts
and tighten the hex jam nut on the cable tension
equalizer bolt until the distance is less than
63/4 inches / 17 cm. Loosen the jam nut and repeat
step 9.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
e
f
l
k
j
i
i
j
k
l
extension cable coupling
cable retainer bracket
equal distance
guide plate
Illustration 2
10At the platform end of the boom, tighten the
hex jam nut (h) on the cable tension equalizer
bracket located underneath the number 1 boom
tube (Illustration 3). Tighten the hex jam nut
until it is snug. Do not overtighten.
11Hold the hex jam nut with a wrench and tighten
the nylock nut (g) against the hex jam nut.
12Re-check that the cable break limit switch is
centered in the limit switch actuator. Adjust the
extension cable adjustment bolts to center it.
e
f
g
h
boom tube 1
boom tube 2
nylock nut
hex jam nut
Part No. 102916
g
Illustration 3
14Install the red locking bracket over the cable
adjustment bolts. A flat edge of each bolt head (b)
must be on top for the locking bracket to secure
the bolts.
Bodily injury hazard. Failure to reinstall the red cable adjustment
locking bracket would allow the
cable mounting bolts to loosen
and fall out which could result in
death or serious injury.
13 At the pivot end of the boom, measure the
distance between the end of the number 3
boom tube and the end of the number 2 boom
tube.
Result: The measurement between the end of
the number 3 boom tube and the end of the
number 2 boom tube should be
63/4 to 67/8 inches / 17 to 17.5 cm (d).
h
15Lower the boom to the stowed position.
16Start the engine from the platform controls.
S-100 • S-105 • S-120 • S-125
4 - 51
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
17Extend the boom approximately 2 feet / 0.6 m.
18Retract the boom. While retracting the boom,
visually inspect the number 2 and number 3
boom tubes.
Result: The number 2 should not move more
than 1/2 inch (13 mm) before the number 3
boom tube begins to retract.
Note: If the number 2 boom tube moves more than
/2 inch (13 mm) before the number 3 boom tube
begins to retract, repeat the procedure until the
number 2 boom moves less than 1/2 inch before
the number 3 boom begins to retract.
1
How to Replace the Boom Extend/
Retract Cables
Note: The cable pulleys must also be replaced
when replacing the cables.
1 Remove the boom extension cylinder. See 4-4,
How to Remove the Primary Boom Extension
Cylinder.
Boom extend cables:
2 Remove the retaining fasteners that secure the
extension cable retainer to the pulley mount.
Remove the retainer.
3 Remove the cables from the lower boom extend
cable bracket that attaches to the number 3
boom tube.
o
Boom Tube One
Boom Tube Two
Boom Tube Three
Boom Tube One
n
4 Remove the front and rear fasteners from the
anchor bracket that supports the cable anchors.
Remove the bracket.
5 Remove the pulley and boom extend cables
from the extension cylinder assembly. Discard
the old cables and pulleys.
m
m figure 3 platform end
n figure 2, boom tube 3
o figure 1, pivot end
Illustration 4
6 Route the new boom extend cables through the
boom extend pulley bracket.
Note: Be sure before installing the extend cables
through the boom adjustment coupling that the tall
end of the cable anchors are facing down.
7 Install the new boom extend cable pulley, pivot
pin and snap rings.
Note: Be sure the boom extend cables are routed
through the grooves of the pulley and the upper
wear pad on the extension cylinder.
8 Install the boom extend cables to the lower
extend cable bracket that mounts to the number
3 boom tube.
4 - 52
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
Boom retract cables:
9 Remove the fasteners from the boom retract
cables at the platform end of the boom.
10Attach a rope to one of the boom retract cables
at the pivot end of the boom.
11At the platform end of the boom, pull on the
boom retract cable that has the rope attached
to it.
12Pull the old cable completely out of the boom
tube. Discard the old boom retract cable.
13Remove the rope from the old cable and
securely attach the rope to the same end of the
new boom retract cable.
20Secure the number 2 and number 3 booms
together at the platform end with a chain or
strap to prevent them from moving.
21Install the boom extension cylinder assembly
into the boom.
Note: Before lowering the extension cylinder into
the saddles of the number 1 boom tube, wrap the
boom retract cables around the pulleys.
22Remove the chain or strap from the platform
end of the number 2 and number 3 boom tubes.
23Adjust the boom extend/retract cables.
See, How to Adjust the Boom Extend/Retract
Cables.
14At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
15Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
the boom tube. Remove the rope.
16Repeat steps 11 through 16 for the other boom
retract cable.
17At the platform end of the boom, install the
retract cables and fasteners to the adjustment
plate.
18Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
19Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 53
October 2015
Section 4 • Repair Procedures
Turntable Covers
5-1
Turntable Covers
4 Mark the location of the hinges on the bulkhead
to ensure proper cover alignment during
installation.
In addition to the standard hinged turntable covers,
there are two fixed turntable covers. One fixed
cover protects the fuel tank on the engine side of
the machine and the other protects the turntable
rotator assembly on the ground controls side of the
machine.
5 Remove the cover hinge to bulkhead retaining
fasteners.
6 Carefully lift and remove the cover from
the machine.
Crushing hazard. The turntable
cover could become unbalanced
and fall when it is removed from
the machine if it is not properly
supported and secured to a
appropriate lifting device.
How to Remove a Hinged
Turntable Cover
1 Raise the turntable cover. Support and secure
the open cover to an overhead crane or forklift.
Do not lift it.
Bodily injury hazard. Safety
decals are essential to safe
machine operation. Failure to
replace all safety and instructional
decals could result in death
or serious injury. If a turntable
cover must be replaced, be sure
that all appropriate safety and
instructional decals are applied to
the new cover.
Crushing hazard. Due to its heavy
weight, do not attempt to support
the cover by hand.
Component damage hazard.
Protect the cover from damage
by using carpet or padding on the
crane or forklift forks.
2 Remove the upper and lower retaining clips
from the gas strut.
Note: Alignment adjustments may be necessary
when a new cover is installed.
3 Gently pry the strut pivot sockets off of the ball
studs and remove the strut. Protect the strut
cylinder rod from damage.
Crushing hazard. The turntable
cover will fall when the gas struts
are removed if it is not properly
supported.
4 - 54
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
TURNTABLE COMPONENTS
How to Remove a Fixed
Turntable Cover
1 Ground controls side: Remove the top
retaining fasteners from the power to platform
plug panel and loosen the bottom retaining
fasteners. 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 turntable
cover may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported.
Bodily injury hazard. Safety
decals are essential to safe
machine operation. Failure to
replace all safety and instructional
decals could result in death
or serious injury. If a turntable
cover must be replaced, be sure
that all appropriate safety and
instructional decals are applied to
the new cover.
Note: Alignment adjustments may be necessary
when a new cover is installed.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 55
October 2015
Section 4 • Repair Procedures
Engines
6-1
RPM Adjustment
How to Remove the Flex Plate
1 Disconnect the wiring plug at the electronic
proportional controller located on the drive
pump.
Refer to Maintenance Procedure,
Check and Adjust the Engine RPM.
2 Remove the hose clamp from the air cleaner
hose at the air cleaner. Carefully disconnect
the hose from the air cleaner.
6-2
Flex Plate
The flex plate couples the engine to the pump. The
flex plate is bolted to the engine flywheel and has
a cut-out in the center for the pump coupler.
a
b
c
d
e
3 Remove the air cleaner mounting fasteners.
Remove the air cleaner from the machine.
4 Remove the fuel filter/water separator retaining
fasteners from the pump mounting plate. Do
not disconnect the fuel hoses.
5 Remove the fuel filter/water separator and lay it
to the side.
6 Support the drive pump assembly with an
appropriate lifting device. Then remove all of
the pump mounting plate to engine bell housing
bolts.
f
apump
b pump shaft
ccoupler
d flex plate
e flywheel
f
Deutz models- .245 inch / 6.2 mm gap
Cummins or Perkins models
.255 inch / 6.5 mm gap
4 - 56
7 Carefully pull the pump away from the engine
and secure it from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
8 Remove the flex plate mounting fasteners,
then remove the flex plate from the flywheel.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
ENGINES
How to Install the Flex Plate
1
8
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Apply Loctite® removable thread sealant to the
mounting fasteners. Then torque the flex plate
mounting bolts in sequence to:
Cummins engines: 23 ft-lbs / 31.2 Nm.
Deutz and Perkins engines: 28 ft-lbs / 38 Nm.
5
6
4
3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump
end plate for your engine.
7
2
Perkins Engines
Cummins Engines
Before Serial Number 1029
Deutz 913 Engines
4 Apply Loctite® removable thread sealant to the
pump coupler set screw.
Perkins and Cummins engines before serial
number 1029 and Deutz 913 engines:
Torque the set screw to 20 ft-lbs / 27 Nm.
Perkins and Cummins engines after serial
number 1028 and Deutz 2011 engines:
Torque the set screw to 61 ft-lbs / 83 Nm.
5 Install the bell housing/mounting plate
assembly. Apply Loctite® removable thread
sealant to the mounting fasteners. Then torque
the pump retaining fasteners to:
Cummins, Perkins and Deutz 913 engines:
28 ft-lbs / 38 Nm.
Deutz 2011 engines: 47 ft-lbs / 63 Nm.
3
1
8
3
5
6
7
4
2
Perkins Engines
Cummins Engines
After Serial Number 1028
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
1
Component damage hazard.
When installing the pump, do not
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.
6
3
4
5
2
Deutz 2011 Engines
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 57
October 2015
Section 4 • Repair Procedures
ENGINES
6-3
Oil Pressure and Coolant
Temperature Sending Units Cummins and Perkins Models
The coolant temperature sending unit is an
electrical device. If the coolant temperature
reaches 210° F / 99° C, the ECM will shut the
engine off to prevent damage and will not start
until the coolant temperature drops below
210° F / 99° C. The engine temperature will be
shown on the display screen at the ground controls
when the key is on and the Emergency Stop
Button is pulled out to the on position. Use the
scroll buttons and scroll to the Engine Temperature
screen.
Component damage hazard.
Do not crank the engine with
a water temperature fault shown
on the display at the ground
controls.
The oil pressure sending unit is an electrical
device. If the oil pressure drops below
12 psi / 0.8 bar, the ECM will shut the engine off
to prevent damage. The engine oil pressure will
be indicated on the display screen at the ground
controls while the engine is running. Use the scroll
buttons and scroll to the Engine Oil Pressure
screen.
6-4
Oil Pressure and Temperature
Sending Units - Deutz Models
The engine oil temperature sending unit is an
electrical device. If the engine oil temperature
reaches 275° F / 135° C, the ECM will shut the
engine off to prevent damage and will not start
until the engine oil temperature drops below
275° F / 135° C. The engine temperature will be
shown on the display screen at the ground controls
when the key is on and the Emergency Stop
Button is pulled out to the on position. Use the
scroll buttons and scroll to the Engine Temperature
screen.
Component damage hazard.
Do not crank the engine with
a oil temperature fault shown on
the display at the ground controls.
The oil pressure sending unit is an electrical
device. If the oil pressure drops below
12 psi / 0.8 bar, the ECM will shut the engine off
to prevent damage. The engine oil pressure will
be indicated on the display screen at the ground
controls while the engine is running. Use the scroll
buttons and scroll to the Engine Oil Pressure
screen.
Component damage hazard.
Do not crank the engine with a low
oil pressure fault shown on the
display at the ground controls.
4 - 58
S-100 • S-105 • S-120 • S-125
Component damage hazard.
Do not crank the engine with a low
oil pressure fault shown on the
display at the ground controls.
Part No. 102916
October 2015
Section 4 • Repair Procedures
Ground Controls
The ground control box (TCON) is the
communication and operations center for the
machine. The ground control box contains two
key switches. The key switch towards the top
of the control box is for selection of ground or
platform controls. The key switch at the bottom
of the control box is the Service Bypass key
switch. It is used to allow the boom to be raised
above 10° with the axles retracted and to correct
an out-of-level platform. If the machine trips an
envelope safety switch, the operator at the ground
controls can turn and hold the Service Bypass key
switch in the recover position and the machine
will automatically lower the boom to the stowed
position in sequence.
The ground control box contains a replaceable
membrane decal with touch sensitive buttons for
various machine functions. The ground control box
also contains two printed circuit boards:
The LCD (Liquid Crystal Display) circuit board
is mounted to the inside of the control box lid which
controls the LCD display screen.
The ECM circuit board is the main circuit board
for the machine. There are relays on the ECM
circuit board that can be replaced. All operating
parameters and configuration of options for the
machine are stored in the ECM memory.
7-1
Circuit Boards
How to Remove the LCD Display
Screen Circuit Board
1 Push in the Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the platform control box mounting
fasteners. Remove the platform control box
from the machine.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
3 Locate the cables that connect to the bottom
of the control box. Number each cable and its location at the control box.
4 Disconnect the cables from the bottom of the
platform control box.
5 Remove the control cable plug retaining
fasteners from the bottom of the platform
control box.
6 Remove the platform control box lid fasteners.
Open the control box lid.
Note: The ECM circuit board inside the ground
control box (TCON) cannot be replaced by itself.
If the ECM circuit board is faulty and needs to be
replaced, contact the Genie Industries Service
Department.
Note: When an ECM circuit board is replaced, the
proportional valves will need to be calibrated. See
1-3, How to Calibrate a Joystick.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 59
October 2015
Section 4 • Repair Procedures
GROUND CONTROLS
7 Locate the ECM circuit board mounted to the
inside of the platform control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
8 Remove the ECM circuit board mounting
fasteners.
9 Carefully remove the ECM circuit board from
the platform control box.
7-2
Membrane Decal
The membrane decal is a special decal that
consists of a decal with an electronic membrane
on the backside. The membrane contains touch
sensitive areas that, when pushed, activates the
machine functions. The membrane buttons activate
machine functions similar to toggle switches, but
do not have any moving parts.
How to Replace the Membrane
Decal
1 Turn the key switch at the ground controls to
the off position.
2 Push in the Emergency Stop button to the
off position at both the ground and platform
controls.
3 Remove the ground control box lid fasteners.
Open the control box lid.
4 Carefully disconnect the two ribbon cables from
the membrane decal at the ECM circuit board.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 - 60
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
GROUND CONTROLS
5 Carefully remove the membrane decal from the
control box lid while guiding the ribbon cables
out of the control box lid.
7-3
Control Relays
6 Remove any decal adhesive from the control
box lid with a mild solvent.
Relays used for single function switching are single
pole double throw (SPDT) relays.
Note: Do not allow any solvent to come in contact
with the LCD display screen.
How to Test a Single Pole Double
Throw Relay
7 Install the new membrane decal (Genie part
number 50811) while guiding the ribbon cables
through the control box lid.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
8 Connect the ribbon cables to the ECM circuit
board.
9 Close the control box lid and install the retaining
fasteners.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
1 Turn the key switch to the off position.
2 Open the ground control box and remove the
relay to be tested from the ECM circuit board.
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
GROUND CONTROLS
3 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test
Desired result
85 to 95 Ω
terminal 85 to 86
no continuity
terminal 87 to 87a & 30
(infinite Ω)
continuity
terminal 87a to 30
(zero Ω)
87
86
87a
85
30
4 Connect 12V DC to terminal 85 and a ground
wire to terminal 86, then test the following
terminal combinations.
Test
Desired result
terminal 87 to 87a
no continuity
(infinite Ω)
terminal 87a to 30
no continuity
(infinite Ω)
terminal 87 to 30
continuity
(zero Ω)
85
86
87
87a
30
Control Relay Schematic
4 - 62
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Limit Switches
120 ft / 36.6 m
110 ft / 33.5 m
LSB9AS
65
LSB14AO
68
100 ft / 30.5 m
LSB2RO
102 ft
(31.1 m)
90 ft / 27.4 m
LSB4EO
100 ft
(30.5 m)
80 ft / 24.4 m
LSB8AS
50
LSB13AO
53
LSB13AO
53
70 ft / 21.3 m
60 ft / 18.3 m
LSB3EO
75 ft
(22.9 m)
LSB4ES
75.5 ft
(23 m)
LSB2RS
101 ft
(30.8 m)
LSB8AS
50
LSB3EO
75 ft
(22.9 m)
LSB4ES
75.5 ft
(23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS
11
LSB1DO
10
LSB1DO
10
20 ft / 6.1 m
LSB7DS
11
10 ft / 3 m
LSB3RS
3.5 ft (1.1 m)
LSB3RO
3 ft (0.9 m)
LSB3RO
3 ft (0.9 m)
0 ft / 0 m
S-100 and S-105 Models
S-120 and S-125 Models
LSAX1RO
LSAX1EO
LSB3RS
3.5 ft (1.1 m)
LSAX2RO
LST10
LSAX2ES LSAX2EO
LSAX1ES
Part No. 102916
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
8-1
Limit Switches
How to Test the Limit Switches
There are 2 types of limit switches: Mechanical (roller
arm) and proximity. Mechanical limit switches
are activated by a part of the machine physically
moving the roller arm of the switch. Proximity
switches are a magnetic type of switch and are
activated by the close presence of a ferrous metal.
Mechanical Operational Limit Switch:
3 Activate the limit switch. Connect the leads from
an ohmmeter or continuity tester to the deutsch
connector terminals in the combination listed
below and check for continuity.
terminal 1 to 2
no continuity
(infinite Ω)
continuity
terminal 3 to 4
(zero Ω)
terminal 1 to 3 and 4
no continuity
(infinite Ω)
terminal 2 to 3 and 4
no continuity
(infinite Ω)
Mechanical Safety Limit Switch:
1 Manually activate the limit switch.
Result: The limit switch arm should move freely
and spring return to center. A distinct click
should be felt and heard.
2 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector
terminals in the combination listed below and
check for continuity.
terminal 1 to 2
continuity
(zero Ω)
terminal 3 to 4
no continuity
(infinite Ω)
terminal 1 to 3 and 4
no continuity
(infinite Ω)
terminal 2 to 3 and 4
no continuity
(infinite Ω)
Numbering Legend
1 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector
terminals in the combination listed below and
check for continuity.
terminal 1 to 2
continuity
(zero Ω)
terminal 3 to 4
continuity
(zero Ω)
terminal 1 to 3 and 4
no continuity
(infinite Ω)
terminal 2 to 3 and 4
no continuity
(infinite Ω)
terminal 5 to 6
no continuity
(infinite Ω)
Circuit number
AX Axle
B Boom
T Turntable
LS Limit switch
D
A
L
E
R
Down
Angle
Load moment
Extend
O Operational
Retract
S Safety
LS AX 1 R O
4 - 64
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
2 Activate the limit switch. Connect the leads from
an ohmmeter or continuity tester to the deutsch
connector terminals in the combination listed
below and check for continuity.
3 Place a piece of ferrous metal (steel, iron, etc.)
in front of the target area so it is no more than
1
/2 inch / 12.7 mm away from the target area of
the proximity switch.
terminal 1 to 2
terminal 3 to 4
terminal 1 to 3 and 4
terminal 2 to 3 and 4
terminal 5 to 6
4 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector
terminals in the combination listed below and
check for continuity.
no continuity
(infinite Ω)
no continuity
(infinite Ω)
no continuity
(infinite Ω)
no continuity
(infinite Ω)
no continuity
(infinite Ω)
Proximity Switch:
1 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector
terminals in the combination listed below and
check for continuity.
terminal 3 to 4
no continuity
(infinite Ω)
2 Locate the target area of the proximity switch.
terminal 3 to 4
continuity
(zero Ω)
5 Move the piece of ferrous metal (steel, iron,
etc.) so it is more than 1/2 inch / 12.7 mm away
from the target area of the proximity switch.
6 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector
terminals in the combination listed below and
check for continuity.
terminal 3 to 4
no continuity
(infinite Ω)
How to Adjust the Limit Switches
Note: Perform this procedure on a flat and level
area and free from obstructions.
1 Fully retract the boom.
a
2 Place a digital protractor or digital level on top
of the boom tube.
Part No. 102916
Proximity switch
a target area
S-100 • S-105 • S-120 • S-125
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October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
S-120 and S-125 models:
All models:
3 Raise boom until the protractor reads 67.5
degrees.
14S-100 and S-105 models: Raise the boom to
52.5 degrees.
4 Loosen the mounting fasteners from the 68
degree proximity switch (LSB14AO).
15Loosen the mounting fasteners from the 53
degree proximity switch (LSB13AO).
5 Disconnect the deutsch connector from the
68 degree proximity switch (LSB14AO) and
connect an ohmmeter or continuity tester to
terminals 3 and 4 of the deutsch connector.
16Disconnect the deutsch connector from the
53 degree proximity switch (LSB13AO) and
connect an ohmmeter or continuity tester to
terminals 3 and 4 of the deutsch connector.
6 Adjust LSB14AO until the switch contacts just
open. While observing the digital protractor,
raise the boom until the switch contacts close,
then lower the boom until the switch contacts
open. Repeat the process until the switch
contacts open between 67.5 and 68 degrees.
17Adjust LSB13AO until the switch contacts just
open. While observing the digital protractor,
raise the boom until the switch contacts close,
then lower the boom until the switch contacts
open. Repeat the process until the switch
contacts open between 52.5 and 53 degrees.
7 Tighten the 68 degree proximity switch
(LSB14AO) mounting fasteners.
18Tighten the 53 degree limit switch mounting
fasteners.
8 Lower the boom to 65.3 degrees.
19Lower the boom to 50.3 degrees.
9 Loosen the mounting fasteners from the 65
degree safety switch (LSB9AS).
20Loosen the mounting fasteners from the 50
degree safety switch (LSB8AS).
10Disconnect the deutsch connector from the 65
degree safety switch (LSB9AS) and connect
an ohmmeter or continuity tester to terminals 1
and 2, and to terminals 3 and 4 of the deutsch
connector.
21Disconnect the deutsch connector from the 50
degree safety switch (LSB8AS) and connect an
ohmmeter or continuity tester to terminals 1 and 2,
and to 3 and 4 of the deutsch connector.
11Adjust LSB9AS until the switch contacts just
open. While observing the digital protractor,
raise the boom until the switch contacts close,
then lower the boom until the switch contacts
open. Repeat the process until the switch
contacts open between 65 and 65.5 degrees.
22Adjust LSB8AS until the switch contacts just
open. While observing the digital protractor,
raise the boom until the switch contacts close,
then lower the boom until the switch contacts
open. Repeat the process until the switch
contacts open between 50 and 50.5 degrees.
12Tighten the 65 degree safety switch mounting
fasteners.
13Lower the boom to 52.5 degrees.
4 - 66
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
8-2
Limit Switch and Level Sensor
Locations
LSB3RO
LSB3EO
LSB4EO
LSB3RS
LSB9AS
LSB4ES
LSB8AS
LSB1DO
LSB7DS
LSB13AO
LSB14AO
LSB19LO
LSB6S
LSB2RO
LSB19LO
LSAX1ES
TURNTABLE
LEVEL
LSAX1RO SENSOR
LSAX1EO
LSAX2ES
LSB2RS
LSAX2RO
PLATFORM
LEVEL
SENSOR
LSAX2EO
LST1O
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 67
October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
Located under the drive chassis end cover at
the center of the square end (blue): LSAX1RO,
LSAX1EO, LSAX1ES
Located under the drive chassis end cover at
the center 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 bulkhead at the counterweight end: LSB9AS, LSB8AS
Located at the base of the swing chassis near the
counterweight: LSB1LO
Located at the counterweight end of Boom tube 0: LSB6S
Located on the counterweight side of the lift
cylinder support assembly: LSB1DO, LSB7DS,
LSB13AO, LSB14AO
Located on the outside of the platform end of
Boom tube 0:
LSB2RO, LSB2RS
Located on the top of the platform end of Boom
tube 2:
LSB3EO, LSB3RS, LSB3RO, LSB2RO, LSB4ES
Located on the platform rotator: Platform Level
Sensor
8-3
Limit Switch Functions
LSAX1RO: Operational Limit Switch, Front Axle,
Retract. This switch activates when the axle is
fully retracted, activating axle retracted LED and
shutting off power to axle retract coils after two
seconds.
LSAX2RO: Operational Limit Switch, Rear Axle,
Retract. This switch activates when the axle is
fully retracted, activating axle retracted LED and
shutting off power to axle retract coils after two
seconds.
LSAX1EO: Operational Limit Switch, Front Axle,
Extend. This switch is activated when the axle is
fully extended. If this switch is not activated, boom
functions are restricted to the stowed range. If unit
is 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 is
fully extended. If this switch is not activated, boom
functions are restricted to the stowed range. If unit
is 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 not
fully extended. In this condition, if unit is out of
stowed, power is cut to boom up, boom extend
and axle retract.
LSAX2ES: Safety Limit Switch, Rear Axle, Extend. If this switch is tripped, then the axle is not
fully extended. In this condition, if unit is out of
stowed, power is cut to boom up, boom extend
and axle retract.
4 - 68
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
LSB6S: Safety Limit Switch, Cable Tension. Cuts
power to the extend directional valve if extend
cables are out of adjustment or one breaks.
LSB1DO: Operational Limit Switch, 10O Angle.
This switch activates anytime the boom is raised
above 10O. If axles are not extended, boom up is
disabled and the extend axle LED and icon will
flash as long as boom up is operated. At this point,
if axles are extended, the motors are shifted to low
and drive speed is limited to 0.7 mph.
LSB7DS: Safety Limit Switch, 11O Angle. If axles
are not extended, this switch is activated when
boom is raised to 11O, cutting power to boom up
and axle retract.
O
LSB13AO: Operational Limit Switch, 53 Angle.
This switch activates at 53O boom angle, allowing
the boom to be extended beyond 75 feet. If the
boom is lowered past this switch when the boom
is beyond 75 feet, boom extend and boom down
are disabled. The retract boom LED and icon and
alarm will flash as long as boom down is operated.
LSB8AS: Safety Limit Switch, 50O Angle. This
switch cuts power to boom extend, boom down
and the engine fuel solenoid when it is mechanically activated at 50O if the boom length is more
than 75.5 feet.
LSB14AO: Operational Limit Switch, 68O Angle.
This switch is activated at 68O boom angle and allows the boom to be extended beyond 100 feet. If
the boom is lowered past this switch when extended beyond 100 feet, boom extend and boom down
are disabled. The boom retract LED and icon and
alarm will flash as long as boom down is operated.
LSB9AS: Safety Limit Switch, 65O Angle. This
switch cuts power to boom extend, boom down
and the engine fuel solenoid when it is mechanically activated at 65O if the boom length is more
than 101 feet.
Part No. 102916
LSB3RO: Operational Limit Switch, 3’ Extend.
This switch activates anytime the boom is extended beyond 3 feet. If axles are not extended, boom
extend is disabled and the extend axle LED and
icon will flash as long as boom extend is operated. If axles are extended at this point, the motors
are shifted to low and drive speed is limited to
0.7 mph. The boom up/down speed and turntable
rotate speed are limited to 60% of maximum.
LSB3RS: Safety Limit Switch, 3.5’ Extend. If axles
are not extended, this switch is activated when the
boom is extended beyond 3.5 feet, cutting power
to boom extend and axle retract.
LSB3EO: Operational Limit Switch, 75’ Extend.
This switch activates anytime the boom is extended to 75 feet or beyond. At this point drive speed is
reduced to 0.4 mph, boom up/down is reduced to
29% of maximum and turntable rotate is reduced
to 40% of maximum. If boom angle is less than
53O, then boom extend is disabled and the raise
boom LED and icon and alarm will flash as long as
boom extend is operated.
LSB4ES: Safety Limit Switch, 75.5’ Extend. This
switch cuts power to boom extend, boom down
and engine fuel solenoid when it is mechanically
activated at 75.5 feet, if boom angle is less than
50O.
LSB4EO: Operational Limit Switch, 100’ Extend.
This switch activates anytime the boom is extended to 100 feet or beyond. The boom up/down is
reduced to 20% of maximum. If boom angle is less
than 68O, then boom extend is disabled and the
raise boom LED and icon and alarm will flash as
long as boom extend is operated. If boom angle is
greater than 65O, the BO lockout valve will activate
allowing hydraulic flow to the external cylinder to
continue to extend to 120 feet.
S-100 • S-105 • S-120 • S-125
4 - 69
October 2015
Section 4 • Repair Procedures
LIMIT SWITCHES
LSB2RS: Safety Limit Switch, 101’ Extend. This
switch cuts power to boom extend, boom down
and engine fuel solenoid when it is mechanically
activated at 101 feet, if boom angle is less than
65O.
LSB2RO: Operational Limit Switch, 100’ Retract.
This switch is activated anytime boom length is
100’ or less. Anytime the boom is being retracted
while this switch is activated, the BN lockout valve
is activated allowing hydraulic flow out of the inner
cylinder.
LSB19LO: Operational Limit Switch, Down
Overload. This switch disables all functions except
boom retract and boom up and activates a medium frequency alarm and the boom down overload
diagnostic code.
LST1O: Operational Limit Switch, Drive Enable.
This switch is activated when the turntable is rotated in the standard drive zone.
Turntable Level Sensor: Measures the X axis
and Y axis of the turntable. The alarm sounds at
4.5O.
Platform Level Sensor: Measures the angle of
the platform. The range of measurement is +/- 20O.
The safety cutout is set at +/- 10O from gravity and
will disable the primary and secondary boom up/
down functions and the platform level up/down
functions.
4 - 70
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Hydraulic Pumps
9-1
Function Pumps
2 Tag, disconnect and plug the hydraulic hoses
from the function pumps. Cap the fittings on the
pumps.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
There are three hydraulic pumps connected to
the engine. There is one variable displacement
pump that is used for drive functions and two fixed
displacement pumps attached to the drive pump
that are used for all other machine functions.
How to Remove the
Function Pumps
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
3 Support the function pumps with an overhead
crane or other suitable lifing device.
4 Remove the pump mounting bolts. Carefully
remove the pumps.
1 Close the two hydraulic tank valves located at
the hydraulic tank.
Crushing hazard. The function
pumps may become unbalanced
and fall when the mounting
bolts are removed if they are not
properly supported.
Component damage hazard.
Be sure to open the two hydraulic
tank valves and prime the pumps
after installing the pumps.
See 9-2, How to Prime the Pumps.
open
closed
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur.
If the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 71
October 2015
Section 4 • Repair Procedures
HYDRAULIC PUMPS
9-2
Drive Pump
3 Close the two hydraulic tank valves located at
the hydraulic tank.
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral
or null adjustment. Any internal service to the
pump should only be performed at an authorized
Sundstrand-Sauer service center. Call the Genie
Industries Service Department to locate your local
authorized service center.
open
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of
the condition.
How to Remove the Drive Pump
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
4 Tag, disconnect and plug the hydraulic hoses
from the drive pump. Cap the fittings on the
pump.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Remove the function pumps. See How to
Remove the Function Pumps.
2 Disconnect the electrical connection at the
electronic displacement controller (EDC)
located on the drive pump.
4 - 72
closed
5 Support the drive pump with a suitable lifting
device and remove the two drive pump
mounting fasteners.
6 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
HYDRAULIC PUMPS
7 Remove the drive pump from the machine.
Component damage hazard.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
Cummins and Perkins models:
2 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine to access the fuel injection
pump.
Note: Before installing the pump, verify proper
pump coupler spacing. Refer to the appropriate
flex plate installation instructions for your engine.
How to Prime the Pumps
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves are in the open position
before priming the pump. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur.
a
b
a
b
engine pivot plate anchor hole
engine pivot plate retaining fastener
3 Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
4 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
open
closed
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to one of the test ports located under the
drive pump.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Crushing hazard. Failure to install
the bolt into the engine pivot plate
anchor hole to secure it from
moving could result in death or
serious injury.
4 - 73
October 2015
Section 4 • Repair Procedures
HYDRAULIC PUMPS
5 Deutz models: Disconnect the engine wiring
harness from the fuel shutoff solenoid at the
injector pump.
a
a
Perkins models
a fuel shutoff solenoid
6 Have another person crank the engine with the
starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 250 psi / 17.2 bar.
Deutz models
a fuel shutoff solenoid
Cummins and Perkins models: Disconnect
the wire from the fuel shutoff solenoid at the
injector pump.
Bodily injury hazard. Keep hands,
loose clothing and hair clear of
all moving engine parts while the
engine is cranking.
7 Deutz models: Connect the engine wiring
harness to the fuel shutoff solenoid at the
injector pump.
a
Cummins and Perkins models: Connect the wire to the fuel shutoff solenoid at the injector
pump.
8 Start the engine and check for hydraulic leaks.
Cummins models
a fuel shutoff solenoid
4 - 74
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
HYDRAULIC PUMPS
9-3
Auxiliary Pump
4 Activate any function using auxiliary power.
Result: If the pressure gauge reads 2500 psi /
172 bar, immediately stop. The pump is good.
How to Test the Auxiliary Pump
The auxiliary pump is a 2-section, gear-type pump.
Pump number 1 is the pump section closest to
the pump motor and pump number 2 is the pump
section that is farther from the pump motor. Each
section of the pump has its own relief valve located
within the pump body.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Disconnect and plug the high pressure
hydraulic hose from pump number 1.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the high pressure port on pump
number 1.
3 Turn the key switch to ground control and
pull out the Emergency Stop button to the on
position.
Part No. 102916
Result: If pressure fails to reach 2500 psi
/ 172 bar, the internal relief valve setting is
incorrect or the pump is bad and will need to be
serviced or replaced.
5 Turn the key switch to the off position.
6 Remove the pressure gauge and reconnect the
hydraulic hose.
7 Disconnect the hydraulic hose from the high
pressure port from pump number 2.
8 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the high pressure port on pump
number 2.
9 Turn the key switch to ground control and
pull out the Emergency Stop button to the on
position.
10Activate 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 is
incorrect or the pump is bad and will need to be
serviced or replaced.
11Remove the pressure gauge and reconnect the
hydraulic hose.
S-100 • S-105 • S-120 • S-125
4 - 75
October 2015
Section 4 • Repair Procedures
HYDRAULIC PUMPS
How to Remove the Auxiliary
Pump
1 Open the ground controls side turntable cover.
2 Tag, disconnect and plug the hydraulic hoses
from the pumps.
3 Remove the pump mounting fasteners and
remove the pump from the pump motor.
4 - 76
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
Manifolds
10-1
Function Manifold Components, S-100 and S-105 Models
(to serial number 136)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No.
Description
1
Relief valve, 1800 psi / 124.1 bar........ FA...........Boom extend pressure limit.......................18-20 ft-lbs / 24-27 Nm
Item
Function
Torque
2
Proportional solenoid valve................. FB...........Boom extend/retract
proportional 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 proportional
speed control.................................33-37 ft-lbs / 44.9-50.3 Nm
Proportional solenoid valve................. FG...........Turntable rotate proportional
7
speed control......................................18-20 ft-lbs / 24-27 Nm
8
Counterbalance valve,
3200 psi / 220.6 bar
FH
Boom down circuit...............................30-35 ft-lbs / 38-41 Nm
9
Relief valve, 2600 psi / 179.3 bar........ FI.............Turntable rotate, boom lift and
boom 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
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
FA
2
FB
4
3
FD
FC
FE
FR
5
17
16
FQ
FF
6
FG
15
FP
7
FH
8
FI
FJ
FK
FL
FM
14
9
10
11
12
TP
13
4 - 78
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-100 and S-105 Models, continued
(to serial number 136)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No.
Description
11
Orifice - plug,
0.040 inch / 1.02 mm...........................FK...........Differential sensing dampening
Item
Function
Torque
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
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
FA
2
FB
4
3
FD
FC
FE
FR
5
17
16
FQ
FF
6
FG
15
FP
7
FH
8
FI
FJ
FK
FL
FM
14
9
10
11
12
TP
13
4 - 80
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-2
Function Manifold Components, S-100 and S-105 Models
(from serial number 137)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No.
Description
1
Solenoid Valve Assembly,
3 position 4 way, DO3, 12V DC.......... FD...........Boom up/down..............................................30-35 in-lbs / 3-4 Nm
2
Solenoid Valve, 3 position 4 way........ FC...........Turntable rotate control, left/right...............25-27 ft-lbs / 34-37 Nm
Item
Function
Torque
3
Proportional Solenoid Valve................ FG...........Turntable rotate,
proportional speed control.................. 18-20 ft-lbs / 25-27 Nm
4
Solenoid Valve, 2 position 3 way........ AA...........Auxiliary drive/steer selector......................25-27 ft-lbs / 34-37 Nm
5
Relief Valve, 3000 psi / 206.8 bar....... AC...........Platform manifold pressure limit................18-20 ft-lbs / 24-27 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 2
to auxiliary pump............................. 12-14 ft-lbs / 16.3-19 Nm
8
Proportional Solenoid Valve, N.C....... FF...........Primary lift, proportional
valve speed control..............................33-37 ft-lbs / 45-50 Nm
9
Check Valve, 10 psi / 0.69 bar............ AB...........Blocks flow from pump 1 and 2
to auxiliary pump.......................... 18-20 ft-lbs / 24.5-27.2 Nm
10
Check Valve........................................ AG...........Blocks flow from auxiliary pump,
port 2A to pump 1............................... 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
This list continues on the next page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 81
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
FD
FC
24
2
FA
FG
3
FR
23
AA
AC
AD
FQ
22
AE
4
5
6
7
FF
8
21
20
19
18
17
FE
FL
FP
AB
9
FJ
FM
AG
AF
16
FB
FI
FH
FK
10
11
12
13
14
TP
15
4 - 82
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-100 and S-105 Models, continued
(from serial number 137)
The function manifold is mounted to the turntable next to the ground controls.
Index No.
Description
Schematic
Item
Function
Torque
12
Relief Valve, 2600 psi / 179.3 bar....... FI.............Turntable, primary lift and
boom retract pressure limit................. 25-27 ft-lbs / 34-37 Nm
13
Counterbalance Valve,
3200 psi / 220.6 bar............................ FH...........Primary lift, load holding............................30-35 ft-lbs / 38-41 Nm
14
Orifice Plug, 0.040 inch / 1.016 mm.... FK...........Differential sensing damping
15
Diagnostic Nipple................................ TP...........Testing
Proportional Valve............................... FB...........Boom extend/retract solenoid
16
valve proportional speed control.........33-37 ft-lbs / 45-50 Nm
17
Check Valve, 5 psi / 0.34 bar.............. FM...........Extension cylinder
load sense check............................. 12-14 ft-lbs / 16.3-19 Nm
18
Check Valve, 5 psi / 0.34 bar.............. FJ............Primary lift load sense check...........12-14 ft-lbs / 16.3-19 Nm
19
Differential Sensing Valve,
110 psi / 7.58 bar................................ FP...........Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
20
Check Valve, 5 psi / 0.34 bar.............. FL............Extension cylinder
load sense check............................. 12-14 ft-lbs / 16.3-19 Nm
21
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
22
Solenoid Valve, 2 position 3 way........ FQ...........Boom retract control..................................52-60 ft-lbs / 71-82 Nm
23
Solenoid Valve, 2 position 3 way........ FR...........Boom extend control..................................52-60 ft-lbs / 71-82 Nm
24
Relief Valve, 1800 psi / 124.1 bar....... FA...........Boom extend pressure limit............................................18-20ft-lbs/
24.5-27.2 Nm.....................................................
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 83
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
FD
FC
24
2
FA
FG
3
FR
23
AA
AC
AD
FQ
22
AE
4
5
6
7
FF
8
21
20
19
18
17
FE
FL
FP
AB
9
FJ
FM
AG
AF
16
FB
FI
FH
FK
10
11
12
13
14
TP
15
4 - 84
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-3
Valve Adjustments - Function
Manifold, S-100 and S-105 Models
How to Adjust the Function
Manifold Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the test port on the function manifold.
2 Start the engine from the ground controls.
3 Simultaneously push and hold the function
enable/high speed button and the boom
retract button with the boom fully retracted.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic Oil
Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item FI).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
How to Adjust the Boom Extend
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 3000 psi / 0 to 207 bar pressure
gauge to the test port on the function manifold.
2 Start the engine from the ground controls.
3 Fully raise and extend the boom.
4 Simultaneously push and hold the function
enable/high speed button and the boom
extend button with the boom fully extended.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item FA).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm the relief
valve pressure.
6 Repeat steps 2 through 5 to confirm the relief
valve pressure.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 85
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-4
Proportional Valves Function Manifold
Note: When a proportional valve cartridge or coil is
replaced or moved to a different valve cartridge or
cavity, the proportional valve cartridge or coil will
need to be calibrated. See Repair Procedure, How
to Calibrate a Joystick.
4 - 86
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-5
Function Manifold Components, S-120 and S-125 Models
(to serial number 430)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No.
Description
1
Relief valve, 1800 psi / 124.1 bar.........BA...........Boom extend pressure limit................ 18-20 ft-lbs / 24-27 Nm
Item
Function
Torque
2
Proportional solenoid valve................. BB...........Boom extend/retract
proportional 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 proportional
speed control......................................33-37 ft-lbs / 45-50 Nm
Proportional solenoid valve................. BG...........Turntable rotate proportional
7
speed control......................................18-20 ft-lbs / 24-27 Nm
8
Counterbalance valve,
3200 psi / 220.6 bar............................ BH...........Boom down circuit..............................30-35 ft-lbs / 38-41 Nm
9
Relief valve, 2600 psi / 179.3 bar........ BI............Turntable rotate, boom lift and
boom retract pressure limit.................25-27 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
This list continues. Please turn the page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 87
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
BA
2
BB
3
4
BC
BD
BE
5
BR
19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
BI
BJ
BK
BN
15
4 - 88
BM
14
BL
13
8
9
10
11
TP
12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-120 and S-125 Models, continued
(to serial number 430)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No.
Description
12
Diagnostic nipple.................................................Testing
Item
Function
Torque
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
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
BA
2
BB
3
4
BC
BD
BE
5
BR
19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
BI
BJ
BK
BN
15
4 - 90
BM
14
BL
13
8
9
10
11
TP
12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-6
Function 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
No.
Description
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
Item
Function
Torque
3
Proportional Solenoid Valve................ BG...........Turntable rotate, proportional
speed control...................................... 18-20 ft-lbs / 25-27 Nm
4
Solenoid Valve, 2 position 3 way........ AA...........Auxiliary drive/steer selector................25-27 ft-lbs / 34-37 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 2
to 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 2
to auxiliary pump................................ 18-20 ft-lbs / 25-27 Nm
10
Check Valve........................................ AG...........Blocks flow from auxiliary pump,
port 2A to pump 1............................... 33-37 ft-lbs / 45-50 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 boom
retract pressure limit........................... 25-27 ft-lbs / 34-37 Nm
This list continues on the next page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 91
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
BD
BC
26
2
BA
BG
3
25
BR
AA
AC
24
AD
BQ
AE
BF
23
22
21
20
19
18
17
4
5
6
7
8
BO
BE
BL
BP
AB
BJ
9
BM
BN
AG 10
AF
BI
BH
BK
BB
16
4 - 92
11
12
13
14
TP
15
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
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
No.
Description
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
15
Diagnostic Nipple................................ TP...........Testing
Item
Function
Torque
16
Proportional Solenoid Valve, N.C....... BB...........Boom extend/retract proportional
speed 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 cylinder
load 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 rotate
load 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
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 93
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
BD
BC
26
2
BA
BG
3
25
BR
AA
AC
24
AD
BQ
AE
BF
23
22
21
20
19
18
17
4
5
6
7
8
BO
BE
BL
BP
AB
BJ
9
BM
BN
AG 10
AF
BI
BH
BK
BB
16
4 - 94
11
12
13
14
TP
15
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-7
Function Manifold Components, S-120 and S-125 Models
(from serial number 575)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No.
Description
1
Solenoid Valve Assembly,
3 position 4 way, DO3, 12V DC.......... BD...........Boom up/down........................................ 30-35 in-lbs / 3-4 Nm
Item
Function
Torque
2
Solenoid Valve, 2 position 3 way........ AA...........Auxiliary drive/steer selector................25-27 ft-lbs / 34-37 Nm
3
Check Valve, 5 psi / 0.34 bar.............. AE...........Blocks flow from pump 2
to 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 2
to 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
Proportional Solenoid Valve................ BG...........Turntable rotate,
7
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 rotate
load sense check............................. 12-14 ft-lbs / 16.3-19 Nm
10
Proportional Solenoid Valve................ BB...........Boom extend/retract
proportional 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
12
Diagnostic Nipple................................ TP...........Testing
13
Relief Valve, 3000 psi / 206.8 bar....... AC...........Platform manifold
pressure limit..................................... 18-20 ft-lbs / 25-27 Nm
This list continues on the next page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 95
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
BD
2
3
4
5
AA AE AD AB
BC
27
BR
BG
BP
26
25
24
23
22
21
20
19
18
6
7
8
BQ
BL
BN
9
BO
BF
BS
BB
10
BK
AF
BJ
11
BM
TP
BE
AC
BI
AG
BH
BA
4 - 96
S-100 • S-105 • S-120 • S-125
12
13
14
15
16
17
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Function Manifold Components, S-120 and S-125 Models, continued
(from serial number 575)
The function manifold is mounted to the turntable next to the ground controls.
Index No.
Description
Schematic
Item
Function
Torque
14
Relief Valve, 2600 psi / 179.3 bar....... BI............Turntable, primary lift and
boom retract pressure limit.............. 12-14 ft-lbs / 16.3-19 Nm
15
Check Valve........................................ AG...........Blocks flow from auxiliary pump,
port 2A to pump 1............................... 33-37 ft-lbs / 45-50 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 cylinder
load 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
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 97
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
BD
2
3
4
5
AA AE AD AB
BC
27
BR
BG
BP
26
25
24
23
22
21
20
19
18
6
7
8
BQ
BL
BN
9
BO
BF
BS
BB
10
BK
AF
BJ
11
BM
TP
BE
AC
BI
AG
BH
BA
4 - 98
S-100 • S-105 • S-120 • S-125
12
13
14
15
16
17
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-8
Valve Adjustments - Function
Manifold, S-120 and S-125 Models
How to Adjust the Function
Manifold Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the test port on the function manifold.
2 Start the engine from the ground controls.
3 Simultaneously push and hold the function
enable/high speed button and the boom
retract button with the boom fully retracted.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item BI).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
How to Adjust the Boom Extend
Relief Valve
Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 3000 psi / 0 to 207 bar pressure
gauge to the test port on the function manifold.
2 Start the engine from the ground controls.
3 Fully raise and extend the boom.
4 Simultaneously push and hold the function
enable/high speed button and the boom
extend button with the boom fully extended.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item BA).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm the relief
6 Repeat steps 2 through 5 to confirm the relief
valve pressure.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 99
October 2015
Section 4 • Repair Procedures
MANIFOLDS
valve pressure.
10-9
Proportional Valves Function Manifold
Note: When a proportional valve cartridge or coil is
replaced or moved to a different valve cartridge or
cavity, the proportional valve cartridge or coil will
need to be calibrated. See 1-3, How to Calibrate a
Joystick Controller.
4 - 100
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-10
Platform Manifold Components, S-100 and S-120 Models
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
No.
Description
Item
Function
Torque
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 differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
6
Differential sensing valve, N.O............ GE...........Platform rotate differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
7
Orifice - plug, 0.030 inch / 0.762 mm.. GB...........Platform rotate left circuit
8
Orifice - plug, 0.030 inch / 0.762 mm.. GC..........Platform rotate right circuit
9
Shuttle valve....................................... GG..........Platform level load sense circuit..........7.4-9 ft-lbs / 10-12 Nm
10
Shuttle valve....................................... GA...........Platform rotate load sense circuit.........7.4-9 ft-lbs / 10-12 Nm
11
Differential sensing valve, N.C............ GC..........Directs flow to functions.............................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
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
GH
12
3
2
GF
4
GJ
GQ
GD
GO
11
GI
GE
GA
10
4 - 102
GG
GC
9
S-100 • S-105 • S-120 • S-125
8
5
6
GB
7
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-11
Platform Manifold Components, S-105 and S-125 Models
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
No.
Description
Item
Function
Torque
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 differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
8
Differential sensing valve, N.O............ CI............Platform level differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
9
Flow control valve,
0.1 gpm / 0.38 L/min........................... CP...........Bleeds off differential sensing
valve to tank
10
Differential sensing valve, N.O............ CE...........Platform rotate differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
11
Shuttle valve....................................... CK...........Jib boom load sense circuit
12
Orifice - plug, 0.030 inch / 0.762 mm.. CB...........Platform rotate left 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
October 2015
Section 4 • Repair Procedures
MANIFOLDS
2
1
CH
17
16
CF
3
CJ
4
5
CL
CN
6
CQ
CD
CO
CM
7
CI
CP
CE
CA
15
4 - 104
CG
14
CC
13
CB
12
S-100 • S-105 • S-120 • S-125
8
9
10
CK
11
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-12
Proportional Valves Platform Manifold
Note: When a proportional valve cartridge or coil is
replaced or moved to a different valve cartridge or
cavity, the proportional valve cartridge or coil will
need to be calibrated. See 1-3, How to Calibrate a
Joystick.
10-13
Platform Rotate Counterbalance Valve Manifold Components
Index Schematic
No.
Description
Item
Function
Torque
1
Counterbalance valve......................... A.............Platform rotate left.....................................37-44 ft-lbs / 50-60 Nm
2
Counterbalance valve......................... B.............Platform rotate right...................................37-44 ft-lbs / 50-60 Nm
A
1
2
Part No. 102916
A
B
B
S-100 • S-105 • S-120 • S-125
4 - 105
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-14
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
No.
Description
Item
Function
Torque
1
Counterbalance valve......................... A.............Turntable rotate left...................................37-44 ft-lbs / 50-60 Nm
2
Counterbalance valve......................... B.............Turntable rotate right.................................37-44 ft-lbs / 50-60 Nm
3
Shuttle valve, 2 position 3 way............ C.............Turntable rotation brake release...............10-12 ft-lbs / 14-16 Nm
A
A
C
3
B
C
4 - 106
S-100 • S-105 • S-120 • S-125
1
B
2
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-15
Steer and Axle Extend/Retract Manifold Components - View 1
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end
of the machine.
Index
No.Description
Schematic
Item Function
Torque
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
Flow Regulator Valve,
5
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
9
Flow Regulator Valve,
0.1 gpm / 0.38 L/min........................... EO...........Bleeds off differential valve to tank............18-20 ft-lbs / 24-27 Nm
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
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 107
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
EA
3
2
EB
EC
ES
11
ED
4
EW
10
EP
9
EO
8
EV
EU
7
4 - 108
ET
6
5
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-16
Steer and Axle Extend/Retract Manifold Components - View 2
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end
of the machine.
Index No.Description
1
Schematic
Item Function
Torque
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
This list continues. Please turn the page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 109
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
EE
3
2
EJ
EQ
4
5
ER
EX
TP
21
EQQ
EZ
EY
EKK
EOO
20
4 - 110
EPP EMM
19
18
EG
17
ELL EH EK EJJ ENN
16
15
14
13
12
EM
11
6
7
8
9
EII
10
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Steer and Axle Extend/Retract Manifold Components - View 2, continued
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end
of the machine.
Index No.Description
Schematic
Item Function
Torque
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
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 111
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
EE
3
2
EJ
EQ
4
5
ER
EX
TP
21
EQQ
EZ
EY
EKK
EOO
20
4 - 112
EPP EMM
19
18
EG
17
ELL EH EK EJJ ENN
16
15
14
13
12
EM
11
6
7
8
9
EII
10
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-17
Valve Adjustments - Steer and
Axle Extend/Retract Manifold
How to Adjust the Steer and Axle
Retract Relief Valve
Note: Perform this procedure with the axles
retracted and the boom in the stowed position.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the test port on the steer and axle
extend/retract manifold.
2 Start the engine from the platform controls.
3 Position the machine so that the left front wheel
is against an immoveable object such as a
curb.
4 Press down the foot switch and activate the
steer function. Steer the wheel into the curb
and hold. Observe the pressure reading on
the pressure gauge. Refer to Specifications,
Hydraulic Component Specifications.
How to Adjust the Axle Extend
Relief Valve
Note: Perform this procedure with the axles
retracted, the boom in the stowed position and the
machine on a paved surface.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the test port on the steer and axle
extend/retract manifold.
2 Start the engine from the platform controls.
3 Press down the foot switch and push the axle
extend button. Observe the pressure reading
on the pressure gauge. Refer to Specifications,
Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item EQQ).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item EZ).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm relief valve
pressure.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 113
October 2015
Section 4 • Repair Procedures
MANIFOLDS
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4 - 114
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-18
Traction Manifold Components
(S-100/105- to serial number 290)
(S-120/125- to serial number 1194)
The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index
No.
Description
Schematic
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 drive
motors 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 drive
motors in forward and reverse.....130-140 ft-lbs / 176-190 Nm
6
Flow divider/combiner valve................ DF...........Controls flow to front and
rear flow divider combiner valves
(items DC and DE)......................130-140 ft-lbs / 176-190 Nm
7
Check valve........................................ DG..........Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
8
Check valve........................................ DH...........Anti-cavitation............................................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
This list continues. Please turn the page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 115
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
DA
2
DB
3
DC
DO
17
DD
4
DN
16
15
14
DM
DE
5
DP
DF
6
13
12
DL
TP
DG
DH
DK
11
4 - 116
S-100 • S-105 • S-120 • S-125
DJ
10
7
8
DI
9
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Traction Manifold Components, continued
(S-100/105- to serial number 290), (S-120/125- to serial number 1194)
The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index
No.
Description
12
Schematic
Item
Function
Torque
Diagnostic fitting.................................. TP...........Testing
13
Shuttle valve,
3 position 3 way.................................. DL...........Charge pressure circuit that
gets hot oil out of low presure
side of the drive pump.........................35-40 ft-lbs / 47-54 Nm
14
Check valve, 50 psi / 3.45 bar............. DP...........2 speed/brake charge
pressure circuit....................................25-30 ft-lbs / 38-41 Nm
15
Relief valve, 250 psi / 17.2 bar............ DM..........Charge pressure circuit.............................35-40 ft-lbs / 47-54 Nm
16
Orifice - plug,
0.030 inch / 0.762 mm........................ DN...........Brake release and
2 speed shift control
17
Solenoid valve, 2 position 3 way......... DO..........Brake control.............................................25-30 ft-lbs / 38-41 Nm
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 117
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
DA
2
DB
3
DC
DO
17
DD
4
DN
16
15
14
DM
DE
5
DP
DF
6
13
12
DL
TP
DG
DH
DK
11
4 - 118
S-100 • S-105 • S-120 • S-125
DJ
10
7
8
DI
9
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-19
Traction Manifold Components
(S-100/105- from serial number 291)
(S-120/125- from serial number 1195)
The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index
No.
Description
Schematic
Item
Function
Torque
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 temporary
loss of charge pressure.................20-25 ft-lbs / 27.1-33.9 Nm
5
Shuttle Valve, 3 position 3 way........... HE...........Charge pressure circuit that directs
hot oil out of low pressure side
of 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 to
square end drive motors
in 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
This list continues. Please turn the page.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 119
October 2015
Section 4 • Repair Procedures
MANIFOLDS
1
HA
2
HB
3
HC
4
HD
5
HE
HR
18
HQ
17
HF
6
HP
16
HO
15
HG
7
HN
14
HM
HH
13
HI
8
9
HJ
10
HL
12
4 - 120
HK
11
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
Traction Manifold Components, continued
(S-100/105- from serial number 291), (S-120/125- from serial number 1195)
The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index
No.
Description
Schematic
Item
Function
Torque
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 to
circle end drive motors
in forward and reverse................90-100 ft-lbs / 122-135.6 Nm
17
Flow Divider/Combiner Valve.............. HQ..........Controls flow to divider/combiner
valves 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
Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS
1
HA
2
HB
3
HC
4
HD
5
HE
HR
18
HQ
17
HF
6
HP
16
HO
15
HG
7
HN
14
HM
HH
13
HI
8
9
HJ
10
HL
12
4 - 122
HK
11
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Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
10-20
Valve Adjustments Traction Manifold
10-21
Valve Coils
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the test port located on the drive
manifold.
2 Start the engine from the platform controls.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Specifications.
4 Turn the engine off. Use a wrench to hold the
charge pressure relief valve and remove the
cap (item DM or FF).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise
to decrease the pressure. Install the relief valve
cap.
How to Test a Coil
A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite
resistance indicates the coil has failed.
Since coil resistance is sensitive to temperature,
resistance values outside specification can
produce erratic operation. When coil resistance
decreases below specification, amperage
increases. As resistance rises above specification,
voltage increases.
While valves may operate when coil resistance
is outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
6 Repeat steps 2 through 5 to confirm the relief
valve pressure.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance using a multimeter
set to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 102916
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Section 4 • Repair Procedures
MANIFOLDS
Valve Coil Resistance
Specification
How to Test a Coil Diode
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in
air temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.
Description
Specification
Solenoid valve, 2 position 3 way, 12V DC
(schematic item DA, DO, FB, FC)
9Ω
Solenoid valve, 3 position 4 way, 12V DC
(schematic item EA, EB, EC, ED)
(before serial number 292)
9.8 Ω
Solenoid valve, 3 position 4 way, 12V DC
(schematic item EA, EB, EC, ED)
(after serial number 291)
8.8 Ω
Proportional solenoid valve, 12V DC
(schematic item FG, BG, GD, GH)
5.4 Ω
Proportional solenoid valve, 12V DC
(schematic item FB, FF, BB, BF)
5Ω
3 position 4 way D03 valve, 12V DC
(schematic item FD, BD)
4.6 Ω
Solenoid Valve, 2 position 3 way, 12V DC
(schematic item FQ, FR, BQ, BR)
4.6 Ω
Solenoid Valve, 2 position 2 way, 12V DC
(schematic item BN, BO)
7.2 Ω
Solenoid valve, 3 position 4 way 12V
(schematic items ES, FC, BC)
(before serial number 292)
7.2 Ω
Solenoid valve, 3 position 4 way 12V
(schematic items ES)
(after serial number 291)
7.1 Ω
Solenoid valve, 2 position 3 way 12V
(schematic items AA)
7.2 Ω
Genie incorporates spike suppressing diodes in
all of its directional valve coils except proportional
valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes
naturally occur within a function circuit following
the interruption of electrical current to a coil. Faulty
diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
damage.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
1 Test the coil for resistance. Refer to, How to
Test a Coil.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
Note: The battery should read 9V DC or more
when measured across the terminals.
a
AMMETER
COIL
d
-
b
+
c
10 RESISTOR
+
c
9V
BATTERY
b
amultimeter
b 9V DC battery
c10Ω resistor
dcoil
Note: Dotted lines in illustration indicate a
reversed connection as specified in
step 6
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Part No. 102916
October 2015
Section 4 • Repair Procedures
MANIFOLDS
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 terminal
on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
5 Momentarily connect the positive lead from
the multimeter to the positive terminal on the
9V DC battery. Note and record the current
reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
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Section 4 • Repair Procedures
Fuel and Hydraulic Tanks
11-1
Fuel Tank
5 Remove the fuel tank hold down strap retaining
fasteners. Remove the straps from the fuel
tank.
How to Remove the Fuel Tank
6 Support and secure the fuel tank to an
appropriate lifting device.
Explosion and fire hazard.
Engine fuels are combustible.
Remove the fuel tank in an open,
well-ventilated area away from
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. Never
drain or store fuel in an open
container due to the possibility of
fire.
7 Remove the fuel tank from the machine.
Crushing hazard. The fuel tank
may become unbalanced and fall
if it is not properly supported and
secured to the lifting device.
Component damage hazard.
The fuel tank is plastic and may
become damaged if it is allowed to
fall.
Note: Clean the fuel tank and inspect
for cracks and other damage before installing.
1 Remove the fixed engine side turntable cover.
See 5-1, How to Remove a Fixed Turntable
Cover.
2 Tag, disconnect and plug the fuel supply and
return hoses. Cap the fittings on the fuel tank.
3 Remove the fuel filler cap from the tank.
4 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. See
capacity specifications.
Explosion and fire hazard.
When transferring fuel, connect
a grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand operated pump
suitable for use with diesel fuel.
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Section 4 • Repair Procedures
FUEL AND HYDRAULIC TANKS
11-2
Hydraulic Tank
2 Close the two hydraulic shutoff valves located
at the hydraulic tank.
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainers for
the pump supply lines and has an external return
line filter with a filter condition indicator.
How to Remove the
Hydraulic Tank
open
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves are in the open position
before priming the pump. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the hydraulic
tank shutoff valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Component damage hazard. The
work area and surfaces where
this procedure will be performed
must be clean and free of debris
that could get into the hydraulic
system.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the ground controls side turntable
cover. See 5-1, How to Remove a Hinged
Turntable Cover.
Part No. 102916
closed
3 Remove the drain plug from the hydraulic
tank and allow all of the oil from the tank to
drain into a suitable container. See capacity
specifications.
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Section 4 • Repair Procedures
FUEL AND HYDRAULIC TANKS
4 Remove the ground controls support bracket
retaining fasteners. Remove the ground
controls assembly from the machine.
12Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if it is not properly
supported and secured to the
overhead crane.
Component damage hazard.
Be sure to properly support the
ground control box. Do not allow
the ground controls to hang by the
wiring.
Component damage hazard.
The ground control box wiring
can be damaged if it is kinked or
pinched.
Component damage hazard. Be
sure to open the two hydraulic
tank valves and prime the pump
after installing the hydraulic tank.
See 9-2, How to Prime the Pumps.
5 Tag and disconnect the wiring from the horn.
Note: Always use pipe thread sealant when
installing the drain plug and strainers.
6 Remove the horn retaining fasteners. Remove
the horn from the machine.
Note: Refer to Specifications, Machine
Specifications for hydraulic oil requirements.
7 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank shutoff
valves.
8 Tag, disconnect and plug the supply hose for
the auxiliary power unit. Cap the fitting on the
hydraulic tank.
9 Disconnect and plug the T-fitting located at the
return filter with the 2 hoses connected to it.
Cap the fitting on the return filter housing.
10Remove the hydraulic tank retaining fasteners.
11Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.
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Part No. 102916
October 2015
Section 4 • Repair Procedures
Turntable Rotation Components
12-1
Turntable Rotation Hydraulic
Motor and Drive Hub
3 Tag, disconnect and plug the hydraulic hoses
from the manifold that is mounted to the motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
How to Remove the Turntable
Rotation Hydraulic Motor
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
4 Remove the motor/brake mounting fasteners.
Remove the motor from the brake.
a
1 Secure the turntable from rotating with the
turntable rotation lock pin.
b
c
unlocked
locked
2 Remove the ground controls side fixed turntable
cover. See 5-1, How to Remove a Fixed
Turntable Cover.
e
d
amotor
b motor/brake mounting bolts
cbrake
d drive hub mounting bolts
e drive hub
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Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable
Rotation Drive Hub
4 Attach a lifting strap from an overhead crane or
other suitable lifting device to the drive hub.
5 Remove the drive hub mounting bolts and
remove the drive hub from the machine.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
unlocked
Tip-over hazard. If the turntable
rotation lock pin is not properly
installed, machine stability is
compromised and the machine
could tip over when the drive hub
is removed from the machine,
which could result in death or
serious injury.
locked
Crushing hazard. The drive hub
may become unbalanced and
fall if it is not properly supported
by the overhead crane or lifting
device.
2 Remove the turntable rotation motor. See How
to Remove the Turntable Rotation Hydraulic
Motor.
3 Remove the brake from the drive hub and set it
off to the side.
6 Remove the plug from the side of the drive hub.
Drain the oil from the hub.
a
Installing the Drive Hub:
b
7 Install the drive hub. Use blue thread locking
seal on all bolts. Torque the drive hub mounting
bolts to 280 ft-lbs / 380 Nm.
c
8 Install the brake onto the drive hub and torque
the mounting fasteners to 20 ft-lbs / 27 Nm.
9 Install the motor onto the brake and torque the
mounting fasteners to 93 ft-lbs / 126 Nm.
e
9 Fill the drive hub with oil from the side hole
until the oil level is even with the bottom of the
hole. Apply pipe thread sealant to the plugs
and install the plugs. Refer to Specifications,
Specifications.
d
amotor
b motor/brake mounting bolts
cbrake
d drive hub mounting bolts
e drive hub
4 - 130
10Adjust turntable rotation gear backlash.
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Part No. 102916
October 2015
Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
How to Adjust the
Turntable Rotation Gear Backlash
The turntable rotation drive hub is adjustable to
control the gap between the rotation motor gear
and the turntable bearing.
Note: Be sure to check the backlash with the
machine on a flat level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
a
a
b
unlocked
locked
b
adjustment bolt with lock nut
pivot plate mounting bolts
4 Loosen the lock nut on the turntable drive hub
adjustment bolt.
2 Remove the ground controls side fixed turntable
cover. See 5-1, How to Remove a Fixed
Turntable Cover.
5 Tighten the turntable drive hub adjustment
bolt until the turntable drive hub gear is fully
engaged and tight into the turntable rotate gear.
3 Loosen the turntable rotate drive hub mounting
bolts. Do not remove them.
6 Turn the adjustment bolt 3/4 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
Note: It may be necessary to raise the boom
slightly to access all the turntable rotate drive hub
mounting bolts.
7 Rotate the drive hub away from the turntable
rotate gear until it contacts the adjustment bolt.
Torque the turntable rotate drive hub mounting
bolts. Refer to Specifications, Machine Torque
Specifications.
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
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Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
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Part No. 102916
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Section 4 • Repair Procedures
Axle Components
13-1
Steer Sensors
Measure the circle-end tires:
3 Press the square-end steer mode button.
The steer sensor measures steer angle and
communicates that information to the ground
controls ECM. The steer sensor on the ground
controls side of the machine at the square end acts
as the lead sensor. The other three sensors follow
the position, or steer angle, of the lead sensor.
There is a steer sensor mounted to the top of each
upper yoke pivot pin.
Note: If the square-end steering function becomes
inoperative, switch to circle-end steer mode and
the ground controls side circle-end steer sensor
will become the lead sensor.
4 Measure the distance between the inside of
one circle-end tire and the chassis side plate on
both sides of the axle.
Measure here
Square-end
Circle-end
Note: This procedure will require a minimum of two
people.
Note: Perform this procedure with the axles
extended.
How to Measure the Tire
Alignment
1 Start the engine from the platform controls.
2 Press down the foot switch and push the engine
idle select button until the engine switches to
high rpm.
Part No. 102916
Result: Both measurements should be the
same to indicate that the tires are parallel with
the chassis.
Note: If the measurements are different or if a tire
is not parallel with the chassis, the steer sensor
of that tire will need to be adjusted. See How to
Adjust a Steer Sensor.
5 Repeat step 4 for the other circle-end tire.
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October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
Measure the square-end tires:
How to Adjust a Steer Sensor
6 Press the circle-end steer mode button.
Square-end steer sensors:
7 Measure the distance between the inside of
one square-end tire and the chassis side plate
on both sides of the axle.
1 At the platform controls, press the circle-end
steer mode button.
Measure here
2 Locate the steer sensor on top of the yoke pivot
pin.
3 Loosen the steer sensor cover retaining
fasteners. Do not remove them.
Square-end
Circle-end
4 Rotate the steer sensor cover either clockwise
or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
Measure here
Result: Both measurements should be the
same to indicate that the tires are parallel with
the chassis.
Square-end
Circle-end
Note: If the measurements are different or if a tire
is not parallel with the chassis, the steer sensor
of that tire will need to be adjusted. See How to
Adjust a Steer Sensor.
8 Repeat step 4 for the other square-end tire.
5 Repeat step 4 until the tire is parallel with the
chassis.
6 Tighten the steer sensor cover fasteners.
7 Repeat steps 2 through 6 for the other squareend steer sensor.
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Part No. 102916
October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
Circle-end steer sensors:
8 At the platform controls, press the square-end
steer mode button.
9 Locate the steer sensor on top of the yoke pivot
pin.
10Loosen the steer sensor cover retaining
fasteners. Do not remove them.
11Rotate the steer sensor cover either clockwise
or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
Measure here
Square-end
Circle-end
13-2
Yoke and Hub
How to Remove the Yoke
and Hub
The yoke installation utilizes bushings and a thrust
washer that may require periodic replacement.
There is a steer sensor mounted to the upper yoke
pivot pin.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Remove the hose hanger bracket retaining
fasteners mounted to the top of the yoke.
Remove the hose hanger bracket from the
machine.
2 Tag, disconnect and plug the hydraulic hoses
from the drive motor and brake assembly. Cap
the fittings on the drive motor and brake.
12Repeat step 4 until the tire is parallel with the
chassis.
13Tighten the steer sensor cover fasteners.
14Repeat steps 9 through 13 for the other circleend steer sensor.
Part No. 102916
S-100 • S-105 • S-120 • S-125
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 - 135
October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
3 Mark the mounting position of the steer sensor
cover on the yoke.
Note: It is very important that the steer sensor
is installed in the exact position it was in prior
to removal. If the steer sensor is not installed
correctly, the steer function may operate
improperly. If any steer functions operate
improperly after removing and installing a steer
sensor, see 13-1, How to Adjust a Steer Sensor.
4 Remove the steer sensor cover retaining
fasteners. Carefully remove the steer sensor
cover and lay it out of the way.
Component damage hazard. The
steer sensor is a very sensitive
instrument. It can be damaged
internally if it is dropped or
sustains any physical shock, even
if the damage is not visible.
5 Lay the hoses and steer sensor cable out of the
way.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
6 Mark the mounting position of the steer sensor
activator pin mounted to the top of the yoke
pivot pin.
7 Remove the steer sensor activator pin retaining
fasteners. Remove the steer sensor activator
pin from the machine.
Note: It is very important that the steer sensor
activator pin is installed in the exact position it was
in prior to removal. If the steer sensor activator pin
is not installed correctly, the steer function may
operate improperly. If any steer functions operate
improperly after removing and installing a steer
sensor activator pin, see 13-1, How to Adjust a
Steer Sensor.
8 Loosen the wheel lug nuts. Do not remove
them.
9 Center a lifting jack of ample capacity under the
axle of the yoke and drive hub to be removed.
Do not raise the machine.
10Block the wheels at the opposite end of the
machine.
11Raise the machine approximately 6 inches
(15 cm) and place blocks under the chassis for
support.
12Remove the lug nuts and remove the tire and
wheel assembly.
13Remove the drive motor mounting fasteners.
14Slide the drive motor shaft out of the drive hub
and remove the drive motor from the machine.
15Remove the pin retaining fasteners from the
steering cylinder rod-end pivot pins. Remove
the pins.
16Remove the pin retaining fasteners from the
upper and lower yoke pivot pins.
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October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
17Support the yoke/drive hub assembly with a
lifting jack. Secure the yoke/drive hub assembly
to the lifting jack.
13-3
Drive Motor
18Use a soft metal drift to remove both yoke pivot
pins.
How to Remove a Drive Motor
Component damage hazard.
Repairs to the motor should only
be performed by an authorized
dealer.
19Remove the yoke/drive hub assembly from the
machine.
Crushing hazard. The yoke/
hub assembly may become
unbalanced and fall when the yoke
pivot pins are removed if it is not
properly supported and secured to
the lifting jack.
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
20Place the yoke/drive hub assembly on a flat
surface with the drive hub facing down.
21Remove the drive hub mounting fasteners that
attach the yoke to the drive hub. Remove the
yoke weldment from the drive hub.
Note: Replace the thrust washer with a new one
when installing the yoke/drive hub assembly onto
the axle. Refer to Specifications, Machine Torque
Specifications.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
drive motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Remove the drive motor mounting fasteners.
3 Slide the drive motor shaft out of the brake and
drive hub. Remove the drive motor from the
machine.
Part No. 102916
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Section 4 • Repair Procedures
AXLE COMPONENTS
13-4
Drive Hub
8 Place a second lifting jack under the drive hub
for support and secure the drive hub to the
lifting jack.
How to Remove a Drive Hub
9 Remove the drive hub mounting bolts that
attach the drive hub to the yoke. Remove the
drive hub from the machine.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the drive motor. See 13-3, How to
Remove a Drive Motor.
Crushing hazard. The drive
hub may become unbalanced and
fall if it is not properly supported
and secured to the lifting jack.
Refer to Specifications, Machine
Torque Specifications.
2 Tag, disconnect and plug the hydraulic hose
from the brake. Cap the fittting on the brake.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 Loosen the wheel lug nuts. Do not remove
them.
4 Center a lifting jack of ample capacity under
the axle of the drive hub to be removed. Do not
raise the machine.
5 Block the wheels at the opposite end of the
machine.
6 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
7 Remove the wheel lug nuts. Remove the tire
and wheel assembly.
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Part No. 102916
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Section 4 • Repair Procedures
AXLE COMPONENTS
13-5
Steer Cylinders
7 Place a rod through each steer cylinder pivot
pin and twist to remove the pins.
How to Remove a
Steering Cylinder
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Hose and Fitting Torque Specifications.
1 Locate the hose bracket mounted to the steer
cylinder.
8 Remove the steering cylinder from the machine.
2 Remove the hose bracket cover retaining
fasteners. Remove the hose bracket cover.
Crushing hazard. The steer
cylinder may become unbalanced
and fall if it is not properly
supported by the lifting device.
3 Remove the hose bracket retaining fasteners
from the steering cylinder.
4 Tag, disconnect and plug the hydraulic hoses
from the steering cylinder. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
5 Remove the pin retaining fasteners from the
steer cylinder pivot pins.
6 Support the steer cylinder with a suitable lifting
device.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 139
October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
13-6
Extendable Axles
Top and bottom wear pads:
The extendable axles are used to widen the foot
print of the drive chassis for stability.
How to Shim an Extendable Axle
Note: Measure each wear pad. Replace the wear
pad 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 to
obtain zero clearance and zero drag.
4 Use a round punch through the wear pad
mounting holes to align the shims with the wear
pad. Install the wear pad retaining fasteners.
3 Center a lifting jack of ample capacity under the
axle that needs to be shimmed. Do not raise
the machine.
4 Block the wheels at the opposite end of the
machine.
5 Raise the machine just until the weight of the
machine is relieved off of the axle. Do not raise
the wheels off of the ground.
6 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
7 Use a round punch through the wear pad
mounting holes to align the shims with the wear
pad. Install the wear pad retaining fasteners.
8 Extend and retract the axle through an entire
cycle. Check for tight spots that could cause
binding or scraping of the axle tubes.
Note: Always maintain squareness between the
inner and outer axle tubes.
5 Extend and retract the axle through an entire
cycle. Check for tight spots that could cause
binding or scraping of the axle tubes.
Note: Always maintain squareness between the
inner and outer axle tubes.
4 - 140
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
How to Remove an Inner Axle
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Specifications, Hydraulic Hose and Fitting
Torque Specifications.
Note: Perform this procedure with the tires parallel
to the chassis and the axles fully extended.
8 Remove the pin retaining fasteners from the
axle stop pin. Use a slide hammer to remove
the pin.
9 Remove the access cover fasteners from
the end of the inner axle to access the axle
extension cylinder clevis pin. Remove the
cover.
10Place support blocks under the end of the axle
extension cylinder for support.
1 Remove the top drive chassis cover.
11Remove the cotter pin from the axle extension
cylinder clevis pin.
2 Remove the yoke and hub assembly. See 13-2,
How to Remove the Yoke and Hub.
Note: Alwayse use a new cotter pin when installing
a clevis pin.
3 Remove the steering cylinder. See 13-5, How
to Remove a Steering Cylinder.
4 Remove the axle cover retaining fasteners
located above the axle. Remove the chassis
cover from the machine.
12Use a soft metal drift to remove the axle
extension cylinder clevis pin.
13Carefully support and slide the inner axle out
of the chassis. Remove the axle from the
machine.
5 Remove the upper wear pad retainer plate
retaining fasteners. Remove the plate from the
machine.
Crushing hazard. The inner
axle may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported by the overhead crane.
6 Attach a lifting strap from an overhead crane of
ample capacity to the inner axle for support. Do
not lift it.
Component damage hazard. The
aluminum limit switch track and
the axle extension cylinder may
become damaged if the axle is
allowed to fall when it is removed
from the machine.
7 Remove the retaining fasteners from the upper
and lower wear pads at the outer axle. Do not
remove the side wear pads.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
Note: When installing an inner axle, there needs to
be a minimum of 1/8 inch / 3.1 mm gap between the
proximity switches and the aluminum limit switch
track. Measure the gap with the axles in both
the retracted and extended positions. Adjust the
proximity switches as necesary to obtain a
1
/8 inch / 3.1 mm gap.
Part No. 102916
S-100 • S-105 • S-120 • S-125
4 - 141
October 2015
Section 4 • Repair Procedures
AXLE COMPONENTS
How to Remove the Axle
Extension Cylinder
7 Attach a lifting strap from an overhead crane to
the end of the axle extension cylinder.
1 Remove a yoke and hub assembly. See 13-2,
How to Remove the Yoke and Hub.
2 Remove the axle. See How to Remove an Inner
Axle.
3 Remove the access covers from the end of the
remaining axle.
4 Tag, disconnect and plug the axle extension
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
5 Tag and disconnect the wiring connectors from
the proximity switches and limit switch. Do not
remove the switches.
Note: The wiring connectors for the switches can
be accessed through the access holes on either
side of the chassis end plate.
Note: Attach the lifting strap to the end of the
cylinder that has the inner axle removed.
8 Remove the cotter pin from the axle extension
cylinder clevis pin on the remaining inner axle.
Note: Alwayse use a new cotter pin when installing
a clevis pin.
9 Use a soft metal drift to remove the pin.
Crushing hazard. The axle
extension cylinder may fall if it is
not properly supported.
Component damage hazard. The
axle extension cylinder and limit
switches can become damaged
if the axle extension cylinder is
allowed to fall.
10Carefully support and slide the axle extension
cylinder out of the axle.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
6 Place blocks under the axle extension cylinder
for support.
4 - 142
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
Diagnostic Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-100, S-105, S-120, S-125 Operator’s
Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Read each appropiate fault code thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Repair any machine damage or malfunction
before operating the machine.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Unless otherwise specified, perform each
repair procedure with the machine in the
following 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 disconnected
from the machine
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Note: Perform all troubleshooting on a firm, level
surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
Part No. 102916
S-100 • S-105 • S-120 • S-125
5-1
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Fault Diagnostics Control System
How to Read Control System
Fault Codes
Note: Initial fault testing occurs at power-up.
Faults are abnormal conditions that exist due
to component failure or System misuse. CPU,
memory, LCD, LED, limited joystick and limited
operator switch testing is done on power-up. If
an operator switch is depressed on power-up,
the display should show and error and not allow
any machine functions.
Releasing the switch will clear the error and
allow all machine functions. The joystick
operates similarly.
All other fault testing is done continuously.
1 When a fault is diagnosed, the PCON fault
indicator will flash and a fault message will be
displayed on the TCON LCD. The message will
contain the fault source and type.
2 Additional information, including the occurrence
counter and a time-stamp is available with a
PC, connected to one of the RS232 ports. Up
to 16 unique fault messages can be saved.
Each fault is saved with the device identity,
fault type, engine hour time-stamp and an 8-bit
occurrence counter.
3 The fault code table on the following pages lists
the functions or components monitored by the
system.
5 - 2
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Not calibrated
Normal function except threshold for
one or the other direction is zero, Display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Not calibrated
Normal function except threshold for
one or the other direction is zero, Display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Primary Boom Ext/Ret Flow Valve
Value at 5.0 V
Value Too High
Value Too Low
Value at 0 V
Primary Boom Up/Down Flow Valve
Value at 5.0 V
Value Too High
Value Too Low
Value at 0 V
Primary Boom Extend Valve
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Range Check
(underspeed)
Range Check
(low oil pressure)
Range Check
(high temperature)
Display message on LCD
Power up controller with
problem
corrected
Fault Check
Display message on LCD
Power up controller with
problem
corrected
Axle Extend/Retract Buttons
Fault Check (both
buttons pressed)
Axle Extend/Retract disabled, display
message on LCD
Power up controller with
problem
corrected
Axle Valves
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Primary Boom Retract Valve
Primary Boom Up Valve
Primary Boom Down Valve
Engine Speed
Oil Pressure
Water/Oil Temp
Water/Oil Temp Sensor
Oil Pressure Sensor
Part No. 102916
S-100 • S-105 • S-120 • S-125
5-3
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Value at 5.0 V
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Not calibrated
Joystick Speed and Direction frozen
at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Not calibrated
Joystick Speed and Direction frozen
at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Joystick Speed and Direction frozen
at zero and neutral
Calibrate Joystick
Value Too High
Value Too Low
Primary Ext/Ret Joystick
Value at 0 V
Value at 5.0 V
Value Too High
Value Too Low
Primary Up/Down Joystick
Value at 0 V
Value at 5.0 V
Value Too High
Value Too Low
Value at 0 V
Steer Joystick
Not calibrated
Just calibrated
Initiate one second beep of audible
warning device
Primary Boom Up/Down switches on
TCON
Fault Check (both
buttons pressed)
Primary Boom Up/Down disabled, display message on LCD
Primary Boom Ext/Ret switches on
TCON
Fault Check (both
buttons pressed)
Primary Boom Ext/Retract disabled,
display message on LCD
Primary Boom Length
Fault Check
(unknown length)
Primary Boom Angle
Fault Check
(unknown angle)
5 - 4
Self-clearing
(transient)
Power up controller with
problem
corrected
Power up controller with
problem
corrected
Power up controller with
problem
corrected
Stop all boom functions, allow only
boom retract, once fully retracted allow
boom down. Display message on LCD
Stop all boom functions, allow only
Power up controller with
boom retract. Display message on LCD
problem
corrected
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Primary Up/Down Speed
Not calibrated
Display message on LCD and allow
operation at default speed
Perform auto calibrate
precedure
Display message on LCD and allow
operation at default speed
Perform auto calibrate
precedure
Primary Extend/Retract Speed
Not calibrated
SAFETY SWITCH P3
Display message on LCD
P3 SAFETY SWITCH FAULT
SAFETY SWITCH P6R1
Display message on LCD
P6R1 SAFETY SWITCH FAULT
SAFETY SWITCH P6R2
Display message on LCD
P6R2 SAFETY SWITCH FAULT
SAFETY SWITCH P7
Display message on LCD
P7 SAFETY SWITCH FAULT
SAFETY SWITCH P7R
Display message on LCD
P7R SAFETY SWITCH FAULT
SAFETY SWITCH P9A
Display message on LCD
P9A SAFETY SWITCH FAULT
SAFETY SWITCH P9B
Fault Check
Display message on LCD
P9B SAFETY SWITCH FAULT
SAFETY SWITCH P10
Display message on LCD
P10 SAFETY SWITCH FAULT
SAFETY SWITCH P11
Display message on LCD
P11 SAFETY SWITCH FAULT
SAFETY SWITCH P12
Display message on LCD
P12 SAFETY SWITCH FAULT
SAFETY SWITCH P14
Display message on LCD
P14 SAFETY SWITCH FAULT
SAFETY SWITCH P18
Display message on LCD
P18 SAFETY SWITCH FAULT
SAFETY SWITCH P22
Display message on LCD
P22 SAFETY SWITCH FAULT
SAFETY SWITCH P22R
Display message on LCD
P22R SAFETY SWITCH FAULT
CAN Bus
Part No. 102916
Fault Check
Display message on LCD
S-100 • S-105 • S-120 • S-125
Power up controller with
problem
corrected
Power up controller with
problem
corrected
5-5
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Primary Boom Lock-Out Valve #1
Primary Boom Lock-Out Valve #2
Platform Overload
Shut Down Mode
Error Type
Effects
Recovery Actions
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem corrected
Fault Check
(if active)
Display message on LCD
Power up controller with
problem corrected
Value at 5.0 V
Value Too High
Value Too Low
Turntable Rotate Joystick
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem corrected
Value at 0 V
Not calibrated
Just calibrated
Joystick Speed and Direction frozen
at zero and neutral
Calibrate Joystick
Initiate one second beep of audible
warning device
Self-clearing
(transient)
TT rotate disabled, display message on Power up controller with
problem corrected
LCD
Turntable Rotate Buttons
Fault Check (both
buttons pressed)
Turntable Rotate Speed
Not calibrated
Display message on LCD and allow
operation at default speed
Perform auto calibrate
procedure
Not calibrated
Normal function except threshold for
one or the other directions is zero,display message on LCD
Calibrate Thresholds
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem corrected
Turntable Rotate Flow Valve
Value at 5.0 V
Value Too High
Value Too Low
Value at 0 V
Turntable Rotate CW Valves
Turntable Rotate CCW Valves
Fault Check
Limited Speed and Direction frozen at Power up controller with
zero and neutral, Alarm sounds
problem corrected
Fault Check
Display message on LCD and sound
audible alarm
Turntable Level Sensor X-Direction
Turntable Level Sensor Y-Direction
Correct problem
Platform Level Sensor Y-Direction
5 - 6
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Limited Speed and Direction frozen
at zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Not calibrated
Joystick Speed and Direction frozen
at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Value at 5.0 V
Value Too High
Value Too Low
Propel Joystick
Value at 0 V
Not calibrated
Just calibrated
Propel Valves (High Current)
Calibrate Thresholds
Self-clearing
(transient)
Value at 5.0 V
Value Too High
Value Too Low
Value at 0 V
Motor Speed Valve
Normal function except threshold for
one or the other direction is zero, Display message on LCD
Initiate one second beep of audible
warning device
Shut down engine, Limited Speed and
Direction frozen at zero and neutral,
Alarm sounds
Power up controller with
problem
corrected
Shut down engine, Limited Speed and
Direction frozen at zero and neutral,
Alarm sounds
Power up controller with
problem corrected
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Fault Check (both
buttons pressed)
Affected functions disabled, display
message on LCD
Power up controller with
problem
corrected
Display message on LCD
Recycle power
Disable Generator, Display message
on LCD Display
Power up controller with
problem
corrected
Fault Check
Brake Valve
Platform Level Up Valve
Platform Level Down Valve
Platform Rotate CW Valve
Platform Rotate CCW Valve
Jib Up Valve
Jib Down Valve
Jib Switches
Platform Rotate Switches
Platform Level Switches
Footswitch Timeout
Hydraulic Generator/Welder - Bypass
Valve
Part No. 102916
Fault Check
S-100 • S-105 • S-120 • S-125
5-7
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Error Source
Error Type
Effects
Recovery Actions
Limited Speed and Direction frozen
at zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Not calibrated
Joystick Speed and Direction frozen
at zero and neutral
Calibrate Joystick
Just calibrated
Initiate one second beep of audible
warning device
Self-clearing
(transient)
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Value at 5.0 V
Value Too High
Value Too Low
SteeringJoystick
Value at 0 V
Value at 5.0 V
Value Too High
LF Steer Angle Sensor
Value Too Low
Value at 0 V
Value at 5.0 V
Value Too High
RF Steer Angle Sensor
Value Too Low
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Value at 0 V
Value at 5.0 V
Value Too High
LR Steer Angle Sensor
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Fault Check
Limited Speed and Direction frozen at
zero and neutral, Alarm sounds
Power up controller with
problem
corrected
Fault Check
Display message on LCD
Power up controller with
problem
corrected
Value Too Low
Value at 0 V
Value at 5.0 V
RR Steer Angle Sensor
Value Too High
Value Too Low
Value at 0 V
LF Steer Valves
RF Steer Valves
LR Steer Valves
RR Steer Valves
Hydraulic Generator/Welder - Bypass
Valve
5 - 8
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES
P_38-Propel
(P13-17 TCON)
P_22-Jib Jib
Lvl Pwr
P_39-Turntable
Rotate (P13-19
TCON)
P_22R - Primary
Up/Down FC
P_10-Primary
Boom Extend
(P12-08 TCON)
P_12 - Axle
Retract (P121-08
SCON)
P_38
P_39
Turntable tilt axis (+5°, secondary
boom not stowed)
Primary Boom Angle (crosscheck)
OFF
OFF
OFF
OFF
OFF
OFF
OFF*
Primary Boom Length (crosscheck)
OFF
OFF
OFF
OFF
OFF*
Primary 2 Cylinder (crosscheck)
OFF
OFF
OFF*
Boom Envelope Safety Interlock
OFF
Axle Safety Not Stowed
OFF
Axles crosscheck Angle sensor vs.
safety switch(es)
Axle (not fully extended) and TT
Rotate (stowed and in drive disable
zone)
Turntable Tilt Angle (crosscheck
SCON internal sensor 3 in a delta
configuration)
Loss of CAN
OFF
P_10
P_11-Primary
Up (P12-09
TCON)
P_11
P_9A
P_9A-Primary
Down (P12-06
TCON)
P_9B
P_22R
P_12
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF*
Platform Overload (SCON pin #1)
OFF
OFF
Platform Out of Level (>10°)
OFF
Jib Bellcrank Out of Level (>10°)
OFF
Boom Safety (max angle)
OFF
OFF
Boom Safety (max length)
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Axle Retract Safety
Cable Tension (#1 or #2)
P_22
P_9BIgnition/Fuel
(P12-07 TCON)
OFF
OFF
OFF
* P-9A and P-10 energized if boom is fully retracted as indicated by LSB3RS
Part No. 102916
S-100 • S-105 • S-120 • S-125
5-9
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES
Fault Source and Type will display as:
Source
" ID XXX_xx FAULT "
Type
Where XXX is the one to three digit Fault Source and xx is
the two digit Fault Type.
TCON - Turntable Controller
PCON - Platform Controller
SCON - Safety Controller
DCON - Drive Controller
Fault Type
ID
Description
11
Value at 5V
12
Value too High
13
No Response
15
Value too Low
16
Value at 0V
17
Not Calibrated
21
Fault
26
Timeout
31
Invalid Setup
32
Min Cal Too Low
33
Min Cal Too High
5 - 10
Fault Source
ID
Description
3
SCON Controller Area Network
4
Primary Boom Angle Zone
5
Primary Boom Length Switches Cross-Check
8
PCON Controller Area Network
9
Engine
18
DCON Controller Area Network
20
Boom Extend/Retract Joystick
21
Boom Up/Down Joystick
26
Boom Extend/Retract Buttons
27
Boom Up/Down Buttons
28
Boom Angle Sensors Cross-Check (SCON)
29
LSB2RS/LSB4ES Cross-Check (SCON)
30
Propel Joystick
35
Propel Valve
40
Turntable Rotate Joystick
43
Footswitch Timeout
44
Jib Up/Down Joystick
48
PBMAS Safety Envelope (SCON)
49
Jib Up/Down Buttons
50
Jib Up/Down Flow Valve
52
Steer Joystick
53
Left Front Steer Sensor
54
Right Front Steer Sensor
55
Left Rear Steer Sensor
56
Right Rear Steer Sensor
59
Rocker Steer Joystick
61
PBMLS Safety Envelope (SCON)
63
Front Axle Sensor
64
Rear Axle Sensor
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES
Fault Source
ID
Description
65
Turntable Level Sensor X-Direction
66
Turntable Level Sensor Y-Direction
67
Boom Length Sensor Cross-Check (SCON)
68
Boom Safety Envelope (SCON)
70
Turntable Controller - Platform Controller
Software Version
73
Engine Pressure Sensor
74
Engine Temperature Sensor
75
LSB2RO/LSB4EO Cross-Check
80
TCON/SCON Calibration Inconsistent
81
Boom Up/Down Flow Valve (Fine)
82
Boom Extend/Retract Flow Valve
83
Boom Extend/Retract Speed
85
Boom Up/Down Speed
86
Boom Angle Sensor
90
Jib Rotate Flow Valve
91
Turntable Rotate Buttons
92
Turntable Rotate Flow Valve
93
Turntable Rotate Speed
94
Boom Length Sensor
95
Jib Rotate Joystick
98
Platform Level Sensor
99
Platform Level Buttons
110
Platform Rotate Buttons
113
Jib Rotate Buttons
117
Propel Power P38
118
Turntable Rotate Power P39
121
Valve Power P6R1
122
Engine Power P6R2
123
Enable Input Power P7
Part No. 102916
Fault Source
ID
Description
124
Enable Output Power P7R
125
Primary Down Power P9A
126
IGN/Fuel Power P9B
127
Primary Extend Power P10
128
Primary Up Power P11
129
Axle Retract Power P12
132
Platform Level Power P22
133
Primary Up/Down Valve Power P22R
134
DCON Valve Power P7R
142
Turntable Rotate CW Valve
143
Turntable Rotate CCW Valve
144
Axle Safety Not Stowed (SCON)
145
Boom Up Valve
146
Boom Down Valve
147
Platform Overload Switches Inconsistent
(SCON)
148
Boom Extend Valve
149
Boom Retract Valve
152
Boom Up/Down Flow Valve (Gross)
153
Primary Lockout P1 Valve
154
Primary Lockout P2 Valve
157
Axles Fully Extended Cross-Check (SCON)
158
Drive Disable Zone and Axles Not Fully
Extended (SCON)
160
Left Front Steer Valve
161
Right Front Steer Valve
162
Left Rear Steer Valve
163
Right Rear Steer Valve
164
Axle Valve
165
Boom Not Retracted and Chassis Tilted (SCON)
S-100 • S-105 • S-120 • S-125
5 - 11
October 2015
Section 5 • Diagnostic Codes
CONTROL SYSTEM FAULT CODES
Fault Source
ID
Description
166
Brake Valve
167
Motor Shift Valve
168
Chassis Tilt Sensors Cross-Check (SCON)
170
Jib Bellcrank Level Sensor
171
Jib Bellcrank Level Flow Valve
172
AUX Relay
173
Platform Level Toggle Switch
174
Platform Rotate Toggle Switch
175
Platform Level Flow Valve
176
Platform Rotate Valve
180
Boom Length Sensor
195
Safety Platform Overload (SCON)
220
RSB1AO Active Cross-Check
221
LTB1LO Active Cross-Check
222
Axle Extend/Retract Toggle Switch
235
RSB1AO/LSB1DO Cross-Check
236
LTB1LO/LSB3RO Cross-Check
237
LTB1LO/LSB4EO Cross-Check
238
Pressure Comp Enable #1 Valve
239
Pressure Comp Enable #2/Generator Valve
245
Check Machine Software Type at TCON
246
Check Machine Software Type at SCON
247
TCON/SCON Software Inconsistent
5 - 12
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
51
3
1019
EGR-Valve, short circuit to
battery
51
3
1024
Position sensor error of actuator EGR-Valve; signal range check high 51
3
1226
EGR-Valve; short circuit to
battery (A02)
51
3
1227
EGR-Valve; short circuit to
battery (A67)
51
4
1020
EGR-Valve; short circuit to
ground
51
4
1025
Position sensor error of actuator EGR-Valve; signal range check low
SPN FMI KWP
Description
51
6
1022
Actuator error EGR-Valve; signal range check high
51
6
1224
Actuator EGR-Valve; over
current
51
6
1230
Actuator error EGR-Valve;
Overload by short-circuit
51
7
1016
Actuator position for EGR-Valve not plausible
51
11
1231
Actuator error EGR-Valve; Power stage over temp due to high
current
51
12
1018
Actuator EGR-Valve; powerstage over temperature
51
12
1021
Mechanical actuator defect
EGR-Valve
51
12
1225
Actuator EGR-Valve;
over temperature
51
4
1228
EGR-Valve; short circuit to
ground (A02)
94
1
474
51
4
1229
EGR-Valve; short circuit to
ground (A67)
Low fuel pressure; warning
threshold exceeded
94
1
475
51
4
1232
Actuator error EGR-Valve;
Voltage below threshold
Low fuel pressure; shut off
threshold exceeded
94
3
472
51
5
1015
Actuator error EGR-Valve; signal range check low
Sensor error low fuel pressure;
signal range check high
94
4
473
51
5
1017
Actuator EGR-Valve; open load
Sensor error low fuel pressure;
signal range check low
51
5
1023
Actuator error EGR-Valve; signal range check low
97
3
464
Sensor error water fuel; signal
range check high
51
5
1223
Actuator EGR-Valve; open load
97
4
465
Sensor error water fuel; signal
range check low
51
6
1014
Actuator error EGR-Valve; signal range check high
97
12
1157
Water in fuel level prefilter;
maximum value exceeded
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 13
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
100
0
734
High oil pressure; warning
threshold exceeded
100
0
735
High oil pressure; shut off
threshold exceeded 100
1
736
Low oil pressure; warning
threshold exceeded
100
1
737
Low oil pressure; shut off
threshold exceeded
100
3
732
Sensor error oil pressure; signal range check high
100
4
733
Sensor error oil pressure; signal range check low
102
2
88
Charged air pressure above
warning threshold
102
2
89
Charged air pressure above shut off threshold
102
4
777
Sensor error charged air press;
signal range check low
105
0
996
High charged air cooler
temperature; warning threshold
exceeded
105
0
997
High charged air cooler
temperature; shut off threshold
exceeded
105
3
994
Sensor error charged air
temperature; signal range check high
105
4
995
Sensor error charged air
temperature; signal range check low
5 - 14
SPN FMI KWP
Description
108
3
412
Sensor error ambient air press;
signal range check high
108
4
413
Sensor error ambient air press;
signal range check low
110
0
98
High coolant temperature;
warning threshold exceeded
110
0
99
High coolant temperature; shut
off threshold exceeded
110
3
96
Sensor error coolant temp;
signal range check high
110
4
97
Sensor error coolant temp;
signal range check low
111
1
101
Coolant level too low
132
11
1
Air flow sensor load correction
factor exceeding the maximum
drift limit; plausibility error
132
11
2
Air flow sensor load correction
factor exceeding drift limit;
plausibility error
132
11
3
Air flow sensor low idle correction factor exceeding the maximum
drift limit
132
11
4
Air flow sensor load correction
factor exceeding the maximum
drift limit
157
3
877
Sensor error rail pressure; signal range check high
157
4
878
Sensor error rail pressure; signal range check low
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
168
0
1180
Physical range check high for
battery voltage
168
1
1181
Physical range check low for
battery voltage 168
2
47
High battery voltage; warning
threshold exceeded
168
2
48
Low battery voltage; warning
threshold exceeded
168
3
45
Sensor error battery voltage;
signal range check high
168
4
46
Sensor error battery voltage;
signal range check low
171
3
417
Sensor error environment
temperature; signal range check high
171
4
418
Sensor error environment
temperature; signal range check low
SPN FMI KWP
Description
174
0
481
High low fuel temperature;
warning threshold exceeded
174
0
482
High low fuel temperature; shut
off threshold exceeded
175
0
740
Physical range check high for oil temperature
175
0
745
High oil temperature; warning
threshold exceeded
175
0
746
High oil temperature; shut off
threshold exceeded
175
1
741
Physical range check low for oil
temperature
175
2
738
Sensor oil temperature;
plausibility error
175
2
739
Sensor oil temperature;
plausibility error oil temperature
too high
175
3
743
Sensor error oil temperature;
signal range check high
175
4
744
Sensor error oil temperature;
signal range check low
172
0
1182
Physical range check high for
intake air temperature
190
0
389
172
1
1183
Physical range check low for
intake air temperature
Engine speed above warning
threshold (FOC-Lewel 1)
190
2
421
172
2
9
Sensor ambient air temperature; plausibility error
Offset angle between crank and camshaft sensor is too large
190
8
419
172
2
983
Intake air sensor; plausibility
error
Sensor camshaft speed;
disturbed signal
172
3
981
Sensor error intake air; signal
range check high
172
4
982
Sensor error intake air; signal
range check low
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 15
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
190
8
422
Sensor crankshaft speed;
disturbed signal
190
11
390
Engine speed above warning
threshold (FOC-Lewel 2)
190
12
420
Sensor camshaft speed; no
signal
190
12
423
Sensor crankshaft speed; no
signal
190
14
391
Engine speed above warning
threshold (Overrun Mode)
190
14
1222
Camshaft and Crankshaft speed sensor signal not available on
CAN
411
0
791
Physical range check high for
differential pressure Venturiunit
(EGR)
411
1
792
Physical range check low for
differential pressure Venturiunit
(EGR)
411
3
795
Sensor error differential pressure Venturiunit (EGR); signal range check high
411
4
381
Physical range check low for
(EGR) differential pressure
411
4
796
Sensor error differential pressure Venturiunit (EGR); signal range check low
5 - 16
SPN FMI KWP
Description
412
3
1007
Sensor error EGR cooler
downstream temperature; signal range check high
412
4
1008
Sensor error EGR cooler
downstream temperature; signal range check low
520
9
306
Timeout Error of
CAN-Receive-Frame TSC1TR;
Setpoint
597
2
49
Break lever mainswitch and
break lever redundancy switch
status not plausible
624
3
971
SVS lamp; short circuit to batt
624
4
972
SVS lamp; short circuit to grd
624
5
969
SVS lamp; open load
624
12
970
SVS lamp; powerstage over
temperature
630
12
376
Access error EEPROM memory (delete)
630
12
377
Access error EEPROM memory (read)
630
12
378
Access error EEPROM memory (write)
639
14
84
CAN-Bus 0 "BusOff-Status"
651
3
580
Injector 1 (in firing order); short
circuit
651
4
586
High side to low side short circuit in the injector 1 (in firing order)
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
677
3
956
SPN FMI KWP
Description
Starter relay high side; short
circuit to battery
651
5
568
Injector 1 (in firing order);
interruption of electric connection
677
3
960
Starter relay low side; short
circuit to battery
652
3
581
Injector 2 (in firing order); short
circuit
677
4
957
Starter relay high side; short
circuit to ground
652
4
587
High side to low side short circuit in the injector 2 (in firing order)
677
4
961
Starter relay low side; short
circuit to ground
652
5
569
Injector 2 (in firing order);
interruption of electric connection
677
5
958
Starter relay; no load error
677
12
959
653
3
582
Injector 3 (in firing order); short
circuit
Starter relay; powerstage over
temperature
703
3
426
653
4
588
High side to low side short circuit in the injector 3 (in firing order)
Engine running lamp; short circuit to battery
703
4
427
653
5
570
Injector 3 (in firing order);
interruption of electric connection
Engine running lamp; short circuit to ground
703
5
424
Engine running lamp; open load
703
12
425
Engine running lamp;
powerstage over temperature
729
5
545
Cold start aid relay open load
729
12
547
Cold start aid relay; over
temperature error
898
9
305
Timeout Error of
CAN-Receive-Frame TSC1TE;
Setpoint
1079 13
946
Sensor supply voltage monitor
1 error (ECU)
1080 13
947
Sensor supply voltage monitor
2 error (ECU)
654
3
583
Injector 4 (in firing order); short
circuit
654
4
589
High side to low side short circuit in the injector 4 (in firing order)
654
5
571
Injector 4 (in firing order);
interruption of electric connection
676
11
543
Cold start aid relay error
676
11
544
Cold start aid relay open load
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 17
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN FMI KWP
Description
1180 1
1463
Exhaust gas temperature
upstream turbine; shut off
threshold exceeded
1180 3
1067
Sensor error exhaust gas
temperature upstream turbine;
signal range check high
1180 11
1066
Sensor exhaust gas temperature upstream turbine; plausibility
error
1188 2
1414
Wastegate; status message from ECU missing
1188 7
1415
Wastegate actuator; blocked
1188 11
1411
Wastegate actuator; internal
error
1188 11
1412
Wastegate actuator; ELO
calibration not performed
correctly
1188 11
1416
Wastegate actuator; over
temperature (> 145°C )
1188 11
1417
Wastegate actuator; over
temperature (> 135°C )
1188 11
1418
Wastegate actuator; operating
voltage error
1188 11
1413
Wastegate actuator calibration
deviation too large, recalibration required
1231 14
85
CAN-Bus 1 "BusOff-Status"
1231 14
86
CAN-Bus 2 "BusOff-Status"
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
1109 2
121
Engine shut off demand ignored
1136 0
1398
Physikal range check high for
ECU temperature
1136 1
1399
Physikal range check low for
ECU temperature
1136 3
1400
Sensor error ECU temperature;
signal range check high
1136 4
1401
Sensor error ECU temperature;
signal range check low
1176 3
849
Sensor error pressure sensor
upstream turbine; signal range
check high
1176 4
850
Sensor error pressure sensor
downstream turbine; signal range check high
1180 0
1193
Physical range check high for
exhaust gas temperature
upstream turbine
1180 0
1460
Turbocharger Wastegate CAN
feedback; warning threshold
exceeded
1180 0
1462
Exhaust gas temperature
upstream turbine; warning
threshold exceeded
1180 1
1194
Physical range check low for
exhaust gas temperature
upstream turbine
1180 1
1461
Turbocharger Wastegate CAN
feedback; shut off threshold
exceeded
5 - 18
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP
Description
1237 2
747
Override switch; plausibility error
1322 12
610
Too many recognized misfires in more than one cylinder
1323 12
604
Too many recognized misfires in cylinder 1 (in firing order)
1324 12
605
Too many recognized misfires in cylinder 2 (in firing order)
1325 12
606
Too many recognized misfires in cylinder 3 (in firing order)
1326 12
607
Too many recognized misfires in cylinder 4 (in firing order)
2659 0
1524
Physical range check high for
EGR exhaust gas mass flow
Physical range check low for
EGR exhaust gas mass flow
2659 1
1525
2659 2
1523
Exhaust gas recirculation AGS
sensor; plausibility error
2659 2
1527
AGS sensor temperature exhaust gas mass flow; plausibility error
2659 12
1526
Exhaust gas recirculation; AGS
sensor has "burn off" not
performed
2797 4
1337
Injector diagnostics; timeout error of short circuit to ground
measurement cyl. Bank 0
Part No. 102916
SPN FMI KWP
Description
2798 4
1338
Injector diagnostics; timeout error of short circuit to ground
measurement cyl. Bank 1
2798 4
1339
Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 0
2798 4
1340
Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 1
3224 2
127
DLC Error of
CAN-Receive-Frame AT1IG1
NOX Sensor (SCR-system
upstream cat; DPF-system
downstream cat); length of frame
incorrect
3224 9
128
Timeout Error of
CAN-Receive-Frame AT1IG1;
NOX Sensor upstream
3248 4
1047
Sensor error particle filter
downstream temperature; signal range check low
3699 2
1616
DPF differential pressure sensor and a further sensor or actuator CRT system defective
3699 2
1617
Temperature sensor us. and ds. DOC simultaneously defect
3699 14
1615
Maximum stand-still-duration
reached; oil exchange required
4765 0
1039
Physical range check high for
exhaust gas temperature
upstream (DOC)
4765 1
1042
Physical range check low for
exhaust gas temperature
upstream (DOC)
S-100 • S-105 • S-120 • S-125
5 - 19
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
FMI KWP Description
523008 2
649
Timeout error in Manipulation
control
523009 9
825
Pressure Relief Valve (PRV)
reached maximum allowed
opening count
523009 10
833
Pressure Relief Valve (PRV)
reached maximum allowed
open time
523212 9
171
Timeout Error of
CAN-Receive-Frame
ComEngPrt; Engine Protection
523216 9
198
Timeout Error of
CAN-Receive-Frame
PrHtEnCmd; pre-heat command, engine command
SPN
FMI KWP Description
4766
0
1029 Physical range check high for
exhaust gas temperature
downstream (DOC)
4766
1
1032 Physical range check low for
exhaust gas temperature
downstream (DOC)
4768
2
1036 Sensor exhaust gas temperature upstream (DOC); plausibility
error
4768
3
1044 Sensor error exhaust gas
temperature upstream (DOC);
signal range check high
4768
4
1045 Sensor error exhaust gas
temperature upstream (DOC);
signal range check low
523240 9
179
Timeout CAN-message
FunModCtl; Function Mode
Control
4769
2
1026 Sensor exhaust gas temperature downstream (DOC); plausibility error
523350 4
565
Injector cylinder-bank 1; short
circuit
4769
3
1034 Sensor error exhaust gas
temperature downstream (DOC); signal range check high
523352 4
566
Injector cylinder-bank 2; short
circuit
523354 12
567
Injector powerstage output defect
523470 2
826
Pressure Relief Valve (PRV)
forced to open; performed by
pressure increase
523470 2
827
Pressure Relief Valve (PRV)
forced to open; performed by
pressure shock
4769
4
1035 Sensor error exhaust gas
temperature downstream (DOC);
signal range check low
523006 3
34
Controller mode switch; short
circuit to battery
523006 4
35
Controller mode switch; short
circuit to ground
523008 1
648
Manipulation control was
triggered
5 - 20
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523470 7
876
Maximum rail pressure in limp
home mode exceeded (PRV)
523470 11
831
The PRV can not be opened at
this operating point with a
pressure shock
FMI KWP Description
523612 12
613
Internal ECU monitoring
detection reported error
523612 12
614
Internal ECU monitoring
detection reported error
523612 12
615
Internal ECU monitoring
detection reported error
523612 12
616
Internal ECU monitoring
detection reported error
523470 11
832
Rail pressure out of tolerance
range
523612 12
617
523470 12
828
Open Pressure Relief Valve
(PRV); shut off condition
Internal ECU monitoring
detection reported error
523612 12
618
523470 12
829
Open Pressure Relief Valve
(PRV); warning condition
Internal ECU monitoring
detection reported error
523612 12
619
523470 14
830
Pressure Relief Valve (PRV) is
open
Internal ECU monitoring
detection reported error
523612 12
620
523550 12
980
T50 start switch active for too
long
Internal ECU monitoring
detection reported error
523612 12
621
523601 13
948
Sensor supply voltage monitor
3 error (ECU)
Internal ECU monitoring
detection reported error
523612 12
623
523603 9
126
Timeout Error of
CAN-Receive-Frame AMB;
Ambient Temperature Sensor
Internal ECU monitoring
detection reported error
523612 12
624
Internal ECU monitoring
detection reported error
523605 9
300
Timeout Error of
CAN-Receive-Frame TSC1AR;
Traction Control
523612 12
625
Internal ECU monitoring
detection reported error
523612 12
627
Internal ECU monitoring
detection reported error
523612 12
628
Internal ECU monitoring
detection reported error
523606 9
301
Timeout Error of
CAN-Receive-Frame TSC1AR;
Retarder
523612 12
387
Internal software error ECU;
injection cut off
523612 12
612
Internal ECU monitoring
detection reported error
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 21
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523615 3
596
Metering unit (Fuel-System);
short circuit to battery low side
523615 4
595
Metering unit (Fuel-System);
short circuit to ground high side
523615 4
597
Metering unit (Fuel-System);
short circuit to ground low side
523615 5
592
Metering unit (Fuel-System);
open load
523615 12
593
Metering unit (Fuel-System);
powerstage over temperature
523619 2
488
Physical range check high for
exhaust gas temperature
upstream (SCR-CAT)
523698 11
122
Shut off request from supervisory monitoring function
523717 12
125
Timeout Error of
CAN-Transmit-Frame AmbCon; Weather environments
523718 3
1488 SCR mainrelay; short circuit to
battery (only CV56B)
523718 4
1489 SCR mainrelay; short circuit to
ground (only CV56B)
523612 12
637
523612 12
1170 Internal software error ECU
523612 14
973
Softwarereset CPU SWReset_0
523612 14
974
Softwarereset CPU SWReset_1
523612 14
975
Softwarereset CPU SWReset_2
523613 0
856
Maximum positive deviation of
rail pressure exceeded
(RailMeUn0)
523613 0
857
Maximum positive deviation of
rail pressure in meeting unit
exceeded (RailMeUn1)
523613 0
858
Railsystem leakage detected
(RailMeUn10)
523613 0
859
Maximum positive deviation of
rail pressure in meeting unit
exceeded (RailMeUn2)
523613 0
860
Negative deviation of rail
pressure second stage
(RailMeUn22)
523718 5
523613 0
862
Maximum rail pressure exceeded (RailMeUn4)
1486 SCR mainrelay; open load (only CV56B)
523718 12
523613 1
861
Maximum rail pressure exceeded (RailMeUn3)
1487 SCR mainrelay; powerstage over temperature (only CV56B)
523766 9
281
523613 2
864
Setpoint of metering unit in
overrun mode not plausible
Timeout Error of
CAN-Receive-Frame Active
TSC1AE
523613 3
594
Metering unit (Fuel-System);
short circuit to battery high side
523767 9
282
Timeout Error of
CAN-Receive-Frame Passive
TSC1AE
5 - 22
Internal ECU monitoring
detection reported error
FMI KWP Description
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523897 13
561
Check of missing injector
adjustment value programming
(IMA) injector 3 (in firing order)
Check of missing injector
adjustment value programming
(IMA) injector 4 (in firing order)
FMI KWP Description
523768 9
283
Timeout Error of
CAN-Receive-Frame Active
TSC1AR
523898 13
562
523769 9
284
Timeout Error of
CAN-Receive-Frame Passive
TSC1AR
523910 6
1261 Air Pump; over current
523913 3
74
Timeout Error of
CAN-Receive-Frame Passive
TSC1DE
Sensor error glow plug control
diagnostic line voltage; signal
range check high
523913 4
75
Sensor error glow plug control
diagnostic line voltage; signal
range check low
523914 3
78
Glow plug control; short circuit to battery
523914 4
79
Glow plug control; short circuit to ground
523914 5
76
Glow plug control; open load
523914 5
1216 Glow plug control release line;
short circuit error
523914 11
1217 Glow plug control; internal error
523914 12
77
523919 2
1378 Sensor air pump airpressure;
plausibility error
523920 2
1379 Sensor exhaust gas back
pressure burner; plausibility error
523770 9
523776 9
285
291
Timeout Error of
CAN-Receive-Frame TSC1TE
active
523777 9
292
Passive Timeout Error of
CAN-Receive-Frame TSC1TE;
Setpoint
523778 9
293
Active Timeout Error of
CAN-Receive-Frame TSC1TR
523779 9
294
Passive Timeout Error of
CAN-Receive-Frame TSC1TR
523788 12
299
Timeout Error of
CAN-Transmit-Frame TrbCH;
Status Wastegate
523793 9
202
Timeout Error of
CAN-Receive-Frame UAA10;
AGS sensor service message
523794 9
203
Timeout Error of
CAN-Receive-Frame UAA11;
AGS sensor data
523895 13
559
Check of missing injector
adjustment value programming
(IMA) injector 1 (in firing order)
523896 13
560
Check of missing injector
adjustment value programming
(IMA) injector 2 (in firing order)
Part No. 102916
Glow plug control; powerstage
over temperature
S-100 • S-105 • S-120 • S-125
5 - 23
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
523936 12
169
523946 0
1158 Zerofuel calibration injector 1 (in firing order); maximum value
exceeded
523946 1
1164 Zerofuel calibration injector 1 (in firing order); minimum value
exceeded
523947 0
1159 Zerofuel calibration injector 2 (in firing order); maximum value
exceeded
523947 1
1165 Zerofuel calibration injector 2 (in firing order); minimum value
exceeded
523948 0
1160 Zerofuel calibration injector 3 (in firing order); maximum value
exceeded
523948 1
1166 Zerofuel calibration injector 3 (in firing order); minimum value
exceeded
523949 0
1160 Zerofuel calibration injector 4 (in firing order); maximum value
exceeded
523949 1
1166 Zerofuel calibration injector 4 (in firing order); minimum value
exceeded
523960 0
1011 Physical range check high for
EGR cooler downstream temp.
FMI KWP Description
523922 7
1262 Burner Shut Off Valve; blocked
closed
523922 7
1264 Burner Shut Off Valve; blocked
closed
523929 0
109
Fuel Balance Control integrator injector 1 (in firing order);
maximum value exceeded
523929 1
115
Fuel Balance Control integrator injector 1 (in firing order);
minimum value exceeded
523930 0
110
Fuel Balance Control integrator injector 2 (in firing order);
maximum value exceeded
523930 1
116
Fuel Balance Control integrator injector 2 (in firing order);
minimum value exceeded
523931 0
111
Fuel Balance Control integrator injector 3 (in firing order);
maximum value exceeded
523931 1
117
Fuel Balance Control integrator injector 3 (in firing order);
minimum value exceeded
523932 0
112
Fuel Balance Control integrator injector 4 (in firing order);
maximum value exceeded
523932 1
118
Fuel Balance Control integrator injector 4 (in firing order);
minimum value exceeded
523935 12
168
Timeout Error of
CAN-Transmit-Frame
EEC3VOL1; Engine send
messages
5 - 24
FMI KWP Description
Timeout Error of
CAN-Transmit-Frame
EEC3VOL2; Engine send
messages
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
523960 0
1458 High exhaust gas temperature
EGR cooler downstream;
warning threshold exceeded
523960 1
1012 Physical range check low for
EGR cooler downstream temp.
523960 1
1459 High exhaust gas temperature EGR cooler downstream; shut off threshold exceeded
523980 14
1187 Bad quality of reduction agent
detected
523981 11
918
Urea-tank without heating
function (heating phase)
523982 0
360
Powerstage diagnosis disabled; high battery voltage
523982 1
361
Powerstage diagnosis disabled; low battery voltage
523988 3
1245 Charging lamp; short circuit to
battery
523988 4
1246 Charging lamp; short circuit to
ground
523988 5
1243 Charging lamp; open load
523988 12
1244 Charging lamp; open temp.
523998 4
1327 Injector cylinder bank 2 slave;
short circuit
523999 12
1328 Injector powerstage output Slave defect
524014 1
1254 Air pressure glow plug flush line; below limit
Part No. 102916
FMI KWP Description
524016 2
1259 Amount of air is not plausible to pumb speed
524016 2
1260 Calculated amount of air is not
plausible to HFM reading
524016 11
1258 HFM sensor; electrical fault
524021 11
1263 Burner fuel line pipe leak behind Shut Off Valve
524024 11
1302 Deviation of the exhaust gas
temp. setpoint to actual value
downstream (DOC) too high
524028 2
1431 CAN message PROEGRActr;
plausible error
524029 2
1432 Timeout Error of
CAN-Receive-Frame
ComEGRActr - exhaust gas
recirculation positioner
524030 7
1440 EGR actuator; internal error
524031 13
1441 EGR actuator; calibration error
524032 2
1442 EGR actuator; status message
EGRCust is missing
524033 7
1443 EGR actuator; due to overload in Save Mode
524034 3
1438 Disc separator; short circuit to
battery
524034 4
1439 Disc separator; short circuit to
ground
524034 5
1436 Disc separator; open load
524034 12
1437 Disc separator; powerstage over temperature
S-100 • S-105 • S-120 • S-125
5 - 25
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
524108 9
1669 Timeout Error of
CAN-Transmit-Frame
ComEGRTVActr
FMI KWP Description
524035 12
1341 Injector diagnostics; time out
error in the SPI communication
524109 9
524057 2
1505 Electric fuel pump; fuel pressure build up error
1679 Timeout Error of
CAN-Receive-Frame
ComRxEGRTVActr
524110 9
524097 9
1663 Timeout Error of
CAN-Transmit-Frame
DPFBrnAirPmpCtl
1670 Timeout Error of
CAN-Transmit-Frame
ComETVActr
524111 9
524098 9
1664 Timeout Error of
CAN-Transmit-Frame
ComDPFBrnPT
1680 Timeout Error of
CAN-Receive-Frame
ComRxETVActr
524112 9
1671 Timeout ComlTVActr
524099 9
1665 Timeout Error of
CAN-Transmit-Frame
ComDPFC1
524113 9
1681 Timeout Error of
CAN-Receive-Frame
ComRxlTVActr
524100 9
1666 Timeout Error of
CAN-Transmit-Frame
ComDPFHisDat
524114 9
1659 Timeout Error of
CAN-Transmit-Frame A1DOC
524101 9
1667 Timeout Error of
CAN-Transmit-Frame
ComDPFTstMon
524115 9
1660 Timeout Error of
CAN-Transmit-Frame AT1S
524116 9
524102 9
1674 Timeout Error of
CAN-Receive-Frame
ComRxDPFBrnAirPmpCtl
1661 Timeout Error of
CAN-Transmit-Frame SCR2
524117 9
1662 Timeout Error of
CAN-Transmit-Frame SCR3
524103 9
1675 Timeout Error of
CAN-Receive-Frame
ComRxDPFBrnAirPmp
524118 9
1672 Timeout Error of
CAN-Receive-Frame
ComRxCM1
524104 9
1676 Timeout Error of
CAN-Receive-Frame
ComRxDPFCtl
524119 9
1673 Timeout Error of
CAN-Receive-Frame
ComRxCustSCR3
524105 9
1668 Timeout Error of
CAN-Transmit-Frame
ComEGRMsFlw
524106 9
1677 Timeout Error of
CAN-Receive-Frame
ComRxEGRMsFlw1
524107 9
1678 Timeout Error of
CAN-Receive-Frame
ComRxEGRMsFlw2
5 - 26
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
DEUTZ TD 2.9 L4 ENGINE FAULT CODES
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN
FMI KWP Description
524120 9
1682 Timeout Error of
CAN-Receive-Frame
ComRxSCRHtDiag
524121 9
1683 Timeout Error of
CAN-Receive-Frame
ComRxTrbChActr
524122 9
1684 Timeout Error of
CAN-Receive-Frame
ComRxUQSens
524123 9
1685 Timeout Error of
CAN-Receive-Frame
ComSCRHtCtl
524124 9
1686 Timeout Error of
CAN-Receive-Frame
ComTxAT1IMG
524125 9
1687 Timeout Error of
CAN-Receive-Frame
ComTxTrbChActr
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 27
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
27
3
Engine Exhaust Gas Recirculation Valve Position: Voltage
Above Normal
Value Position Sensor- Test
27
4
Engine Exhaust Gas Recirculation Valve Position: Voltage
Be- low Normal
Value Position Sensor- Test
29
3
Accelerator Pedal Position 2: Voltage Above Normal
Analog Throttle Position Sensor Circuit
Test
29
4
Accelerator Pedal Position 2: Voltage Above Normal
Analog Throttle Position Sensor Circuit
Test
51
3
Engine Throttle Valve 1 Position: Voltage Above Normal
Value Position Sensor- Test
51
4
Engine Throttle Valve 1 Position: Voltage Below Normal
Value Position Sensor- Test
91
3
Accelerator Pedal Position 1: Voltage Above Normal
Analog Throttle Position Sensor Circuit
Test
91
4
Accelerator Pedal Position 1: Voltage Below Normal
Analog Throttle Position Sensor Circuit
Test
97
4
Water In Fuel Indicator: High - least severe
Fuel Contains Water
100
2
Engine Oil Pressure: Erratic, Intermittent, or Incorrect
Switch Circuits - Test
100
17
Engine Oil Pressure: Low - least severe (1)
Oil Pressure Is Low
102
3
Engine Intake Manifold #1 Pressure: Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test
102
4
Engine Intake Manifold #1 Pressure: Voltage Below Normal Engine Pressure Sensor Open or Short
Circuit - Test
102
20
Engine Intake Manifold #1 Pressure: Data Drifted High
Engine Pressure Sensor Open or Short
Circuit - Test
102
21
Engine Intake Manifold #1 Pressure: Data Drifted Low
Engine Pressure Sensor Open or Short
Circuit - Test
105
3
Engine Intake Manifold #1 Temperature: Voltage Above
Normal
Engine Temperature Sensor Open or
Short Circuit - Test
105
4
Engine Intake Manifold #1 Temperature: Voltage Below
Normal
Engine Temperature Sensor Open or
Short Circuit - Test
107
2
Engine Air Filter 1 Differential Pressure:
Erratic, Intermittent, or Incorrect
Switch Circuits - Test
107
15
Engine Air Filter 1 Differential Pressure: High - least severe Inlet Air Is Restricted
(1)
107
16
Engine Air Filter 1 Differential Pressure: High - moderate
severity (2)
5 - 28
Inlet Air Is Restricted
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
108
3
Barometric Pressure: Voltage Above Normal
Engine Pressure Sensor Open or
Short Circuit - Test
108
4
Barometric Pressure: Voltage Below Normal
Engine Pressure Sensor Open or
Short Circuit - Test
110
3
Engine Coolant Temperature: Voltage Above Normal
Engine Temperature Sensor Open or Short Circuit - Test
110
4
Engine Coolant Temperature: Voltage Below Normal
Engine Temperature Sensor Open or Short Circuit - Test
110
15
Engine Coolant Temperature: High - least severe (1)
Coolant Temperature Is High
110
16
Engine Coolant Temperature: High - moderate severity (2)
Coolant Temperature Is High
152
2
Number Of ECU Resets: Erratic, Intermittent, or Incorrect
ECM Memory - Test
157
0
Engine Injector Metering Rail#1 Pressure: High - most severe
(3)
Fuel Rail Pressure Problem
157
2
Engine Injector Metering Rail#1 Pressure: Erratic, Intermittent,
or Incorrect
Fuel Rail Pressure Problem
157
3
Engine Injector Metering Rail#1 Pressure: Voltage Above
Normal
Engine Temperature Sensor Open or Short Circuit - Test
157
4
Engine Injector Metering Rail#1 Pressure: Voltage Below
Normal
Engine Temperature Sensor Open or Short Circuit - Test
157
10
Engine Injector Metering Rail#1 Pressure: Abnormal Rate of
Change
Engine Temperature Sensor Open or Short Circuit - Test
157
16
Engine Injector Metering Rail#1 Pressure: High - moderate
severity (2)
Fuel Rail Pressure Problem
157
17
Engine Injector Metering Rail#1 Pressure: Low - least severe (1) Fuel Rail Pressure Problem
157
18
Engine Injector Metering Rail#1 Pressure: Low - moderate
severity (2)
Fuel Rail Pressure Problem
168
3
Battery Potential/ Power Input 1: Voltage Above Normal
Ignition Keyswitch Circuit and Battery Supply Circuit - Test
166
2
Engine Rated Power: Erratic, Intermittent, or Incorrect
ECM Memory - Test
166
14
Engine Rated Power: Special Instruction
ECM Memory - Test
168
4
Battery Potential/ Power Input 1: Voltage Below Normal
Ignition Keyswitch Circuit and Battery Supply Circuit - Test
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 29
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
172
3
Engine Air Inlet Temperature Sensor: Voltage Above
Normal
Engine Temperature Sensor Open or Short
Circuit - Test
172
3
Engine Air Inlet Temperature Sensor: Voltage Below
Normal
Engine Temperature Sensor Open or Short
Circuit - Test
173
3
Engine Exhaust Gas Temperature: Voltage Above
Normal
Engine Temperature Sensor Open or Short
Circuit - Test
173
4
Engine Exhaust Gas Temperature: Voltage Below
Normal
Engine Temperature Sensor Open or Short
Circuit - Test
174
3
Engine Fuel Temperature 1: Voltage Above Normal
Engine Temperature Sensor Open or Short
Circuit - Test
174
4
Engine Fuel Temperature 1: Voltage Below Normal
Engine Temperature Sensor Open or Short
Circuit - Test
190
8
Engine Speed: Abnormal Frequency, Pulse Width, or
Period
Engine Speed/Timing Sensor Circuit - Test
190
15
Engine Speed: High - least severe (1)
Engine Over speeds
558
2
Accelerator Pedal1Low Idle Switch: Erratic,
Intermittent, or Incorrect
Idle Validation Switch Circuits - Test
593
31
Engine Idle Shutdown has Shutdown Engine
This code indicates that an engine idle
shutdown is about to occur. This code does
not represent a fault. If equipped, the warning
lamp will come on.
594
31
Engine Idle Shutdown Driver Alert Mode
This code indicates that an engine idle shut
down has occurred. This code does not
represent a fault. If equipped, the warning lamp will flash and the shutdown lamp will come on.
623
6
Red Stop Lamp: Current Above Normal
Indicator Lamp Circuit- Test
624
6
Amber Warning Lamp: Current Above Normal
Indicator Lamp Circuit- Test
630
2
Calibration Memory: Erratic, Intermittent, or Incorrect
Injector Data Incorrect- Test
637
11
Engine Timing Sensor: Other Failure Mode
Engine Speed/Timing Sensor Circuit - Test
639
9
J1939 Network #1: Abnormal Update Rate
CAN Data Link Circuit - Test
639
14
J1939 Network #1: Special Instruction
CAN Data Link Circuit - Test
651
5
Engine Injector Cylinder #01: Current Below Normal
Injector Solenoid Circuit - Test
651
6
Engine Injector Cylinder #01: Current Above Normal
Injector Solenoid Circuit - Test
651
20
Engine Injector Cylinder #01: Data Drifted High
Injector Data Incorrect- Test
651
21
Engine Injector Cylinder #01: Data Drifted Low
Injector Data Incorrect- Test
5 - 30
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
652
5
Engine Injector Cylinder #02: Current Below Normal
Injector Solenoid Circuit - Test
652
6
Engine Injector Cylinder #02: Current Above Normal
Injector Solenoid Circuit - Test
652
20
Engine Injector Cylinder #02: Data Drifted High
Injector Data Incorrect- Test
652
21
Engine Injector Cylinder #02: Data Drifted Low
Injector Data Incorrect- Test
653
5
Engine Injector Cylinder #03: Current Below Normal
Injector Solenoid Circuit - Test
653
6
Engine Injector Cylinder #03: Current Above Normal
Injector Solenoid Circuit - Test
653
20
Engine Injector Cylinder #03: Data Drifted High
Injector Data Incorrect- Test
653
21
Engine Injector Cylinder #03: Data Drifted Low
Injector Data Incorrect- Test
654
5
Engine Injector Cylinder #04: Current Below Normal
Injector Solenoid Circuit - Test
654
6
Engine Injector Cylinder #04: Current Above Normal
Injector Solenoid Circuit - Test
654
20
Engine Injector Cylinder #04: Data Drifted High
Injector Data Incorrect- Test
654
21
Engine Injector Cylinder #04: Data Drifted Low
Injector Data Incorrect- Test
676
5
Engine Glow Plug Relay: Current Below Normal
Glow Plug Starting Aid - Test
676
6
Engine Glow Plug Relay: Current Above Normal
Glow Plug Starting Aid - Test
676
19
Engine Glow Plug Relay: Data Error
Glow Plug Starting Aid - Test
677
3
Engine Starter Motor Relay: Voltage Above Normal
Start Relay Circuit - Test
677
5
Engine Starter Motor Relay: Current Below Normal
Start Relay Circuit - Test
677
6
Engine Starter Motor Relay: Current Above Normal
Start Relay Circuit - Test
723
8
Engine Speed Sensor #2: Abnormal Frequency, Pulse Engine Speed/Timing Sensor Circuit - Test
Width, or Period
976
2
PTO Governor State: Erratic, Intermittent, or Incorrect PTO Switch Circuit - Test
1041
2
Start Signal Indicator: Erratic, Intermittent, or Incorrect Start Relay Circuit - Test
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 31
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
1076
2
Engine Fuel Injection Pump Fuel Control Value:
Erratic, Intermittent, or Incorrect
Solenoid Value - Test
1076
5
Engine Fuel Injection Pump Fuel Control Value:
Current Below Normal
Solenoid Value - Test
1076
6
Engine Fuel Injection Pump Fuel Control Value:
Current Above Normal
Solenoid Value - Test
1081
5
Engine Wait to Start Lamp: Current Below Normal
Indicator Lamp Circuit - Test
1081
6
Engine Wait to Start Lamp: Current Above Normal
Indicator Lamp Circuit - Test
1127
16
Engine Turbocharger 1 Boost Pressure: High - moderate Intake Manifold Air Pressure Is High
severity (2)
1127
18
Engine Turbocharger 1 Boost Pressure: Low - moderate Intake Manifold Air Pressure Is Low
severity (2)
1188
5
Engine Turbocharger Wastegate Actuator 1
Position: Current Below Normal
Solenoid Value - Test
1188
6
Engine Turbocharger Wastegate Actuator 1
Position: Current Above Normal
Solenoid Value - Test
1209
3
Engine Exhaust Gas Pressure: Voltage Above Normal
Engine Pressure Sensor Open or Short
Circuit - Test
1209
4
Engine Exhaust Gas Pressure: Voltage Below Normal
Engine Pressure Sensor Open or Short
Circuit - Test
1221
2
Continuously Monitored Systems
Support/Status: Erratic, Intermittent, or Incorrect
ECM Memory - Test
1221
14
Continuously Monitored Systems Support/Status:
Special Instruction
Another diagnostic code has requested
engine speed limitation. The warning lamp
will flash. The engine speed is limited to
1200rpm. Troubleshoot all other diagnostic
codes. No troubleshooting is required for
this diagnostic code.
1239
0
Engine Fuel Leakage 1: High- most severe (3)
Fuel Rail Pressure Problem
1485
7
ECM Main Relay: Not Responding Properly
Electrical Power Supply - Test
1485
14
ECM Main Relay: Special Instruction
Electrical Power Supply - Test
5 - 32
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
2791
5
Engine Exhuast Gas Recirculation (EGR) Value
Control: Current Below Normal
Motorized Value - Test
2791
6
Engine Exhuast Gas Recirculation (EGR) Value
Control: Current Above Normal
Motorized Value - Test
2791
7
Engine Exhuast Gas Recirculation (EGR) Value Control: Motorized Value - Test
Not Responding Properly
2797
6
Engine Injector Group 1: Current Above Normal
Injector Solenoid Circuit - Test
2797
7
Engine Injector Group 1: Not Responding Property
Injector Solenoid Circuit - Test
2798
6
Engine Injector Group 2: Current Above Normal
Injector Solenoid Circuit - Test
2840
12
ECU Instance: Failure
ECM Memory - Test
2840
14
ECU Instance: Special Instruction
Electrical Power Supply - Test
2880
2
Engine Operator Primary Intermediate Speed Select:
Erratic, Intermittent, or Incorrect
Throttle Switch Circuit - Test
2880
3
Engine Operator Primary Intermediate Speed Select:
Voltage Above Normal
Throttle Switch Circuit - Test
2880
4
Engine Operator Primary Intermediate Speed Select:
Voltage Below Normal
Throttle Switch Circuit - Test
2970
2
Accelerator Pedal 2 Low Idle Switch: Erratic, Intermittent, Idle Validation Switch Circuit - Test
or Incorrect
3217
3
After treatment #1 Intake 02: Voltage Above Normal
Oxygen Level - Test
3217
4
After treatment #1 Intake 02: Voltage Below Normal
Oxygen Level - Test
3217
5
After treatment #1 Intake 02: Current Below Normal
Oxygen Level - Test
3217
6
After treatment #1 Intake 02: Current Above Normal
Oxygen Level - Test
3217
12
After treatment #1 Intake 02: Failure
Oxygen Level - Test
3217
13
After treatment #1 Intake 02: Out of Calibration
Oxygen Level - Test
3217
15
After treatment #1 Intake 02: High - least severe (1)
Oxygen Level - Test
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 33
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
3219
15
After treatment #1 Intake Gas Sensor at Temperature:
High - least severe (1)
Oxygen Level - Test
3219
17
After treatment #1 Intake Gas Sensor at Temperature:
Low - least severe (1)
Oxygen Level - Test
3222
3
After treatment #1 Intake Gas Sensor Heater: Voltage
Above Normal
Oxygen Level - Test
3222
4
After treatment #1 Intake Gas Sensor Heater: Voltage
Below Normal
Oxygen Level - Test
3222
5
After treatment #1 Intake Gas Sensor Heater: Current
Below Normal
Oxygen Level - Test
3242
3
Particulate Trap Intake Gas Temperature: Voltage
Above Normal
Engine Temperature Sensor Open or
Short Circuit - Test
3242
4
Particulate Trap Intake Gas Temperature: Voltage
Below Normal
Engine Temperature Sensor Open or
Short Circuit - Test
3251
0
Particulate Trap Differential Pressure: High- most
severe (3)
Diesel Particulate Filter Collects
Excessive Soot
3251
3
Particulate Trap Differential Pressure: Voltage Above
Normal
Engine Pressure Sensor Open or
Short Circuit - Test
3251
4
Particulate Trap Differential Pressure: Voltage Below
Normal
Engine Pressure Sensor Open or
Short Circuit - Test
3251
7
Particulate Trap Differential Pressure: Not Responding
Properly
Diesel Particulate Filter Has
Differential Pressure Problem
3251
10
Particulate Trap Differential Pressure: Abnormal Rate of
Change
Diesel Particulate Filter Has
Differential Pressure Problem
3251
16
Particulate Trap Differential Pressure: High-moderate
severity (2)
Diesel Particulate Filter Collects
Excessive Soot
3251
17
Particulate Trap Differential Pressure: Low - least severe
(1)
Diesel Particulate Filter Has
Differential Pressure Problem
3509
2
Sensor Supply Voltage 1: Erratic, Intermittent, or Incorrect
5 Volt Sensor Supply Circuit - Test
3510
2
Sensor Supply Voltage 2: Erratic, Intermittent, or Incorrect
5 Volt Sensor Supply Circuit - Test
3511
2
Sensor Supply Voltage 3: Erratic, Intermittent, or Incorrect
5 Volt Sensor Supply Circuit - Test
3697
6
Particulate Trap Lamp Command: Current Above Normal
Indicator Lamp Circuit - Test
3698
6
Exhaust System High Temperature Lamp Command:
Current Below Normal
Indicator Lamp Circuit - Test
5 - 34
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
PERKINS 854F-34T ENGINE FAULT CODE
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN
FMI
Description
Refer to Engine Manual
3702
6
Diesel Particulate Filter Active Regeneration Inhibited
Status: Current Above Normal
Indicator Lamp Circuit - Test
4765
3
After treatment #1 Diesel Oxidation Catalyst Intake Gas
Temperature: Voltage Above Normal
Engine Temperature Sensor Open or
Short Circuit - Test
4765
4
After treatment #1 Diesel Oxidation Catalyst Intake Gas
Temperature: Voltage Below Normal
Engine Temperature Sensor Open or
Short Circuit - Test
5055
17
Engine Oil Viscosity: Low - least severe (1)
Oil Contains Fuel
5055
18
Engine Oil Viscosity: Low - moderate severity (2)
Oil Contains Fuel
5099
6
Engine Oil Pressure Low Lamp Data: Current Above Normal Indicator Lamp Circuit - Test
5319
31
After treatment Diesel Particulate Filter Incomplete
Regeneration
Diesel Particulate Filter Active
Regeneration Was Interrupted
5324
7
Engine Glow Plug 1: Not Responding Properly
Glow Plug Starting Aid - Test
5325
7
Engine Glow Plug 2: Not Responding Properly
Glow Plug Starting Aid - Test
5326
7
Engine Glow Plug 3: Not Responding Properly
Glow Plug Starting Aid - Test
5327
7
Engine Glow Plug 4: Not Responding Properly
Glow Plug Starting Aid - Test
5419
5
Engine Throttle Actuator #1: Current Below Normal
Motorized Valve - Test
5419
6
Engine Throttle Actuator #1: Current Above Normal
Motorized Valve - Test
5419
7
Engine Throttle Actuator #1: Not Responding Properly
Motorized Valve - Test
5571
2
High Pressure Common Rail Fuel Pressure Relief
Valve: Erratic, Intermittent, or Incorrect
Fuel Rail Pressure Problem
5571
7
High Pressure Common Rail Fuel Pressure Relief
Valve: Not Responding Properly
Fuel Rail Pressure Problem
5571
10
High Pressure Common Rail Fuel Pressure Relief
Valve: Abnormal Rate of Change
Fuel Rail Pressure Problem
5571
14
High Pressure Common Rail Fuel Pressure Relief
Valve: Special Instruction
Fuel Rail Pressure Problem
5571
16
High Pressure Common Rail Fuel Pressure Relief
Valve: High-moderate severity (2)
Fuel Rail Pressure Problem
5826
16
Emission Control System Operator Inducement Severity
High-moderate severity (2)
Refer to "Operator Inducement
Codes"
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 35
October 2015
Section 5 • Diagnostic Codes
DIAGNOSTIC CODES
Control System Fault Codes
How to Clear Boom Safety
Switch Faults
Note: Beginning with software release 3.0, the
boom envelope switches will latch and faults
must be reset in software or through the use
of the TCON LCD. They will not clear by repowering the machine.
Note: There are two methods to reset the faults,
by using Web GPI or through the menu available
on the TCON LCD.
Using Web GPI
1 Connect the device containing the WEB GPI
software to the TCON with an RS-232 cable.
2 Select the Safety folder, then the Fault Status
screen.
Using the TCON LCD
Note: Take care when using this method to avoid
resetting threshold defaults.
1 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.
2 Press the
switch faults
button until clear all safety
appears.
3Select yes, then press the
4 Press the
button.
button until exit appears.
5Select yes, then press the
button.
Note: This clears all latching faults, not standard
faults.
3 Change any safety switch drop down menus
displaying fault to ok. Press send.
4 Exit Web GPI.
5 - 36
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 5 • Diagnostic Codes
Software
About This Section
This section explains various parts of the machine
software operating system and how to access
some of the adjustable parameters of the control
system.
Web GPI
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
The software system used on the machine is
called Web GPI. It is a software application that is
typically used with a laptop computer. The laptop
can be connected to the ground controls via a tee
harness connector (Genie part number 75094).
The Web GPI software can access all adjustable
parameters for the machine. It can also be used
to aid in troubleshooting and viewing fault code
history.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the Genie S-100 &
Genie S-105 Operator’s Manual and the
Genie S-120 & Genie S-125 Operator’s Manual.
Be sure that all necessary tools and parts are
available and ready for use.
Part No. 102916
S-100 • S-105 • S-120 • S-125
5 - 37
October 2015
Section 5 • Diagnostic Codes
This page intentionally left blank.
5 - 38
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Hydraulic Schematics
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Operator's Manual on your machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-1
October 2015
Section 6 • Schematics
Wire Circuit Legend
Circuit numbering
Circuit suffix
1 Circuit numbers consist of three parts: the
circuit prefix, circuit number and circuit suffix.
The circuit prefix indicates the type of circuit.
The circuit number describes the function
of the circuit. The circuit suffix provides an
abbreviation for the number or may be used to
further define the function of this portion of the
circuit. It also may be used to indicate the final
end of the circuit, i.e., LS or limit sw.
Definition
Suffix
AC Generator
GEN
Alternator Field
AF
AngleANG
Auxiliary Boom Valve
ABV
Auxiliary Forward Valve
AFV
Auxiliary Hydraulic Pump
AH
Auxiliary Platform Valve
APV
Auxiliary Reverse Valve
ARV
Auxiliary Steer/Drive Valve
ASV
Axle Extend Valve
AXE
Axle Oscillate
AXO
Axle Retract Valve
AXR
Axle Front Position
FAP
Axle Rear Position
RAP
BatteryBAT
Boom Extended
BEX
Boom Stowed
BST
BrakeBRK
Bypass Valves
BV
CalibrateCAL
CAN Signal
CAN
CAN Shield
SHD
CATS Module
CAT
Chain Break
CNK
Data High
DTH
Data Low
DTL
Drive Chassis Controller
DCN
Drive Enable
DE
Drive Enable Left
DEL
Drive Enable Right
DER
Electrical Displacement Control
EDC
Envelope Light
ENV
Engine Speed Select
ESP
Engine Status Lamp
ESL
Envelope Lockout
ENL
Extend/retract Lockout
ERL
Filter Restricted
FLR
Filter Switch
FLT
Flashing Beacon
FB
Float Switch
FS
Footswitch Signal
FTS
ForwardFWD
Fuel Pump
FP
Fuel Select (gas/LP)
FL
Fuel Solenoid
FSL
2 The circuit number may be used more than once
in a circuit.
For Example:
C 74 PL – This is the circuit for the lockout
valve #1. C stands for control, 74 is the number of the circuit for
the primary #1 lock out valve.
PL stands for Primary Lockout.
S 62 BST – This is the circuit that communicates to the onboard
computers of the machine that the boom is fully stowed. S
stands for safety, 62 is the number of the circuit for boom
stowed and BST stands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuit number for work
lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is the wire that feeds
the relay coil for the work lamp. All other numbers remain the
same.
Circuit prefix
C........Control
D........Data
E........Engine
G........Gauges
N........Neutral
P........Power
R........Relay Output
S........Safety
V........Valve
6 - 2
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND
Definition
Suffix
Function Enable
FE
Ground Control
TCN
Ground GND
Horn
HRN
High RPM
HS
Hydraulic Generator
HG
IgnitionIGN
Jib Bellcrank Down
JBD
Jib Bellcrank Up
JBU
Jib Sensor
JBS
Jib U/D Control
JUD
Jib Down
JD
Jib Up/Down Flow Control
JFC
Jib Select Valve
JSV
Jib Up
JU
Jib E/R Control
JER
Jib Ext
JBE
Jib Ret
JBR
Jib Rotate Left (CCW)
JRL
Jib Rotate Right (CW)
JRR
Joystick 5 VDC Power
JPW
LampsLPS
Left Front
LF
Left Front Steer Sensor
LFS
Left Rear
LR
Left Rear Steer Sensor
LRS
Limit Switch
LS
Lift Speed Reduction
LSR
Load Sensor
LDS
LockoutLO
Low RPM
LS
Low fuel
LOF
Motor Shift (Speed)
MS
Multi Function Valve
MFV
Platform Control
PCN
Primary Ext/Ret Lockout
PEL
Platform Level Down
PLD
Platform Level Flow Control
PLF
Platform Level Up
PLU
Platform Rotate Flow Control
PRF
Platform Rotate Control
PRC
Platform Rotate Left (CCW)
PRL
Platform Rotate Right (CW)
PRR
PowerPWR
Power to Length Sensor
PSL
Platform Tilt Alarm
PTA
Platform Tilt Sensor
PTS
Part No. 102916
Definition
Suffix
Pressure Comp Enable
PCE
Pressure Sender
PSR
Pressure Switches
PS
Primary Boom Angle Sensor
PBS
Primary Boom Down
PBD
Primary Boom Ext/Ret Lockout Valve
PBL
Primary Boom Extend
PBE
Primary Boom Extend/Retract Flow Control PER
Primary Boom Retract
PBR
Primary Boom Angle Sensor
PBS
Primary Boom Down
PBD
Primary Boom Ext/Ret Lockout Valve
PBL
Primary Boom Extend
PBE
Primary Boom Extend/Retract Flow Control PER
Primary Boom Retract
PBR
Primary Boom Up
PBU
Primary Boom Up/Dwn Flow Control
PUD
Primary Boom Extend/Retract Signal
PLS
Primary Boom Up/Down Signal
PES
Primary Lockout PL
Primary Length Sensor
PSL
Propel Signal
JPL
Program Setup Enable
PSE
Propel Lockout
PLL
Proportional Valve
PRV
Proximity Sensor
PXS
ReceptacleREC
RecoveryRCV
Retract Lockout
RL
ReturnRET
ReverseREV
Right Front
RF
Right Front Steer Sensor
RFS
Right Rear
RR
Right Rear Steer Sensor
RRS
RPMRPM
Secondary Boom Angle Sensor
SBS
Secondary Boom Elevated
SBL
Sec Boom Down
SBD
Sec Boom Extend
SBE
Sec Boom Extend/Retract Flow Control
SER
Sec Boom Retract
SBR
Sec Boom Up
SBU
Sec Boom Up/Dwn Flow Control
SUD
Secondary Boom
SB
This list continues on the next page.
S-100 • S-105 • S-120 • S-125
6-3
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND
Definition
Suffix
Secondary Boom Lockout Valve (Extend)
SLE
Secondary Boom Lockout Valve (Riser Down) SLD
SensorSEN
SpareSP
Speed Sensor
SS
Start Aid (Glow Plug or choke)
SA
StarterSTR
Steer Control Signal
STC
Steering Valve Clockwise
SCW
Steering Valve Counter Clockwise
SCC
Temp Sender
TSR
Temp Switches
TS
TetherTET
Tilt Alarm X axis
TAX
Tilt Alarm Y axis
TAY
Turntable or Ground Control Panel
TCN
Turntable Rotate Flow Control
TRF
Turntable Rotate Right (CW)
TRR
Turntable Rotate Signal
TRS
Turntable Tilt Alarm
TTA
Turntable Tilt Sensor
TTS
Test Switch
TSW
6 - 4
Wire Coloring
1 All cylinder extension colors are solid and all
retract functions are striped black. When using
black wire, the stripe shall be white.
2 All rotations that are LEFT or CW are solid,
RIGHT or CCW are striped and black. When the
wire is black, the stripe is white.
3 All proportional valve wiring is striped.
Wire Color Legend
BLBlue
BL/BKBlue/Black
BL/RDBlue/Red
BL/WH
Blue/White
BKBlack
BK/RDBlack/Red
BK/WH
Black/White
BRBrown
GNGreen
GN/BKGreen/Black
GN/WH
Green/White
RDRed
RD/BKRed/Black
RD/WH
Red/White
OROrange
OR/BLOrange/Blue
OR/BKOrange/Black
OR/RDOrange/Red
WH
White
White/Black
WH/BK
WH/RD
White/Red
YLYellow
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND
Color, Circuit #, and Primary function
RD
1
Primary boom up drive
RD/BK 2
Primary boom down drive
RD/WH 3
Primary boom up/dwn FC
proportional valve drive
WH
4
Turntable rotate left valve drive
WH/BK 5
Turntable rotate right valve drive
WH/RD 6
Turntable rotate FC proportional valve drive
BK
7
Primary boom extend
BK/WH 8
Primary boom retract
BK/RD 9
Primary boom Extend/Retract proportional valve drive
BL
10
Secondary boom up valve drive
BL/BK 11
Secondary boom down valve drive
BL/WH 12
Secondary boom up/dwn FC proportional valve drive
BL/RD 13
Drive enable
OR
14
Platform level up valve
OR/BK 15
Platform level down valve
OR/RD 16
Platform up/dwn FC proportional valve drive
GN
17
Platform rotate left valve driver
GN/BK 18
Platform rotate right valve driver
GN/WH 19
Jib select valve driver circuit
RD
20
12V battery supply
WH
21
12V ignition supply
BK
22
Keyswitch power to platform ESTOP
WH
23
Power to platform
RD
24
Power to warning senders
WH/BK 25
Power to oil pressure sender
WH/RD 26
Power to temp sender
RD
27
Auxiliary power
RD/BK 28
Platform level alarm
RD/WH 29
Drive motor shift (speed)
WH
30
Forward/EDC-A
Part No. 102916
Color, Circuit #, and Primary function
WH/BK 31
Reverse/EDC-B
WH/RD 32
Brake
BK 33Start
BK/WH 34
Start aid (glow plug or choke)
BK/RD 35
High engine speed select
BL
36
Steer clockwise
BL/BK 37
Steer counterclockwise
BL/WH 38
Gas
BL/RD39 LP
OR
40
Limit switch signal stowed
OR/BK 41
RPM signal
OR/RD 42
Boom retracted signal
GN
43
Jib up
GN/BK 44
Jib down
GN/WH 45
AC Generator
WH
46
Drive horn
WH/BK 47
Output power enable
WH/RD 48
Work lamp
WH/BK 49
Motion lamp
BL
50
Auxiliary boom
BL/WH 51
Auxiliary steer
BL/RD 52
Auxiliary platform
WH/BK 53
Boom envelope safety valve cutoff
BK/WH 54
Power to safety interlock switches (engine)
GN/BK 55
Axle oscillation
RD
56
Foot switch/TCON estop power
RD/WH 57
Boom down safety interlock
RD/BK 58
Safety interlock to engine
GN/WH 59
Chain break circuit
GN/WH 60
Axle extend
GN
61
Axle retract
OR
62
Boom stowed (safety)
OR/RD 63
Power to boom envelope safety switch
This list continues on the next page.
S-100 • S-105 • S-120 • S-125
6-5
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND
Color, Circuit #, and Primary function
OR/BK 64
Power for operational switches
BL/WH 65
Low fuel indication
BL
66
Drive enable
BL
67
Secondary boom not stowed
RD
68
Primary boom lowered
(operational)
BL
69
Primary boom #1 extended
BL/WH 70
Primary boom #2 retracted
BL/BK 71
Primary boom #2 extended
GN
72
Secondary boom extend
GN/BK 73
Secondary boom retract
RD
74
Primary #1 Lockout
RD/WH 75
Primary #2 Lockout
BL
76
Pri boom #3 extended
WH
77
Lower angle #1 operational
WH/BK 78
Upper angle #2 operational
BK
79
power from TCON ESTOP
N/A
80
Can 2.0/J1939 Shield
GN
81
Can 2.0/J1939 Low
YL
82
Can 2.0/J1939 High
GN/WH 83
Tilt signal x axis
GN/BK 84
Tilt signal y axis
GN
85
Tilt sensor power
OR
86
Hydraulic filter restricted
RD
87
Platform level safety power
RD/BK 88
Platform level safety output
BR
89
Platform level safety ground
RD/BK 90
Proximity kill
RD/WH 91
Gate Interlock
WH/BK 92
Motor speed (LO/HI)
WH/RD 93
Motor bypass
WH
94
Load sensor
OR
95
Tether ESTOP return
RD
96
Tether power
BK
97
Tether ESTOP power
WH
98
J1708 + (high)
6 - 6
Color, Circuit #, and Primary function
BK
99
J1708 - (low)
WH/RD 100 Outrigger lowered
WH/BK 101 Outrigger raised
OR
102 Pothole protector up
OR/RD 103 Pothole protector down
BK/WH 104 Proprietary data buss –
(i.e. ITT or AP)
BK/RD 105 Proprietary data buss +
(i.e. ITT or AP)
GN 106Spare
RD
107 Alternator field
BL/WH 108 Engine status
GN/WH 109 Sensor pwr
BK
110 Sensor return
OR
111 Steer signal
RD
112 Steer signal to solenoid valve
OR/RD 113 Multi function valve
BK/RD 114 Load moment overweight
RD/BK 115 Load moment underweight
OR
116 Hydraulic oil cooler
RD
117 Flashing beacon
OR
118 Lift speed reduction
BL
119 Hydraulic pressure sensor output
OR
120 Oil cooler fan
GR
121 Axle oscillate LEFT
GN/BK 122 Axle oscillate RIGHT
RD/BK 123 Primary boom angle signal operational
RD/WH 124 Secondary boom angle signal operational
WH/RD 125 Secondary boomlockout
(Ext Enable)
WH/BK 126 Secondary boom lockout
(Riser Down Enable)
GN
127 ECU test switch
OR/RD 128 Low engine speed
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
WIRE CIRCUIT LEGEND
Color, Circuit #, and Primary function
RD/BK 129 Descent alarm
WH/RD 130 Travel alarm
BL
131 Motion alarm
GN
132 Platform load input
GN/WH 133 Platform load alarm
GN/BK 134 Key switch power
BL/WH 135 Fuel pump
RD
136 Power to safety module
RD/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 safety
RD
141 Primary boom angle signal safety
OR
142 Secondary boom angle signal safety
BL/RD 143 Drive enable left
BL/WH 144 Drive enable right
RD/WH 145 Calibrate
BL
146 Jib bellcrank up FC
BL/BK 147 Jib bellcrank down FC
BL/WH 148 Jib bellcrank sensor
GN/WH 149 Jib Up/Down FC
GN/BK 150 Hydraulic generator bypass
GN
151 Hydraulic EDCoutput
BK
152 Injector retard
BK
153 Jib extend
BK/WH 154 Jib retract
OR/RD 155 Pressure comp enable
GN/WH 156 Jib Up/Down
BK/RD 157 Jib Ext/Ret
BL/RD158 Spare
BL/WH 159 Steer joystick signal
WH/RD 160 Propel joystick signal
WH/BK 161 Sec boom joystick signal
OR
162 Joystick 5 VDC power
Part No. 102916
Color, Circuit #, and Primary function
BL/WH 163 Pri extend/retract signal
RD/WH 164 Pri up/down signal
WH/RD 165 TT Rotate signal
OR
166 Boom length signal safety
OR/BK 167 Boom length signal operational
BL/RD 168 Primary boom hydraulic valve lockout
GN
169 Envelope active LED
WH/RD 170 Load sense relay source
WH/BK 171 Load sense relay sink
BL
172 UP/DN flow control ground
BK
173 Ext/Ret flow control ground
WH
174 Key switch power, ground position
WH/BK 175 Load sensor signal operational
GN/WH 176 Secondary extend/retract FC
BL/RD 177 Extend/retract lockout
BK
178 Control module status light
GN
179 Drive power relay
BK
180 Lift power relay
OR
181 48 Volt alternator field (or battery)
RD
182 24 Volt battery
BL
183 Envelope or load sense recovery
WH
184 Program setup enable
WH
185 Encode A
BL
186 Encode B
BL
187 Bootstrap or program enable
GN
188 Safety cross check
BK
189 Data receive
BK/WH 190 Data transmit
WH/RD 191 Multi-Function pressure relief
WH/BK 192 Jib rotate left
WH/RD 193 Jib rotate right
WH/RD 194 Speed select input
OR/RD 195 Electric brake source
YL
196 2.5V Sensor power
BR
N/A Ground or return
S-100 • S-105 • S-120 • S-125
6-7
October 2015
Section 6 • Schematics
Limit Switches
Types of Limit Switches
Limit Switch Numbering
There are two types of limit switches, which are
found in various locations throughout the machine:
mechanical-type operational or safety switches
and magnetic proximity switches. As in aircraft,
which features redundant safety systems, each
mechanical safety switch is backed up with an
independently functioning proximity switch.
LSAX1RO
LSAX2RO
LSAX1EO
LSAX2EO
LSAX1ES
LSAX2ES
LSB6S
LSB7DS
LSB3RS
LSB2RS ••
LSB9AS ••
LSB8AS
LSB4ES
LST1O
LSB1DO
LSB2RO ••
LSB3RO
LSB3EO
LSB4EO ••
LSB13AO
LSB14AO ••
LSB19LO
The mechanical-type operational or safety
switches are used to sense a positive displacement
or movement of the limit switch actuator, or
arm, as the machine moves through its range of
operational functions. Included in this group are
envelope limit switches, which sense the extended
length and angle of the boom, position of the axles
and rotational position of the turntable.
For example, when the 53° operational switch is
activated by achieving a 53° boom angle, the boom
may then be extended beyond 75 feet (22.9 m).
Another example is the drive enable limit switch,
which disables the drive function anytime the boom
is rotated past the rear axles, indicated by the
'square' end of the drive chassis.
In some cases, the engine will be stopped if safety
parameters are exceeded.
Magnetic proximity switches are used to sense
very specific positions of a part of the machine in
relation to the remainder of the machine. Proximity
switches must be correctly aligned for the machine
functions to operate. Proximity switches are found
at the front and rear axle, the turntable and several
locations on the boom.
Numbering Legend
Circuit number
AX Axle
B Boom
T Turntable
LS Limit switch
D
A
L
E
R
Down
Angle
Load moment
Extend
O Operational
Retract
S Safety
Front axle retract proximity
Rear axle retract proximity
Front axle extend proximity
Rear axle extend proximity
Front axle extend safety
Rear axle extend safety
Cable tension safety
Boom 11° angle safety
Boom 3 foot (0.9 m) extend safety
Boom 101 feet (30.8 m) extend
safety
Boom 65° angle safety
Boom 50° angle safety
Boom 76 feet (23.2 m) extend
safety
Drive enable mechanical
Boom 10° mechanical
Boom >100 feet (30.5 m)
retract proximity
(changed to mechanicalS-100/105- sn 160
S-120/125- sn 628)
Boom >3 feet (0.9 m) stowed
mechanical
Boom 75 feet (22.9 m)
extend proximity
(changed to mechanicalS-100/105- sn 160
S-120/125- sn 628)
Boom 100 feet (30.5 m)
extend proximity
(changed to mechanicalS-100/105- sn 160
S-120/125- sn 628)
Boom 53° angle proximity
Boom 68° angle proximity
Load moment mechanical
(•• S-120 and S-125 models only)
LS AX 1 R O
6 - 8
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
LIMIT SWITCHES
120 ft / 36.6 m
110 ft / 33.5 m
LSB9AS
65
LSB14AO
68
100 ft / 30.5 m
LSB2RO
102 ft
(31.1 m)
90 ft / 27.4 m
LSB4EO
100 ft
(30.5 m)
80 ft / 24.4 m
LSB8AS
50
LSB13AO
53
LSB13AO
53
70 ft / 21.3 m
60 ft / 18.3 m
LSB3EO
75 ft
(22.9 m)
LSB4ES
75.5 ft
(23 m)
LSB2RS
101 ft
(30.8 m)
LSB8AS
50
LSB3EO
75 ft
(22.9 m)
LSB4ES
75.5 ft
(23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS
11
LSB1DO
10
LSB1DO
10
20 ft / 6.1 m
LSB7DS
11
10 ft / 3 m
LSB3RS
3.5 ft (1.1 m)
LSB3RO
3 ft (0.9 m)
LSB3RO
3 ft (0.9 m)
0 ft / 0 m
S-100 & S-105 Models
(S-100 shown)
S-120 & S-125 Models
(S-120 shown)
LSAX1RO
LSAX1EO
LSB3RS
3.5 ft (1.1 m)
LSAX2RO
LST10
LSAX2ES LSAX2EO
LSAX1ES
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-9
October 2015
Section 6 • Schematics
Relay Layout
a
b
c
e
d
f
a
b
c
d
e
f
g
h
i
j
k
l
m
n
Fuel solenoid relay (Deutz F4L913 models only).
Oil cooler relay.
Engine cold start relay.
Starter relay.
Horn relay.
Flashing beacon relay.
CR17 relay (K7) - powers C35RPMcircuit
(Hi/low solenoid).
CR16 relay (K8) - powers C34SA circuit
(Engine cold start).
CR12 relay (K4) - powers primary valves 1 and
2, ignition, glow plug, starter relay, generator,and the boom retract, multifunction andplatform rotate valve coils.
CR14 relay (K2) - powers P7R or S56PRV circuit including the auxiliary valve, boom extend/retract and turntable rotate valve coils.
CR10 relay (K6) - powers C21IGN and C107AF
circuits (Fuel on/off solenoid and alternator field).
CR15 relay (K1) - powers P22R or C03PBF circuit (Boom up/down valve coil).
CR13 relay (K5) - powers P_7 and throttle relay.
CR11 relay (K3) - powers P-6R2 or P54ENG circuits.
g
h
i
j
k
l
n
6 - 10
m
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Drive Chassis Controller Pin Legend
DCON
DRIVE CHASSIS
CONTROLLER
J2
1 = VLVRET - BR
2 = V61AXRT - GR
3 = V60AXEX - GN/WH
4 = V29MS - RD/WH
5 = (UNUSED)
6 = (UNUSED)
7 = (UNUSED)
8 = V36RRS - BL
9 = V37RRS - BL/BK
10 = C111RRS - OR
11 = C111LRS - OR
12 = C111RFS - OR
13 = C111LFS - OR
14 = VLVRET2 - BR
15 = V32BRK - WH/RD
16 = V36LRS - BL
17 = V37LRS - BL/BK
18 = V36RFS - BL
19 = P110RT - BK
20 = P109ANG - GN/
WH
21 = V37RFS - BL/BK
22 = V36LFS - BL
23 = V37LFS - BL/BK
Part No. 102916
DCON
DRIVE CHASSIS
CONTROLLER
J1
1 = GND-DCON - BR
2 = P21DCON - WH
3 = P53LS - GR
4 = (UNUSED)
5 = S56PRV - RD
6 = C61AXRT - GR
7 = (UNUSED)
8 = P61LS - GR
9 = C61LS - GR
10 = (UNUSED)
11 = (UNUSED)
12 = (UNUSED)
13 = (UNUSED)
14 = (UNUSED)
15 = C61LS(A) - GR
16 = (UNUSED)
17 = D81CAN(-) - GR
18 = D82CAN(+) - YL
19 = (UNUSED)
20 = (UNUSED)
21 = (UNUSED)
22 = (UNUSED)
23 = P61LS(A) - GN
J1
BLACK
23 PIN
CONNECTOR
J2
1
8
16
23
WHITE
23 PIN
CONNECTOR
PIN NUMBERING FOR
23 PIN
CONNECTORS
S-100 • S-105 • S-120 • S-125
6 - 11
October 2015
Section 6 • Schematics
Platform Controller Pin Legend
J1
PCON
PCON
PLATFORM
PLATFORM
CONTROLLER
CONTROLLER
J2
1 = VLVRET - BR
2 = (UNUSED)
3 = C17PRL - GR
4 = C18PRR - GR/BK
5 = C43JU - GR
6 = C44JD - GR/BK
7 = C14PLU - OR
8 = C15PLD - OR/BK
9 = (UNUSED)
10 = R90PXS - RD/BK
11 = C90PXS - RD/BK
12 = RET94LDS - GR
13 = C94LDS - WH
14 = R94LDS - BK
15 = C88PTS - RD/BK
16 = R56PTS - RD
17 = C56PTS - RD
18 = (UNUSED)
19 = PLATRET - BR
20 = C84TAY - GR/BK
21 = P85PTS - GR
22 = PTSRET - BR
23 = P87PTS - RD
6 - 12
BLACK
23 PIN
CONNECTOR
J1
1 = GNDPCON - BR
2 = P52PCON - BL/RD
3 = (UNUSED)
4 = S56PRV - RD/WH
5 = (UNUSED)
6 = (UNUSED)
7 = P56PRV - RD
8 = (UNUSED)
9 = (UNUSED)
10 = (UNUSED)
11 = (UNUSED)
12 = (UNUSED)
13 = (UNUSED)
14 = (UNUSED)
15 = C47OUT - WH/BK
16 = C46HN - WH
17 = D81CAN(+) - YL
18 = D82CAN(-) - GR
19 = (UNUSED)
20 = (UNUSED)
21 = (UNUSED)
22 = (UNUSED)
23 = P23PCON - BK
J2
WHITE
23 PIN
CONNECTOR
1
8
16
23
PIN NUMBERING FOR
23 PIN
CONNECTORS
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Turntable Controller Pin Legend
1
24
J4
1
WHITE
35 PIN
CONNECTOR
8
RETRACT BOOM
35
23
MACHINE
NOT LEVEL
PLATFORM
NOT LEVEL
12
16
EMERGENCY STOP
RAISE BOOM
EXTEND AXLE
61227
A
8
23
WHITE
23 PIN
CONNECTOR
PIN NUMBERING FOR
23 PIN
CONNECTORS
1
16
J3
AUXILIARY POWER
J5
WIRE LOOM
HIGH SPEED
FUNCTION ENABLE
24
1
24
1
LOW SPEED
FUNCTION ENABLE
12
J2
35
BLACK
35 PIN
CONNECTOR
ALARM
SERVICE
BYPASS
RECOVERY
8
23
Part No. 102916
1
J1
1 = GNDPCON - BR
2 = P52PCON - WH
3 = C46HN - WH
4 = C47OUT - WH/BK
5 = P23PCON - BK
6 = S56PRV - RD/WH
7 = P56PRV - RD
8 = R48LP - WH/RD
9 = R117FB - RD
10 = (UNUSED)
11 = (UNUSED)
12 = (UNUSED)
13 = (UNUSED)
14 = (UNUSED)
15 = P97TET - BK
16 = (UNUSED)
17 = D81CAN(-) - GR
18 = D82CAN(+) - YL
19 = (UNUSED)
20 = (UNUSED)
21 = (UNUSED)
22 = (UNUSED)
23 = P95TET - OR
16
CONTROLLER
35
TCON
TURNTABLE
RUN
BLACK
23 PIN
CONNECTOR
TCON
12
J1
PIN NUMBERING FOR
35 PIN
CONNECTORS
TCON
TCON
TCON
TURNTABLE
TURNTABLE
TURNTABLE
TURNTABLE
CONTROLLER
CONTROLLER
CONTROLLER
CONTROLLER
J2
J2
J3
(S-120 & S-125 MODELS)
1 = GNDDCON - BR
2 = P21DCON - RD
3 = P53LS - WH/BK
4 = P54ENG - BK/WH
5 = P56PRV - RD
6 = P57PBD - RD/WH
7 = P58LS - RD/BK
8 = S59CNBK - GR/WH
9 = C60AXEX - GR/WH
10 = C61AXRT - GR
11 = S62BSTO - OR
12 = P63LS - OR/RD
13 = C64LS - OR/BL
14 = C65LOFL - BL/WH
15 = C66DREN - BL
16 = (UNUSED)
17 = C68PBD - RD
18 = C89PBE - BK
19 = C70PBE - BL/WH
20 = C71PBE - BL/BK
21 = (UNUSED)
22 = (UNUSED)
23 = V74PRLO - RD
24 = V75PRLO - RD/WH
25 = SNSR GND - BR
26 = (UNUSED)
27 = G119SR - BL
28 = C76PBE - BL
29 = C77AS - WH
30 = C78PS - WH/BK
31 = (UNUSED)
32 = (UNUSED)
33 = (UNUSED)
34 = (UNUSED)
35 = VLVRET1 - BR
(S-100 & S-105 MODELS)
1 = GNDDCON - BR
2 = P21DCON - RD
3 = P53LS - WH/BK
4 = P54ENG - BK/WH
5 = P56PRV - RD
6 = P57PBD - RD/WH
7 = P58LS - RD/BK
8 = S59CNBK - GR/WH
9 = C60AXEX - GR/WH
10 = C61AXRT - GR
11 = S62BSTO - OR
12 = P63LS - OR/RD
13 = C64LS - OR/BL
14 = C65LOFL - BL/WH
15 = C66DREN - BL
16 = (UNUSED)
17 = C68PBD - RD
18 = (UNUSED)
19 = C70PBE - BL/WH
20 = C71PBE - BL/BK
21 = (UNUSED)
22 = (UNUSED)
23 = V74PRLO - RD
24 = V75PRLO - RD/WH
25 = SNSR GND - BR
26 = (UNUSED)
27 = G119SR - BL
28 = (UNUSED)
29 = C77AS - WH
30 = (UNUSED)
31 = (UNUSED)
32 = (UNUSED)
33 = (UNUSED)
34 = (UNUSED)
35 = VLVRET1 - BR
1 = (UNUSED)
2 = R35RPM - BK/RD
3 = C21IGN - WH
4 = C34SA - BK/WH
5 = V30FWD - WH
6 = V31REV - WH/BK
7 = C46HRN - WH
8 = (UNUSED)
9 = C33STR - BK
10 = C30EDC - WH
11 = C31EDC - WH/BK
12 = C25PSR - WH/BK
13 = C26TSR - WH/RD
14 = RET85TTSR - BR
15 = P85TTSR - GN
16 = VLVRET2 - BR
17 = (UNUSED)
18 = C41RPM - OR/BK
19 = C107AF - RD
20 = C83TAX - GR/WH
21 = C84TAY - GR/BK
22 = C45GEN - GR/WH
23 = VLVRET3 - BR
TCON
TURNTABLE
CONTROLLER
J5
1 = BATVLV - RD
2 = BATGND - BR
3 = BATGND - BR
4 = BATECU - RD
S-100 • S-105 • S-120 • S-125
J4
1 = VLVRET4 - BR
2 = C03PBF - RD/WH
3 = C09PERF - BK/RD
4 = C06TRF - WH/RD
5 = (UNUSED)
6 = (UNUSED)
7 = C01PBU - RD
8 = C02PBD - RD/BK
9 = C07PBE - BK
10 = C08PBR - BK/WH
11 = (UNUSED)
12 = (UNUSED)
13 = R49LP - WH/BK
14 = VLVRET5 - BR
15 = S2PLD2 - GN/BK
16 = S7PLE2 - GR/WH
17 = S7PLE1 - BL/BK
18 = S2PLD1 - BL.RD
19 = (UNUSED)
20 = (UNUSED)
21 = (UNUSED)
22 = (UNUSED)
23 = C113MFV - OR/RD
24 = (UNUSED)
25 = C0RTRL - WH
26 = C05TRR - WH/BK
27 = VLVRET7 - BR
28 = (UNUSED)
29 = (UNUSED)
30 = VLVRET6 - BR
31 = (UNUSED)
32 = C27AUX - RD
33 = (UNUSED)
34 = (UNUSED)
35 = (UNUSED)
6 - 13
October 2015
Section 6 • Schematics
Engine Relay and Fuse Panel Legend - Deutz TD2011 and
Perkins 1104D Models
Deutz TD2011L04i and Perkins 1104D-44T Models
1
CR77A
4
CR28
5
CR77B
CR41
7
F20
8
F23
9
10
F22
F7
CR17
6
13
CR5
11
12
15
16
CR1
CR15
14
Number
Component
Description
1
CR77A
PCE#1
2
CR28
Engine / Fule Relay
3
CR17
Hydraulic Oil Cooler Fan Relay
4
CR77B
PCE#2
5
CR41
Flashing Beacon Relay
6
CR5
Horn Relay
7
F20
Fuse, 20A, RPM Solenoid
8
F23
Fuse, 30A, Eng / Start / Fuel
9
F22
Fuse, 60A, Glow Plug
10
F7
Fuse, 20A, Hydraulic Oil Cooler / Horn
11
B3BAT
Fused Power from B1
12
B1BAT
Power from Battery
13
R21PIGN
Ignition
14
02PGND
Ground
15
CR1
Start Relay
16
CR15
Glow Plug Relay
6 - 14
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models
Deutz TD2.9 Models
1
2
3
4
CR39
CR77A
CR2
CR17
5
6
7
9
F27
10
F23
11
12
F22
F7
8
CR77B
CR41
17
30
CR5
16
Number
Component
1
CR39
Engine Shutdown
2
CR77A
PCE # 1
3
CR2
Engine Alt. Relay
4
CR17
Hydraulic Oil Cooler / Fan Relay
5
CR28
Fuel Pump
6
CR77B
PCE#2
7
CR41
Flashing Beacon Relay
8
CR5
Horn Relay
9
F27
Fuse, 20A, RPM Solenoid
10
F23
Fuse, 30A, Eng / Start / Fuel
85
87
CR15
Description
11
F22
Fuse, 60A, Glow Plug
12
F7
Fuse, 20A, Hydraulic Oil Cooler / Horn
13
B3BAT
Fused Power from B1
14
B1BAT
Power from Battery
15
R21PIGN
Ignition
16
02PGND
17
CR17
Ground
Glow Plug Relay
Part No. 102916
14
15
86
CR28
13
S-100 • S-105 • S-120 • S-125
6 - 15
October 2015
Section 6 • Schematics
Engine Relay and Fuse Panel Legend - Perkins 854F Models
Perkins 854F-34T Models
86
1
CR77A
30
87
2
3
CR2
CR17
85
4
CR77B
2
4
5
FX1
FX2
1
3
7
7
9
F27
10
F23
11
12
F22
F7
8
18
30
CR5
16
Number
Component
1
CR77A
PCE # 1
2
CR2
Engine Alt
3
CR17
Hydraulic Oil Cooler Fan Relay
4
CR77B
PCE#2
5
FX1
Fuse, 30A, ECU Power
85
87
CR81
Description
6
FX2
Fuse, 20A, Key Switch Power
7
CR41
Flashing Beacon Relay
8
CR5
Horn Relay
9
F27
Fuse, 20A, RPM Solenoid
10
F23
Fuse, 30A, Eng / Start / Fuel
11
F22
Fuse, 60A, Glow Plug
12
F7
Fuse, 20A, Hydraulic Oil Cooler / Horn
13
B3BAT
Fused Power from B1
14
B1BAT
Power from Battery
15
R21PIGN
Ignition
16
02PGND
17
CR1
Ground
Engine Starter
18
CR81
ECU Power
6 - 16
14
15
86
CR41
13
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Telematics Connector Pin Legend
Genie installed Telematics connector is wried with an Active High digital input.
Connector Pin Numbering
Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector.
Pin
Circuit Type
Circuit Properties
Genie Machine Function(s)
Telematics Use Case
1
System Power
12VDC
5 Amp Max. allowed
draw
Battery Positive - constant power
Supply power to device
2
System Ground 0VDC
Battery Negative
Device Ground
3
Digital Output 1 12VDC
Engine Run Hour Meter
12V = engine run, 0V = engine off
Monitor Engine Hours
4
Digital Output 2 12VDC
Key Switch Activation
Monitor mechine utilization
12V = key switch run, 0V = key switch off
5
Digital Output 3 12VDC
Foot Switch
12V = active, 0V = inactive
Monitor mechine utilization
6
Digital Input 1
12VDC
Remote Disable Engine Start
Remotely Prevent Engine Start
7*
Databus H
CAN HIGH
Genie Databus
J1939 Engine Messages, Receive
Proprietary Genie Telematics Message
8*
Databus L
CAN LOW
Genie Databus
J1939 Engine Messages, Receive
Proprietary Genie Telematics Message
*Tier IV engine models only, J1939 engine message available.
*Genie proprietary databus support.
Wireless Certifications
Telematic device(s) should comply with specific wireless carrier certifications where applicable and
comply with the following:
North America
PTCRB, FCC/IC
Europe
CE, R&TTE
Part No. 102916
S-100 • S-105 • S-120 • S-125
6 - 17
October 2015
Section 6 • Schematics
Electrical Symbols Legend
FS1
CB1
BLK
WHT
Quick disconnect
terminal
OPS1
N.C.
PR1
15A
BLK
Foot switch
Circuit breaker
with amperage
Power relay
Oil pressure switch
normally closed
P1
H1
T-circuits
connect
Emergency Stop
button normally
closed
Horn or alarm
Sending unit
Toggle switch
Control relay contact
normally open
G1
Circuits crossing
no connection
Gauge
C
FAN
Hydraulic oil
cooling fan
Fuel or RPM
solenoid
OTS2
N.O.
Aux
Pump
Oil temperature
switch
normally open
HM
Diode
B
HOLD
Flashing beacon
A
CR4
N.O.
PULL IN
FB
Connection
no terminal
Auxiliary pump
Coil
Hour meter
+
CTS1
N.O.
KS2
RUN
SERVICE BYPASS/
RECOVERY
KEY SWITCH
SERVICE BYPASS
A-A
1
2
RECOVERY
L3
A-B
Coolant temperature
switch
normally open
-
Battery
3
4
3
4
3
4
1
2
1
2
B-B
LED
Tilt sensor
C-B
2
30
C-A
87a
85
A
B C
BL
RD
BK
B-A
25A
Fuse
with amperage
1
86
F1
5
87
4
Relay
Service bypass/
recovery
key switch
Starting aid:
glow plug or
flame ignitor
Steer sensor
OFF
KS1
STARTER
PCON
1
A-A
2
D1
ALTERNATOR
Starter motor
Chassis ground
Power relay
A-B
3
4
1
B-A
2
3
4
EXCT
BAT
BAT
-
+
AUX MAIN
MAIN
KEYSWITCH
TCON
B-B
STA.
LS3
REGULATOR
N.O.H.C
Battery separator
6 - 18
N.C.H.O
Limit switch
IND.
ALTERNATOR
S-100 • S-105 • S-120 • S-125
Main key switch
Current limiting
device
Part No. 102916
October 2015
Section 6 • Schematics
Hydraulic Symbols Legend
25 psi
(1.7 bar)
Accumulator
Filter with
bypass valve
relief setting
Differential
sensing valve
.035"
(0.89 mm)
Directional valve
pilot operated
2 position, 2 way
Orifice with size
Shut off valve
Solenoid operated
proportional valve
Pump
fixed displacement
Solenoid operated 3 position,
4 way, directional valve
Check valve
200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
bi-directional,
variable displacement
Relief valve
with pressure setting
Priority
flow regulator valve
o
Hydraulic oil cooler
Solenoid operated 2 position,
3 way, directional valve
Motor
bi-directional
Directional valve
(mechanically activated)
3000 psi
(206.8 bar)
3:1
Brake
Motor
2-speed,
bi-directional
Pilot operated 3 position,
3 way, shuttle valve
Counterbalance valve
with pressure and pilot ratio
E
Pump prime mover
(engine or motor)
50%
50%
Flow divider/combiner valve
with pressure balancing orifice
and flow percentages
2 position, 2 way
solenoid valve
Double acting
cylinder
Part No. 102916
S-100 • S-105 • S-120 • S-125
6 - 19
October 2015
Section 6 • Schematics
This page intentionally left blank.
6 - 20
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Safety Circuit Schematic
CB1
D23
VR1
PWR
STAT
IN 1 OUT 1
IN 2 OUT 2
P_15
40A
(K2)
30
87a
CR11
86
87
30
(K3)
85
87a
CR12
86
87
(K4)
85
30
87a
86
87
D14
P_9A
CR17
5A
P_6R1
P_6R2
(K8)
P_9A
P_7R
TCON/J2/4
TCON/J2/5
TCON/J2/3
TCON/J2/6
87a
30
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
TCON/J3/4
87
TCON/J4/8
TO TURNTABLE FLOW CONTROL
ROTATE VALVE
TO BOOM DOWN VALVE
85
86
CHOKE
NFET
(K7)
87a
P_7R
LSB9AS
65 DEGREES
DCON/J1/3
P_16
LSB2RS
101' (30.8 m)
LSB7DS
88
88
NFET
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
NFET
PWR
STAT
OUT 1 IN 1
OUT 2 IN 2
GND
BOOM DOWN
TO DRIVE LP RELAY
20 K
R3
SJ1
TO STARTER RELAY
LSAX1ES
AXLE EXTEND
SJ2
TCON/J4/35
TCON/J3/9
NFET
PWR
STAT
OUT 1 IN 1
OUT 2 IN 2
GND
D16
TO ROTATE CCW VALVE
LSB4ES
80' (24.4 m)
NFET
LSAX2ES
AXLE EXTEND
PWR
STAT
OUT 1 IN 1
OUT 2 IN 2
P_14
GND
P_11
LSB8AS
50 DEGREES
TCON/J4/10
TO ROTATE CW VALVE
TCON/J4/25
TCON/J4/26
TCON/J4/3
TCON/J3/5
TO FORWARD VALVE
TCON/J3/6
TO REVERSE VALVE
NFET
30
TCON/J3/2
87
TO HI/LO SOLENOID
85
86
HI/LO
TCON/J2/23
TO PRIMARY 1 LOCKOUT VALVE
TCON/J2/24
TO PRIMARY 2 LOCKOUT VALVE
TCON/J4/23
TO MULTIFUNCTION VALVE
NFET
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
NFET
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
88
88
TO ROTATE CCW VALVE
P57PBD
P57PBD
C60AXEX
S62BSTO
P53LS
P58LS
NFET
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
TO AUXILIARY RELAY
NFET
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
CR17
P54ENG
TCON/J4/32
NFET
P53LS
P53LS
P53LS
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
P57PBD
P57PBD
TO
TURNTABLE FLOW CONTROL
ROTATE VALVE
NFET
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
85
CR16
P_7R
TCON/J2/23
CR10
(K6)
C60AXEX
S62BSTO
P58LS
TCON/J2/7
C60AXEX
TCON/J2/9
S62BSTO
P_9B
D13
NFET
TCON/J2/11
P63LS
(P_14)
LSB3RS
BOOM RETRACT
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
P_11
D17
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
87a
30
TCON/J3/3
TO FUEL SOLENOID
TCON/J4/7
TO BOOM UP VALVE
TCON/J4/9
TO BOOM EXTEND VAVLE
87
86
85
NFET
P63LS
TCON/J2/12
88
(P_18)
LSB6S
CABLE TENSION
P_10
PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2
NFET
S59CNBK
TCON/J2/8
C61AXRT
TCON/J2/10
MONITORED BY ECU
P53LS
DCON/J1/3
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-21
Section 6 • Schematics
October 2015
Safety Circuit Schematic
6-21
6-22
October 2015
Section 6 • Schematics
Engine Options- Perkins and Cummins
S-100/105 to serial number 218)
S-120/125 to serial number 932)
6-23
6-24
STARTER
AUX.
PUMP
S-100 • S-105 • S-120 • S-125
REGULATOR
IND.
Part No. 102916
STA.
C26TSR-WT/RD
RET85TTSR-BR
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
TURNTABLE TILT
SENSOR
P85TTSR-GR
OIL TEMP SENDER
70 A FUSE
C34SA-BK/WH
+
+
-
C25PSR-WT/BK
C21IGN-WH
R34SA-BK/WH
VLVRET2-BR
FLAMMSTART
RELAY
BATGND(A) - BK
C83TAX-GN/WH
OIL PRESSURE
3
V31REV-WH/BK
RD-HOLD
C84TAY-GN/WH
FUEL SOLENOID
RELAY
2
BAT GND-BR
SERVICE
HORN
1
86
BAT GND-BR
BAT.
-
2
FLAMMSTART
IGNITOR
EXCT.
REV VLV B
SOLENOID
ALTERNATOR
V30FWD-WH
87a 87 85
4
5
WH-PULL IN
P114BAT-RD
FWD VLV A
SOLENOID
COM
HORN
RELAY
BK
S-500
2
86
RD
1
30
HI/LO SPEED
SOLENOID
BAT.
+
C41RPM-OR/BK
C107AF-RD
-BAT
WH
+AUX
HOLD
+BAT
PULL IN
87a 87 85
4
5
STARTER
WAS 10A BEFORE:
RELAY
S100/105- SN 159
S120/125- SN 619
VLVRET2-BR
TROMBETTA
MOM N.O.
TIME DELAY
VLVRET2-BR
86
P46HRN(A)-WH
2
30
RD-HOLD
P1-01 SYS_BAT_PWR
P1-02 SYS_BAT_GND
P1-03 AUX/START_BAT_GND
P1-04 AUX/START_BAT_PWR
BATVLV-RD
BATGND-BR
BATGND-BR
BATECU-RD
IGNITION/FUEL
STARTER_RELAY
FWD
REV
OIL_PRESSURE
P1-09
P1-11
P1-12
C30EDC-WH
C31EDC-WH/BK
C25PSR-WH/BK
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
VALVE_RTN2
P1-15
P1-16
P85TTSR-GR
VLVRET2-BR
VALVE_RTN3
P1-21
P1-22
P1-23
C84TAY-GR/BK
C45GEN-GR/WH
VLVRET3-BR
J31-TILT SNSR
P31-ENG HARN
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC_GENERATOR
P1-20
C83TAX-GR/WH
ALTENATOR_RPM
ALT_FIELD_WIRE
P1-18
P1-19
C41RPM-OR/BK
C107AF-RD
P1-17
OIL/WATER_TEMP
P1-13
P1-14
C26TSR-WH/RD
RET85TTSR-GR
C33STR-BK
P1-10
SERVICE_HORN
P1-06
P1-07
V31REV-WH/BK
C46HRN-WH
P1-08
P1-05
V30FWD-WH
CHOKE/GLOW PLUG
P1-03
P1-04
C21IGN-WH
C34SA-BK/WH
VALVE RTN1
THROTTLE
P1-01
P1-02
VLVRET1-BR
R35RPM-BK/RD
ENGINE HARN
WH-PULL IN
CB
25A
J3 WHITE 23 PIN
BAT GND-BR
1
C27AUX-RD
15 A FUSE
TO J4-32
WHITE 35 PIN
PR1
J29 PWR HARN
P29 ENG HARN
VLVRET6-BR
P46HRN-WH
AUX MAIN
POWER HARN
BAT GND-BR
P33STR-BK
BAT CBL(A)-RD
P114BAT-RD
J5 BLACK 4 PIN
TO J4-30
WHITE 35 PIN
ENGINE BLOCK
START BAT
+
6-24
+
MAIN (SYS)
BAT
Section 6 • Schematics
October 2015
Engine Option- Perkins and Cummins
S-100/105 to serial number 218)
S-120/125 to serial number 932)
BAT GND-BR
J32-ENG HARN
C45GEN-GR/WH 1
2
3
1
PERKINS 1004-42 ENGINE
CUMMINS 4B3.9L ENGINE
BAT CBL(A)-RD
1
30
85 87 87a
5
4
-
STARTER
AUX.
PUMP
REGULATOR
IND.
STA.
Part No. 102916
FUEL
PUMP
S-100 • S-105 • S-120 • S-125
BAT GND-BR
C26TSR-WT/RD
C25PSR-WT/BK
86
TURNTABLE TILT
SENSOR
RET85TTSR-BR
C21IGN-WH
C34SA-BK/WH
P85TTSR-GN
C21IGN-WH
2
COLD START
ADVANCE
GLOW
PLUG
RELAY
BK-COM
R34SA-RD
VLVRET2-BR
C30EDC-WH
WH-PULL
RD-HOLD
+
+
-
OIL TEMP SENDER
3
C31EDC-WH/BK
C83TAX-GN/WH
OIL PRESSURE
2
BK-COM
C84TAY-GN/BK
FUEL SHUTDOWN
1
VLVRET2-BR
RD-HOLD
P114BAT-RD
GLOW PLUGS
BAT.
-
WH-PULL IN
J32-ENG HARN
C45GEN-GN/WH 1
2
BAT GND-BR
FWD VLV A
SOLENOID
EXCT.
BK
87a 87 85
4
5
HORN
RELAY
REV VLV B
SOLENOID
ALTERNATOR
2
86
HI/LO SPEED
SOLENOID
BAT.
+
1
30
RD
87a 87 85
4
5
WH
2
86
HOLD
S-500
PULL IN
+BAT
R46HRN-WH
+AUX
-BAT
VLVRET2-BR
70 A FUSE
C107AF-RD
P1-01
P1-02
P1-03
P1-04
BATVLV-RD
BATGND-BR
BATGND-BR
BATECU-RD
SYS_BAT_PWR
V31REV-WH/BK
C46HRN-WH
OIL/WATER_TEMP
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
VALVE_RTN2
P1-15
P1-16
P85TTSR-GN
VLVRET2-BR
ALTENATOR_RPM
ALT_FIELD_WIRE
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC_GENERATOR
VALVE_RTN3
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
C84TAY-GN/BK
C45GEN-GN/WH
VLVRET3-BR
J31-TILT SNSR
P31-ENG HARN
C41RPM-OR/BK
C107AF-RD
C83TAX-GN/WH
P1-17
OIL_PRESSURE
P1-13
P1-14
C25PSR-WH/BK
P1-12
P1-11
C30EDC-WH
C26TSR-WH/RD
P1-10
C31EDC-WH/BK
RET85TTSR-BR
C31EDC-WH/BK
C30EDC-WH
P1-09
C33STR-BK
STARTER_RELAY
FWD
REV
SERVICE_HORN
P1-06
P1-07
V30FWD-WH
P1-08
CHOKE/GLOW PLUG
P1-04
P1-05
C34SA-BK/WH
THROTTLE
IGNITION/FUEL
P1-02
P1-03
C21IGN-WH
AUX/START_BAT_PWR
AUX/START_BAT_GND
SYS_BAT_GND
R35RPM-BK/RD
P1-01
ENGINE HARN
C41RPM-OR/BK
CB
25A
J3 WHITE 23 PIN
BAT GND-BR
C27AUX-RD
1
30
TO J4-32
WHITE 35 PIN
PR1
STARTER
RELAY
VLVRET6-BR
AUXMAIN
POWER HARN
BAT GND-BR
P114BAT-RD
J5 BLACK 4 PIN
TO J4-30
WHITE 35
ENGINE BLOCK
START BAT
+
+
MAIN (SYS)
BAT
October 2015
Section 6 • Schematics
Engine Option- Perkins
S-100/105 from serial number 219 to 247)
S-120/125 from serial number 933 to 984)
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
3
SEE GENERATOR OPTIONS PAGE
PERKINS 1104C-44 ENGINE
15 A FUSE
P46HRN-WH
P34SA-RD
TROMBETTA
TIME DELAY
MOM N.O.
1
30
85 87 87a
5
4
SERVICE
HORN
6-25
Section 6 • Schematics
October 2015
Engine Option- Perkins
S-100/105 from serial number 219 to 247)
S-120/125 from serial number 933 to 984)
6-25
6-26
October 2015
Section 6 • Schematics
Engine Options- Perkins
S-100/105 (from serial number 248)
S-120/125 (from serial number 985)
6-27
6-28
-
STARTER
AUX.
PUMP
REGULATOR
S-100 • S-105 • S-120 • S-125
IND.
Part No. 102916
STA.
FUEL
PUMP
OIL TEMP SENDER
BAT GND-BR
C26TSR-WT/RD
85 87 87a
5
4
86
C25PSR-WT/BK
C116HYD-OR
TURNTABLE TILT
SENSOR
RET85TTSR-BR
OIL PRESSURE
2
P116HYD-OR
P85TTSR-GN
C21IGN-WH
1
30
+
+
-
C21IGN-WH
86
R116HYD-OR
2
HYD COOLER
RELAY
CB7
COLD START
ADVANCE
15A
C34SA-BK/WH
WH-PULL
RD-HOLD
R34SA-RD
VLVRET2-BR
GLOW
PLUG
RELAY
C83TAX-GN/WH
FUEL SHUTDOWN
3
C30EDC-WH
C84TAY-GN/BK
BAT GND-BR
2
C31EDC-WH/BK
TROMBETTA
TIME DELAY
MOM N.O.
BAT GND-BR
SERVICE
HORN
1
BK-COM
P114BAT-RD
GLOW PLUGS
BAT.
WH-PULL IN
J32-ENG HARN
C45GEN-GN/WH 1
2
BAT GND-BR
FWD VLV A
SOLENOID
EXCT.
VLVRET2-BR
87a 87 85
4
5
HORN
RELAY
REV VLV B
SOLENOID
ALTERNATOR
2
86
HI/LO SPEED
SOLENOID
BAT.
+
1
30
BK
CB7 ADDED
S100- S/N 710
S125- S/N 2589
PULL IN
87a 87 85
4
5
WH
S-613
HOLD
2
86
RD-HOLD
BK-COM
RD
+BAT
R46HRN-WH
+AUX
-BAT
VLVRET2-BR
70 A FUSE
C41RPM-OR/BK
P1-01
P1-02
P1-03
P1-04
BATVLV-RD
BATGND-BR
BATGND-BR
BATECU-RD
SYS_BAT_PWR
SERVICE_HORN
P1-07
V31REV-WH/BK
C46HRN-WH
OIL/WATER_TEMP
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
VALVE_RTN2
P1-15
P1-16
P85TTSR-GN
VLVRET2-BR
J31-TILT SNSR
P31-ENG HARN
TT_TILT_Y_AXIS
AC_GENERATOR
VALVE_RTN3
P1-21
P1-22
P1-23
C84TAY-GN/BK
P1-20
C83TAX-GN/WH
C45GEN-GN/WH
ALT_FIELD_WIRE
TT_TILT_X_AXIS
P1-19
C107AF-RD
VLVRET3-BR
ALTENATOR_RPM
P1-18
C41RPM-OR/BK
P1-17
OIL_PRESSURE
P1-13
P1-14
C26TSR-WH/RD
RET85TTSR-BR
C31EDC-WH/BK
C30EDC-WH
P1-11
C25PSR-WH/BK
P1-12
C30EDC-WH
P1-09
P1-10
C33STR-BK
C31EDC-WH/BK
STARTER_RELAY
FWD
REV
P1-06
V30FWD-WH
P1-08
CHOKE/GLOW PLUG
P1-04
P1-05
C34SA-BK/WH
THROTTLE
IGNITION/FUEL
P1-02
P1-03
C21IGN-WH
AUX/START_BAT_PWR
AUX/START_BAT_GND
SYS_BAT_GND
R35RPM-BK/RD
P1-01
ENGINE HARN
C107AF-RD
CB
25A
J3 WHITE 23 PIN
BAT GND-BR
C27AUX-RD
STARTER
RELAY
TO J4-32
WHITE 35 PIN
PR1
1
30
VLVRET6-BR
AUXMAIN
POWER HARN
BAT GND-BR
P114BAT-RD
J5 BLACK 4 PIN
TO J4-30
WHITE 35
ENGINE BLOCK
START BAT
+
6-28
+
MAIN (SYS)
BAT
Section 6 • Schematics
October 2015
Engine Option- Perkins
S-100/105 from serial number 248)
S-120/125 from serial number 985)
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
3
SEE GENERATOR OPTIONS PAGE
PERKINS 1104C-44 ENGINE
PERKINS 804D-33T ENGINE
15 A FUSE
P46HRN-WH
P34SA-RD
20 A
FUSE
P116HYD-OR
OTS1
N.O.
1
30
85 87 87a
5
4
October 2015
Section 6 • Schematics
Engine 2ELAY,AYOUT- Perkins
from serial number 874
6-29
6-30
October 2015
Section 6 • Schematics
Engine 2ELAY,AYOUT- Perkins
(from serial number 874)
Number
Component
Description
1
Horn Relay
2
Engine Fule Relay
3
Oil Cooler
4
Start Relay
5
Glow Plug Relay
6
Speed Solenoid
7
Fuse, 30A, Eng / Start / Fuel
8
Fuse, 60A, Glow Plug
9
Fuse, 20A, Hydraulic Oil Cooler / Horn
10
B3PBAT
Fused Power from B1
11
B1PBAT
Power from Battery
12
R21PIGN
Ignition Fuse, 20A, RPM Solenoid
13
02PGND
Ground
6-30
S-100 • S-105 • S-120 • S-125
Part No. 102916
STARTER
AUX.
PUMP
REGULATOR
IND.
STA.
SERVICE
HORN
Part No. 102916
S-100 • S-105 • S-120 • S-125
BAT GND-BR
86
C26TSR-WT/RD
2
TURNTABLE TILT
SENSOR
RET85TTSR-BR
OIL TEMP SENDER
BK-COM
275 A FUSE
P85TTSR-GN
C25PSR-WT/BK
+AUX
C34SA-BK/WH
WH-PULL
C21IGN-WH
GRID HEATER
RELAY
RD-HOLD
R34SA-RD
VLVRET2-BR
C30EDC-WH
TROMBETTA
TIME DELAY
MOM N.O.
+
+
-
OIL PRESSURE
3
C31EDC-WH/BK
C84TAY-GN/BK
FUEL SOLENOID
RELAY
2
BK-COM
C83TAX-GN/WH
BAT GND-BR
1
VLVRET2-BR
RD-HOLD
P114BAT-RD
GRID HEATER
BAT.
-
WH-PULL IN
C45GEN-GN/WH 1
BAT GND-BR 2
FWD VLV A
SOLENOID
EXCT.
BK
87a 87 85
4
5
HORN
RELAY
REV VLV B
SOLENOID
ALTERNATOR
2
86
RD
P34SA-RD
HI/LO SPEED
SOLENOID
BAT.
+
1
30
WH
S-500
HOLD
-BAT
PULL IN
85
5
R46HRN-WH
+BAT
VLVRET2-BR
70 A FUSE
C107AF-RD
SYS_BAT_PWR
SYS_BAT_GND
AUX/START_BAT_GND
AUX/START_BAT_PWR
P1-01
P1-02
P1-03
P1-04
BATVLV-RD
BATGND-BR
BATGND-BR
BATECU-RD
FWD
REV
SERVICE_HORN
P1-06
P1-07
C34SA-BK/WH
V30FWD-WH
V31REV-WH/BK
C46HRN-WH
OIL_PRESSURE
OIL/WATER_TEMP
P1-10
P1-11
P1-12
P1-13
C31EDC-WH/BK
C30EDC-WH
C25PSR-WH/BK
C26TSR-WH/RD
VALVE_RTN2
P1-16
VLVRET2-BR
ALTENATOR_RPM
ALT_FIELD_WIRE
TT_TILT_X_AXIS
P1-19
P1-20
C107AF-RD
C83TAX-GN/WH
VALVE_RTN3
P1-23
VLVRET3-BR
P31-ENG HARN
J31-TILT SNSR
TT_TILT_Y_AXIS
AC_GENERATOR
P1-21
P1-22
C84TAY-GN/BK
C45GEN-GN/WH
C41RPM-OR/BK
P1-18
P1-17
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
P1-14
P1-15
RET85TTSR-BR
P85TTSR-GN
C31EDC-WH/BK
C30EDC-WH
P1-09
C33STR-BK
STARTER_RELAY
CHOKE/GLOW PLUG
P1-04
P1-05
C21IGN-WH
P1-08
THROTTLE
IGNITION/FUEL
P1-02
P1-03
R35RPM-BK/RD
P1-01
J3 WHITE 23 PIN
C41RPM-OR/BK
CB
25A
ENGINE HARN
BAT GND-BR
2
86
C27AUX-RD
1
30
STARTER
RELAY
87a 87
4
TO J4-32
WHITE 35 PIN
PR1
AUXMAIN
J5 BLACK 4 PIN
BAT GND-BR
P114BAT-RD
POWER HARN
VLVRET6-BR
TO J4-30
WHITE 35 PIN
ENGINE BLOCK
START BAT
+
+
MAIN (SYS)
BAT
October 2015
Section 6 • Schematics
Engine Option- Cummins
S-100/105 from serial number 219 to 247)
S-120/125 from serial number 933 to 984)
0-20 DEGREE
SENSOR ALARM
SET AT 4.5
DEGREES
J32-ENG HARN
3
SEE GENERATOR OPTIONS PAGE
CUMMINS B4.5 C80 ENGINE
P46HRN-WH
P34SA-RD
1
30
85 87 87a
5
4
6-31
Section 6 • Schematics
October 2015
Engine Option- Cummins
S-100/105 from serial number 219 to 247)
S-120/125 from serial number 933 to 984)
6-31
6-32
October 2015
Section 6 • Schematics
Engine Option- Cummins
S-100/105 from serial number 248)
S-120/125 from serial number 985)
6-33
6-34
STARTER
AUX.
PUMP
S-100 • S-105 • S-120 • S-125
REGULATOR
IND.
Part No. 102916
STA.
BAT GND-BR
C26TSR-WT/RD
86
C25PSR-WT/BK
2
TURNTABLE TILT
SENSOR
RET85TTSR-BR
OIL TEMP SENDER
85 87 87a
5
4
P116HYD-OR
P85TTSR-GN
OIL PRESSURE
1
30
+
+
-
FUEL SOLENOID
RELAY
15A
C116HYD-OR
275 A FUSE
C84TAY-GN/BK
C21IGN-WH
86
R116HYD-OR
2
HYD COOLER
RELAY
CB7
R34SA-RD
WH-PULL
C34SA-BK/WH
C83TAX-GN/WH
BAT GND-BR
3
VLVRET2-BR
GRID HEATER
RELAY
RD-HOLD
BAT GND-BR
2
C30EDC-WH
TROMBETTA
TIME DELAY
MOM N.O.
BAT GND-BR
SERVICE
HORN
1
C31EDC-WH/BK
P114BAT-RD
GRID HEATER
BAT.
BK-COM
C45GEN-GN/WH 1
BAT GND-BR 2
FWD VLV A
SOLENOID
EXCT.
VLVRET2-BR
87a 87 85
4
5
HORN
RELAY
REV VLV B
SOLENOID
ALTERNATOR
2
86
WH-PULL IN
P34SA-RD
HI/LO SPEED
SOLENOID
BAT.
+
1
30
BK
CB7 ADDED
S100- S/N 710
S125- S/N 2589
WH
S-613
PULL IN
85
5
RD-HOLD
BK-COM
RD
-BAT
HOLD
+AUX
R46HRN-WH
+BAT
VLVRET2-BR
70 A FUSE
C107AF-RD
SYS_BAT_PWR
SYS_BAT_GND
AUX/START_BAT_GND
AUX/START_BAT_PWR
P1-01
P1-02
P1-03
P1-04
BATVLV-RD
BATGND-BR
BATGND-BR
BATECU-RD
FWD
REV
SERVICE_HORN
P1-04
P1-05
P1-06
P1-07
C34SA-BK/WH
V30FWD-WH
V31REV-WH/BK
C46HRN-WH
OIL/WATER_TEMP
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
VALVE_RTN2
P1-12
P1-13
P1-14
P1-15
P1-16
C25PSR-WH/BK
C26TSR-WH/RD
RET85TTSR-BR
P85TTSR-GN
VLVRET2-BR
ALTENATOR_RPM
ALT_FIELD_WIRE
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC_GENERATOR
VALVE_RTN3
P1-19
P1-20
P1-21
P1-22
P1-23
C107AF-RD
C83TAX-GN/WH
C84TAY-GN/BK
C45GEN-GN/WH
VLVRET3-BR
P31-ENG HARN
J31-TILT SNSR
C41RPM-OR/BK
P1-18
P1-17
OIL_PRESSURE
P1-10
P1-11
C33STR-BK
C31EDC-WH/BK
C30EDC-WH
C31EDC-WH/BK
C30EDC-WH
P1-09
STARTER_RELAY
CHOKE/GLOW PLUG
P1-03
C21IGN-WH
P1-08
THROTTLE
IGNITION/FUEL
P1-02
R35RPM-BK/RD
P1-01
J3 WHITE 23 PIN
C41RPM-OR/BK
CB
25A
ENGINE HARN
BAT GND-BR
2
86
C27AUX-RD
1
30
STARTER
RELAY
87a 87
4
TO J4-32
WHITE 35 PIN
PR1
AUXMAIN
J5 BLACK 4 PIN
BAT GND-BR
P114BAT-RD
POWER HARN
VLVRET6-BR
TO J4-30
WHITE 35 PIN
ENGINE BLOCK
START BAT
+
6-34
+
MAIN (SYS)
BAT
Section 6 • Schematics
October 2015
Engine Options- Cummins
S-100/105 (from serial number 248)
S-120/125 (from serial number 985)
0-20 DEGREE
SENSOR ALARM
SET AT 4.5
DEGREES
J32-ENG HARN
3
SEE GENERATOR OPTIONS PAGE
CUMMINS B4.5 C80 ENGINE
CUMMINS B3.3T ENGINE
P46HRN-WH
P34SA-RD
20 A
FUSE
P116HYD-OR
OTS1
N.O.
1
30
85 87 87a
5
4
October 2015
Section 6 • Schematics
Electrical Schematic - Generator Options
6-35
6-36
October 2015
Section 6 • Schematics
Electrical Schematic - Generator Options
Hydraulic Generator Option
Belt-Driven Generator Option
J32-ENG HARN
P32-GEN HARN
WT
2 86
85 5
GN
3
BK
BLACK
WHITE
GREEN
RED
AC
BLACK
BLUE GENERATOR
YELLOW
RED BLACK
BLACK
YELLOW WHITE
BLACK
L1
GREEN
GND
T1
4
1 30
87
C45GEN-GN/WH 1
2
BAT GND-BR
P114BAT-RD
30A
87a 3
RD/12VDC
RD
BR/R45GEN(A)
BR
WHITE
T2
YL/BAT GND
RD
YL
BR/P45GEN(B)
BR
PURPLE/F45GEN
PR
WHITE WHITE
T3
1 2 3 4
DTP04-4P
WHITE
T4
1 2 3 4 GENERATOR
JUMPER HARNESS
L2
RD
BK
BL
PLUG
CB
GREEN BLACK
110 VAC REGULATOR
BLACK
WHT-NEUTRAL
5
120VAC
AUTO
RESET CB
8
PURGE-BL
BLACK
PLUG
PLUG
BLK-120VAC
15A
120VAC, 50Hz, 1 PH
C45GEN-GR/WH
BATGND-BR
P114 BAT-RD
PLUG
120VAC GENERATOR W/REGULATOR.
C45GEN-GR/WH
BATGND-BR
P114 BAT-RD
PLUG
120VAC, 60Hz, 1 PH
87a 3
P32-GEN HARN
30A
WT
BAT GND-BR
2
GR
P114BAT-RD
3
BK
2 86
4
RD/12VDC
RD
87
BR/R45GEN(A)
BR
YL/BAT GND
YL
85 5
BR/P45GEN(B)
RD
BR
PURGE-BL
PURPLE/F45GEN
PR
RED BLACK
WHITE
L2
PLUG
BL
BK
RD
T1
220 VAC
REGULATOR
WHT-NEUTRAL
1 2 3 4
T2
220VAC
AUTO
RESET CB
BLK-220VAC
12.5A
YELLOW
WHITE
WHITE
WHITE
T4
GREEN BLACK
BLACK
220VAC GENERATOR W/REGULATOR.
BLACK
240VAC, 50Hz, 1 PH
Part No. 102916
GND
BLACK
L1
WHITE
BLACK
8
S-100 • S-105 • S-120 • S-125
GREEN
GENERATOR
JUMPER HARNESS
DTP04-4P
1 2 3 4
T3
5
6-36
ENGINE HARNESS
PLUG
PLUG
J32-ENG HARN
C45GEN-GN/WH 1
1 30
ENGINE HARNESS
YELLOW
AC
BLUE
GENERATOR
BLACK
RED
GREEN
WHITE
BLACK
October 2015
Section 6 • Schematics
Electrical Schematic - 12 kW Generator
(welder option)
NEUTRAL BUSS BAR
12.5 KW HYDRAULIC GENERATOR
NEMA 4 CONTROL BOX
L1
MODIFIED ENCLOSURE WIRING
L3
L2
X
Y
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
208 VAC
OUTLET
L2
SX CONTROLLER
SAUER #K23334
WHITE
N
TERMINAL
CIRCUIT
COLOR
A1
P23PWR
RD/WH
SENSOR POWER +5V
A3
BATTERY-
BR
V151HG
GR
NC
V150HG
GR/BK
C1
TxD
YEL
C2
RxD
GR
B3
L3
C3
/BOOT
JOYSTICK
D2
NC
D3
NC
5
4
1
2
BLACK
L1
BLACK
NOT USED
E2
NOT USED
E3
NOT USED
F1
NOT USED
GROUND MADE UP OF
MULTIPLE 8GA CONDUCTORS
BETWEEN MAJOR ASSEMBLIES
GREEN
BLACK 12GA
20 AMP CIRCUIT
BREAKER
GROUND
STUD ON
PANEL
WH
SILVER
E1
WHITE
N
GREEN
D1
Z
RED
RD
A2
B1
B2
6
3
RED
BRASS
6 GA 4 CONDUCTOR
SILVER
BLACK 10GA
WHITE
120 VAC
GFI
GREEN
BRASS
110 VAC
GFI
6 GA 4 CONDUCTOR
GREEN
BLACK
GREEN 10GA
F2
C45GEN
F3
NOT USED
GR/WH
ENCLOSURE
10 GA 3 CONDUCTOR
10 GA 3 CONDUCTOR
EDC-
J159-3
WH/BK
J159-2
WH
8
EDC+
1 32 4
7
EDC -
2
J159-7
EDC +
1
J159-6
2
3
J159-4
BYPASS COIL
J159-10
J159-1
V151HG GR
TCON
P23PWR(A)
BK
BK-2
V150HG GR/BK
RD/WH
J159-5 BK
J3-22
GND1
124 ohms
124 ohms
BATTERY
GR
AUXILIARY
PUMP
RD
FUSE
10A
WH
P23PWR
(12V STUD)
3
2
1
9 10 11 12
RD/WH
P23PWR
J1-18
4
D81CAN- GR
5
D82CAN+ YL
8
J21-17
7
J21-18
TIME DELAY MODULE
4 SECOND
U36
6
PCON
J159-1 P23PWR BK
8 N.C.
J159
1 N.O.
BL/RD
2 COM
WH/BK
BK/RD
3 GND 5 SW INPUT
WH
RD/WH
A1 BATTERY +
A2 SENSOR POWER +5 VDC
A3 BATTERY-
GR/WH
3
J1-17
RD
CR4
HIGH IDLE
RELAY
RD/BK
J3-2
OR/RD
J31-18
DCON
RD/WH
MOTOR STROKE
VALVE
J32-4
J31-17
RD/WH
C45GEN GR/WH
1K
2
1
WH/RD
C1 TxD
GR/BK
GR
B1 VALVE 0 FWD COIL
B2 VALVE 1 NC
B3 DIGITAL OUTPUT BYPASS/OMRON
7
A RS232TxD
CIRCUIT #
P23PWR(A)
C30EDC+
C31EDCGND1
P23PWR
C30EDC+(A)
C31EDC-(A)
GND2
C45GEN
V150HG
P23PWR
GND
C3 BOOT
COLOR
WH/RD
WH
WH/BK
BK/RD
BL/RD
RD
RD/BK
OR/RD
GR/WH
GR/BK
RD/WH
GR
GND
AUXILIARY
PUMP
1
2
3
4
5
6
7
8
9
10
11
12
C2 RxD
SX CONTROLLER
8
PIN#
D1 ANALOG 0 JOYSTICK
D2 ANALOG 1 NC
D3 DIG IN 3 NC
5
J159
(TO EDC HARNESS)
E1 NOT USED
E2 NOT USED
E3 NOT USED
6
CR50
OMRON RELAY
F1 DIG IN 0
3
F2 DIG IN 1 GENERATOR ON
F3 DIG IN 2
4
C
GND
J129 B RS232RxD
RxD
C
J159-9
B
1
2
C57-1
TxD
PRESSURE SWITCH
200 PSI
CIRCUIT
A
RD-1
TERM
PS4
J129
RS232 CONNECTOR
N.O.
BR
C57-2
C
Y75-1
A
PILOT PRESSURE SIGNAL
FROM GENERATOR MANIFOLD
DIVERTER MANIFOLD
YEL
B
J159
J159-12 GND Y75-2
GR
J129
P23PWR(A)
C30EDC+
C31EDCGND1
P23PWR
C30EDC+(A)
C31EDC-(A)
6
5
U4
1
RD
J3-11
WH
BR
J3-10
SX CONTROLLER
CKT#
F
PIN# COLOR
E
C45GEN
V150HG
P23PWR
GND
D
BK
WH
WH/BK
BR
BK
WH
WH/BK
PLUG
GR/WH
GR/BK
BK
BR
C
1
2
3
4
5
6
7
8
9
10
11
12
B
CR50
OMRON
RELAY
A
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-37
Section 6 • Schematics
October 2015
Electrical Schematic - 12 kW Generator
(welder option)
6-37
6-38
October 2015
Section 6 • Schematics
Perkins 1104D-44T Engine Electrical Schematic
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-39
Section 6 • Schematics
October 2015
Perkins 1104D-44T Engine Electrical Schematic
6-39
6-40
October 2015
Section 6 • Schematics
Perkins 854F-34T Engine Electrical Schematic
6-41
6-42
Section 6 • Schematics
October 2015
Perkins 854F-34T Engine Electrical Schematic
6-42
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Perkins 854F-34T Engine Electrical Harness
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-43
Section 6 • Schematics
October 2015
Perkins 854F-34T Engine Harness
6-43
6-44
October 2015
Section 6 • Schematics
Deutz TD2.9 Engine Electrical Schematic
6-45
6-46
Section 6 • Schematics
October 2015
Deutz TD2.9 Engine Electrical Schematic
6-46
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Deutz TD2.9 Engine Electrical Harness
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-47
Section 6 • Schematics
October 2015
Deutz TD2.9 Engine Electrical Harness
6-47
6-48
October 2015
Section 6 • Schematics
Hydraulic Schematic - 12 kW Generator
(welder option)
B
DRIVE PUMP
3.5 GPM / 13.25L/min
OIL COOLER
A
PMP B
CLR
PMP A
WELDER
MANIFOLD
CW
0.030 inch /
0.76 mm
PRESSURE SWITCH
200 PSI / 13.8 BAR
N.O.
CV
CX
CU
270 PSI / 18.6 BAR
@ 3.5 GPM / 13.25 L/min
CY
G2
21 GPM /
79.5 L/min
G1
4
3
HYDRAULIC
ROTARY
COUPLER
MTR A
21 GPM /
79.5 L/min
MTR B
TANK
21CC
G2
G1
GENERATOR
12.5 KW
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-49
Section 6 • Schematics
October 2015
Hydraulic Schematic - 12 kW Generator
(welder option)
6-49
6-50
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models
(serial number 136)
6-51
6-52
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models
(serial number 136)
P1
TURNTABLE ROTATE
3GPM
T2
P3 OUT
PRIMARY LIFT
11GPM/5GPM
CHARGE FILTER
TEST
PRL
CD
CE
D
CO
G
AC
E
P1 OUT
AD
0.030 CA
G
CC
E
0.030
D
A
P2 IN
B
0.1GPM
P2 OUT
AF
CI
CF
PLU
AA
AE
AB
P2A IN
PRR
T1
3.0 GPM
100
PSI
100
PSI
CP
A
P3A IN
CH
C
CG
B
PLD
87
PSI
PLATFORM MANIFOLD
S-105
PLATFORM LEVEL
0.63 GPM
HIGH
PRESS
FILTERS
3 gpm
CB
PRIMARY1 EXT.
18GPM/6GPM
T1
3000 psi
AG
P1 IN
P
PLATFORM ROTATE
0.3 GPM
DISTRIBUTION MANIFOLD
T
3 gpm
C
J
CJ
2500 psi
Fa
1-2
EXT
Fe
TRL
TRR
UP
DWN
CL
1-2
RET
1-2
EXT
JU
JIB
1.25 GPM / 0.75 GPM
Ps
B
CM
D
CK
FH
a
b
H
25
PSI
3000 psi
1.7 .3
M
D
500 psi
4.6 in.cu.
FR
FD
FF
FG
4250
PSI
FB
PLATFORM ROTATE
0.3 GPM
P1
290
PSI
R
T1
T2
25 PSI
25
PSI
Ma
X2
CN
CQ
FC
AUX.
PUMP
6 17 10
E
X1
FQ
FA
LS
4250
PSI
A
JD
1800psi
Mb
0.030
TEST
GE
GO
FL
FJ
GD
FM
GB
PRL
D
GA
S
B
T1
LS
A
GC
T1
0.030
P
FK
0.040 DIA
FP
D
GF
GI
TP
GH
PLU
0.1GPM
FE
FI
3
PSI
3
PSI
PRR
P2 OUT
C
GG
2600 psi
TANK
FUNCTION MANIFOLD
T
T1
PLD
GJ
HYDRAULIC SWIVEL
LS
J
4 WHEEL DRIVE
MANIFOLD
B
A
T
B
P
FRONT LEFT
STEERING
FRB
FRONT AXLE EXTENSION
FRONT RIGHT
STEERING
I
D
I
FRONT
DL
DH
FLR
P
A
50%
50%
50%
DE
DF
50%
50%
2.0 GPM
DB
DI
2.7 GPM
AUXILIARY
DRIVE
OPTION
FLB
REAR LEFT
STEERING
REAR RIGHT
STEERING
COUNTERBALANCE
VALVE
FRB
FRR
FAE
FAR
RAE
RAR
RLR
RLB
RRB
EG
EH
RRR
DD
JF
JE
B
250 PSI
JD
1.40
GPM
EQ
JC
EB
LEFT
TEST
TANK
2.00
GPM
ER
S-100 • S-105 • S-120 • S-125
EPP
EMM
2 SPD
Part No. 102916
1.40
GPM
EW
EX
LS
P1
P1
3000 psi
1.40
GPM
EQQ
ET
1800 psi
2.00
GPM
2.00
GPM
EE
EU
EA
RATIO
PRESS
A
2:1
5000 PSI
ELL
B
4.5:1
5000 PSI
C
1.5:1
ED
1.40
GPM
EJ
3000 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
I
3:1
2200 PSI
900 PSI
EC
EZ
EO
0.1GPM
T1
FOUR WHEEL STEER MANIFOLD
2 SPD
EOO
EII
ES
LS
T
BRAKE
2.00
GPM
EV
JB
EP
DN 0.030
DA
EKK
EY
FLA
DM
DO
EJJ
TP
JA
DP
EM
0.1GPM
FRONT
DG
DJ
EK
ENN
2.0 GPM
50%
DC
6-52
D
FLB
LB
BRAKE
PLATFORM MANIFOLD
S-100
RIGHT
FRA
DK
RA
PLATFORM LEVEL
0.47 GPM
REAR AXLE EXTENSION
RIGHT
LA
3 gpm
A
REAR
LEFT
500 psi
4.6 in.cu.
A
B
RB
REAR
GQ
3 gpm
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models
(from serial number 137 to serial number 290)
TURNTABLE ROTATE
3 GPM
3 gpm
CB
3 gpm
TEST
PRL
CD
CE
D
CO
PRIMARY 1 EXT.
18 GPM / 6 GPM
PRIMARY LIFT
11 GPM / 5 GPM
PLATFORM MANIFOLD
S-105
P
0.030 CA
CC
G
E
0.030
D
0.1GPM
Ps
Fa
CF
Fe
A
CI
B
PLU
CP
CH
PLD
a
b
Mb
A
4250
C
CG
B
C
PSI
J
CJ
6 17 10
E
AUX.
PUMP
4250
PSI
290
Drive pump
changed to
9 GPM at
Serial No. 253
PSI
Ma
A
X2
X1
R
T1
S
T2
.3 1.7
Oil cooler location
before Serial No. 248
P3
T2
TRL
UP
TRR
1-2
EXT
DWN
1-2
RET
1-2
EXT
CM
CL
D
CK
OIL COOLER
FH
AE
M
1800psi
H
P3A
JD
FA
CN
FQ
25 PSI
LS
FC
CQ
FR
FD
25
PSI
25
PSI
FG
FB
FF
3000 psi
Oil cooler location
after Serial No. 247
3
PSI
D
500 psi
4.6 in.cu.
TP3
3
PSI
JU
JIB
1.25 GPM / 0.75 GPM
B
PRR
T1
G
E
PLATFORM LEVEL
0.63 GPM
100
PSI
100
PSI
87
PSI
T
P1
PLATFORM ROTATE
0.3 GPM
Primary extension
CB valve ratio
changed to 'K' at
Serial No. 150
HIGH
PRESS
FILTERS
CHARGE FILTER
PLATFORM ROTATE
0.3 GPM
P1
AC
TANK
0.030
TEST
P2
OIL COOLER
FL
AF
FJ
GE
GO
GD
GB
PRL
GC
T1
25 PSI
TP
FK
.040 DIA
AA
PRR
0.030
D
FP
4
1
3
2
GF
5
GI
AB
P2A
FI
4
1
3
2B
PLU
0.1GPM
5
2A
GH
230 psi
TP2
HYDRAULIC SWIVEL
2600 psi
PLD
GJ
T3
P2 OUT
LS
Valve FP changed from
110 psi to 230 psi at
Serial No. 151
4 WHEEL DRIVE
MANIFOLD
LS
FUNCTION MANIFOLD
J
T
GQ
3 gpm
B
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
B
RB
C
GG
FE
T1
A
D
GA
AD
AG
P1
Hydraulic Swivel
numbered at
Serial No. 255
FM
PLATFORM MANIFOLD
S-100
3 gpm
P
A
REAR
FRB
RIGHT
FRONT
DL
FRONT AXLE EXTENSION
FRONT RIGHT
STEERING
I
DH
DK
RA
FRONT LEFT
STEERING
RIGHT
FRA
D
COUNTERBALANCE VALVE
REAR AXLE EXTENSION
I
D
REAR LEFT
STEERING
FLB
REAR RIGHT
STEERING
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
50%
50%
50%
DC
2.0 GPM
50%
LB
DE
DF
50%
50%
REAR
P
DD
A
DI
2.7 GPM
FRONT
DG
LA
DJ
250 PSI
DP
EK
1.40
GPM
EQ
LEFT
JE
JD
JC
TEST
FAE
DA
RAE
RAR
RLR
RLB
EG
RRB
RRR
EH
EJJ
EKK
EOO
EII
EPP
EMM
2.00
GPM
EV
2.00
GPM
ER
1.40
GPM
EW
EX
EQQ
ET
1800 psi
2.00
GPM
2.00
GPM
EE
EU
EA
ES
JB
LS
LS
P1
P1
3000 psi
ELL
ED
EC
1.40
GPM
EJ
900 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
EZ
EP
The manifold relief valve
EZ was removed at
Serial No. 148
1.40
GPM
EY
EB
BRAKE
2 SPD
FAR
EM
TP
TANK
DN 0.030
2 SPD
FRR
B
DM
DO
FRB
FLA
JA
BRAKE
FLB
0.1GPM
JF
LEFT
AUXILIARY
DRIVE
OPTION
ENN
2.0 GPM
DB
FLR
T
T1
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
EO
0.1GPM
FOUR WHEEL STEER MANIFOLD
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-53
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-100 • S-105 Models
(from serial number 137 to serial number 290)
6-53
6-54
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models
(from serial number 291 to serial number 738)
6-55
6-56
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models
(from serial number 291 to serial number 738)
TURNTABLE ROTATE
3 GPM
HIGH
PRESS
FILTERS
100
PSI
P1
PLATFORM MANIFOLD
S-105
P
3 gpm
3 gpm
CB
TEST
D
CO
0.030 CA
E
E
100
PSI
PRL
CD
CE
G
K
87
PSI
T
PRIMARY1 EXT.
18 GPM / 6 GPM
PLATFORM ROTATE
0.3 GPM
CHARGE FILTER
PRIMARY LIFT
11 GPM / 5 GPM
CC
PRR
T1
B
A
0.030
D
0.1GPM
CI
CF
PLU
E
CP
A
D
CH
B
C
CG
PLD
C
PLATFORM LEVEL
0.63 GPM
M1
315
PSI
M5
P3
3625
PSI
T2
TRL
TRR
UP
1-2
EXT
DWN
J
CJ
1-2
RET
1-2
EXT
CM
FQ
E
AUX.
PUMP
.3 1.7
B
H
P3A
JD
FH
CN
FR
1800psi
LS
FC
TP3-4
D
FD
M
D
CK
FA
AE
9 17 10
3625
PSI
JU
CL
JIB
1.25 GPM / 0.75 GPM
A
M4
CQ
500 psi
4.6 in.cu.
L1
M2
L2
S
FF
FB
FG
3000 psi
AC
25
PSI
25
PSI
PLATFORM ROTATE
0.3 GPM
P1
P2
FJ
FL
FM
0.030
TEST
3
PSI
AF
3
PSI
P1
TANK
AD
TP
25 PSI
AA
FP
CHECK VALVE
REMOVED AT
S/N 291
P2A
GE
GO
GD
PRL
GC
T1
FK
.040 DIA
PRR
0.030
D
GF
AB
GI
230 psi
FI
GH
PLU
0.1GPM
FE
TP2
2600 psi
3
1
2
PLD
GJ
5
T3
P2 OUT
LS-4
HYDRAULIC SWIVEL
LS
J
FUNCTION MANIFOLD
4
3
1
2B
2A
GQ
3 gpm
TEST
REAR
RIGHT
3 gpm
P
T
PLATFORM MANIFOLD
S-100
X
TO FUNCTION MANIFOLD T2
M7
M8
FR
REAR AXLE
EXTENSION
B
A
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
5
FRONT AXLE
EXTENSION
T
C
GG
T1
4
D
GA
GB
AG
FRONT LEFT
STEERING
FRONT
RIGHT
FRONT RIGHT
STEERING
I
D
I
D
TO FUNCTION MANIFOLD P3
FH
REAR LEFT
STEERING
FE
REAR RIGHT
STEERING
CDR
FF
M6
M5
FN
FQ 50%
2.0
GPM
FAE
FAR
RAE
RAR
RLR
RLB
RRB
RRR
EK
EG
EM
EH
ENN
EJJ
EKK
EOO
EII
EPP
EMM
ELL
50%
FD
FK
1.40
GPM
EQ
M4
FG
FD
FB
FC
LBRAKE
LBRAKE
L2SPEED
EA
FRONT
LEFT
M2
LS
COUNTERBALANCE VALVE
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
EP
R2SPEED
RBRAKE
RBRAKE
T
EO
0.1GPM
T1
FOUR WHEEL STEER MANIFOLD
4WD TRACTION MANIFOLD
S-100 • S-105 • S-120 • S-125
Part No. 102916
EX
EQQ
1800 psi
1.40
GPM
ET
2.00
GPM
EE
2.00
GPM
EU
1.40
GPM
EJ
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
ED
900 PSI
G
3:1
EC
600 PSI
H
3:1
3200 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
P1
L2SPEED
R2SPEED
1.40
GPM
EW
EY
EB
FI
2.00
GPM
ER
ES
CDL
FA
2.00
GPM
EV
TP
0.030
6-56
FRR
2.0 GPM FM
M3
M1
FRB
FL
50%
50%
REAR
LEFT
FLB
FJ
280 PSI
2.0
GPM
FLR
P
50%
50%
FP
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-100 • S-105 Models
(from serial number 739)
PRIMARY LIFT
11 GPM / 5 GPM
TURNTABLE ROTATE
3 GPM
HIGH
PRESS
FILTERS
87
PSI
3 gpm
3 gpm
CB
A
100
PSI
B
TEST
G
K
D
0.030 CA
CC
B
A
PRL
CD
CE
CO
E
E
100
PSI
P1
PLATFORM MANIFOLD
S-105
P
PLATFORM ROTATE
0.3 GPM
CHARGE FILTER
T
PRIMARY1 EXT.
18 GPM / 6 GPM
PRR
T1
0.030
D
0.1GPM
CI
CF
C
PLU
E
CH
C
CG
PLATFORM LEVEL
0.63 GPM
CP
C
M1
D
PLD
315
PSI
M5
P3
3625
PSI
TRL
T2
TRR
UP
1-2
EXT
DWN
J
CJ
1-2
RET
1-2
EXT
CM
CL
FQ
E
3625
PSI
AUX.
PUMP
.3 1.7
P3A
D
CK
FA
AE
9 17 10
JU
JIB
1.25 GPM / 0.75 GPM
A
M4
JD
FR
CN
1800psi
FC
TP3-4
LS
FD
M
D
CQ
B
L1
M2
L2
S
FF
500 psi
4.6 in.cu.
FB
FG
3000 psi
AC
25
PSI
25
PSI
P2
FJ
FL
FM
PLATFORM ROTATE
0.3 GPM
P1
3
PSI
AF
3
PSI
AD
0.030
TEST
AG
P1
TANK
GE
GO
TP
GD
GB
AA
FP
AB
0.1GPM
FE
TP2
3
1
2
PRR
0.030
230 psi
FI
4
2600 psi
5
GI
GH
PLU
1
2B
2A
C
GG
HYDRAULIC SWIVEL
3
D
GF
T1
4
D
GC
T1
P2A
PRL
GA
FK
.040 DIA
T3
P2 OUT
LS-4
FUNCTION MANIFOLD
5
PLD
GJ
LS
J
GQ
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
3 gpm
3 gpm
P
T
TEST
REAR
RIGHT
B
A
M7
M8
FR
FRONT AXLE
EXTENSION
X
T
FRONT
RIGHT
FRONT LEFT
STEERING
FH
REAR AXLE
EXTENSION
TO FUNCTION MANIFOLD P3
FRONT RIGHT
STEERING
I
D
I
D
FAR
RAE
RAR
REAR LEFT
STEERING
FE
CDR
FF
PLATFORM MANIFOLD
S-100
TO FUNCTION MANIFOLD T2
REAR RIGHT
STEERING
M6
M5
50%
50%
FP
FN
FJ
280 PSI
2.0
GPM
FQ 50%
2.0
GPM
FLR
P
FL
EK
50%
ENN
50%
50%
FD
FLB
FRB
1.40
GPM
EQ
FD
EJJ
EKK
2.00
GPM
EV
2.00
GPM
ER
TP
FI
RLB
EG
EOO
EII
1.40
GPM
EW
EX
EQQ
1800 psi
ES
0.030
CDL
FA
RLR
EM
M4
FG
M1
FAE
EPP
RRB
RRR
FB
FC
LBRAKE
1.40
GPM
ET
2.00
GPM
EE
EMM
ELL
2.00
GPM
EU
1.40
GPM
EJ
EY
EB
FRONT
LEFT
EA
ED
M2
COUNTERBALANCE
VALVE
RATIO
EH
2.0 GPM FM
FK
M3
REAR
LEFT
FRR
EC
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
900 PSI
G
3:1
600 PSI
I
3:1
2200 PSI
LS
J
1.5:1
2000 PSI
P1
K
1:1
600 PSI
LBRAKE
L2SPEED
L2SPEED
R2SPEED
R2SPEED
RBRAKE
RBRAKE
EP
T
4WD TRACTION MANIFOLD
PRESS
A
T1
EO
0.1GPM
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
FOUR WHEEL STEER MANIFOLD
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-57
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-100 • S-105 Models
(from serial number 739)
6-57
6-58
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 404 to serial number 430)
6-59
6-60
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 404 to serial number 430)
T2
100
PSI
P
3 gpm
PLATFORM MANIFOLD
S-125
CB
T1
G
AC
E
P1 OUT
AD
G
PRL
CD
CE
D
CO
G
F
0.030 CA
E
3.0 GPM
CC
A
P2 IN
AF
100
PSI
0.030
P2A IN
D
AA
AE
PRR
T1
B
P2 OUT
AB
87
PSI
T
3 gpm
PLATFORM ROTATE
0.3 GPM
CHARGE FILTER
P1
TEST
DISTRIBUTION
MANIFOLD 3000 psi
AG
P1 IN
HIGH
PRESS
FILTERS
PRIMARY 2 EXT.
18 GPM / 5 GPM
PRIMARY 1 EXT.
18 GPM / 6 GPM
0.1GPM
A
P3A IN
CI
CF
PLU
B
CP
CH
C
C
CG
PLD
PLATFORM LEVEL
0.63 GPM
P3 OUT
PRIMARY LIFT
11 GPM / 5 GPM
TURNTABLE ROTATE
3 GPM
2500 psi
Fa
1-2
EXT
Fe
TRR
TRL
UP
DWN
J
CJ
0-1
RET
CM
H
JD
BQ
4250
PSI
25
PSI
3000 psi
M
1.7 .3
6 17 10
E
CN
BC
BR
BD
AUX.
PUMP
LS
CQ
25 PSI
25
PSI
Ma
X2
X1
BB
BG
290
PSI
R
T1
T2
D
500 psi
4.6 in.cu.
BF
4250
PSI
D
CK
1800psi
BA
Mb
A
JU
CL
BO
BN
BH
a
b
1-2
RET
0-1
EXT
1-2
EXT
JIB
1.25 GPM / 0.75 GPM
Ps
B
PLATFORM ROTATE
0.3 GPM
P1
BL
BJ
S
0.030
TEST
BM
GE
GO
GD
GB
PRL
D
GA
LS
B
T1
A
P2 OUT
P
GC
T1
PRR
BK
BP
0.040 DIA
0.030
D
TP
GF
BI
3
PSI
3
PSI
GI
GH
PLU
0.1 GPM
2600 psi
TANK
BE
T
FUNCTION MANIFOLD
C
GG
T1
HYDRAULIC SWIVEL
PLD
GJ
LS
4 WHEEL DRIVE
MANIFOLD
B
A
J
A
B
T
GQ
3 gpm
A
FRB
FRONT AXLE EXTENSION
FRONT RIGHT
STEERING
REAR AXLE EXTENSION
RIGHT
I
D
I
FRONT
DL
DH
A
50%
50%
DE
DF
50%
50%
2.0 GPM
DB
DI
2.7 GPM
AUXILIARY
DRIVE
OPTION
COUNTERBALANCE
VALVE
FRB
FRR
FAE
FAR
RAE
RAR
RLR
RLB
RRB
EG
EH
RRR
DJ
250 PSI
DD
JF
JE
JD
1.40
GPM
EQ
JC
EKK
TANK
2.00
GPM
ER
S-100 • S-105 • S-120 • S-125
EPP
EMM
Part No. 102916
EX
LS
P1
P1
3000 psi
1.40
GPM
EQQ
ET
1800 psi
2.00
GPM
2.00
GPM
EE
EU
EA
RATIO
PRESS
A
5:1
5000 PSI
ELL
B
4.5:1
5000 PSI
C
1.5:1
ED
1.40
GPM
EJ
3000 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
900 PSI
EC
EZ
EO
0.1GPM
T1
FOUR WHEEL STEER MANIFOLD
2 SPD
1.40
GPM
EW
ES
LS
T
BRAKE
2.00
GPM
EV
JB
EP
DN 0.030
2 SPD
EOO
EII
EY
EB
LEFT
TEST
DA
EJJ
TP
FLA
DM
DO
EM
B
FRONT
DG
DP
6-60
REAR RIGHT
STEERING
0.1GPM
JA
BRAKE
FLB
EK
ENN
2.0 GPM
50%
DC
LA
FLR
P
50%
LEFT
REAR LEFT
STEERING
FLB
LB
REAR
D
RIGHT
FRA
DK
RA
PLATFORM MANIFOLD
S-120
3 gpm
P
FRONT LEFT
STEERING
REAR
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
B
RB
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 431 to serial number 1194)
Primary extension
CB valve ratio changed
to ‘K’ at Serial No. 562
HIGH
PRESS
FILTERS
CHARGE FILTER
TURNTABLE ROTATE
3 GPM
PRIMARY 1 EXT.
18 GPM / 6 GPM
PRIMARY LIFT
11 GPM / 5 GPM
PRIMARY 2 EXT.
18 GPM / 5 GPM
P1
T
P
3 gpm
3 gpm
PLATFORM MANIFOLD
S-125
CB
100
PSI
G
G
E
PRL
CD
CE
G
F
D
CO
0.030 CA
E
A
CC
B
PRR
T1
0.030
D
Fa
0.1GPM
Fe
Drive Pump changed
to 9 GPM at
Serial No. 1029
A
CI
CF
B
PLU
C
CP
CH
C
CG
a
PLD
b
Mb
4250
PSI
P3
4250
PSI
AUX.
PUMP
290
PSI
.3 1.7
Ma
TRR
TRL
T2
UP
1-2
EXT
DWN
Oil Cooler location
before Serial No. 985
6 17 10
E
1-2
EXT
R
T1
T2
H
P3A
BH
CM
1800psi
BA
D
CK
BC
JD
BR
CN
25 PSI
LS
30 PSI
BS
3000 psi
Oil Cooler location
after Serial No. 984
25
PSI
P2
D
500 psi
4.6 in.cu.
Check valve BS
added at
Serial No. 575
BJ
BL
CQ
BB
BF
BG
AC
OIL COOLER
3
PSI
3
PSI
JU
CL
BQ
M
S
25
PSI
J
CJ
AE
OIL COOLER
BD
X2
X1
0-1
RET
BO
BN
TP3
A
1-2
RET
0-1
EXT
BM
PLATFORM ROTATE
0.3 GPM
P1
AF
TANK
AD
AG
P1
AA
BP
3
1
2
GD
GB
BK
.040 DIA
AB
BI
PRL
D
GA
GC
T1
P2A
4
GE
GO
25 PSI
Hydraulic Swivel
numbered at
Serial No. 1032
0.030
TEST
TP-4
PLATFORM LEVEL
0.63 GPM
Ps
B
JIB
1.25 GPM / 0.75 GPM
100
PSI
87
PSI
PLATFORM ROTATE
0.3 GPM
TEST
PRR
230 psi
5
0.030
0.1GPM
BE
TP2-4
2600 psi
D
GF
HYDRAULIC SWIVEL
4 WHEEL DRIVE
MANIFOLD
GI
T1
4
3
1
2B
2A
GH
PLU
5
T3
P2 OUT
LS
Valve BP changed from
110 psi to 230 psi
at Serial No. 575
FUNCTION MANIFOLD
C
GG
PLD
B
GJ
A
LS
B
RB
J
A
FRONT LEFT
STEERING
FRB
REAR
RIGHT
FRONT AXLE
EXTENSION
FRONT RIGHT
STEERING
REAR AXLE
EXTENSION
T
P
I
D
I
D
FAE
FAR
RAE
RAR
GQ
3 gpm
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
PLATFORM MANIFOLD
S-120
3 gpm
FRONT
DL
P
A
50%
2.0 GPM
50%
DI
2.7 GPM
FRR
RLR
REAR RIGHT STEERING
RLB
RRB
EG
EH
RRR
COUNTERBALANCE VALVE
DJ
EK
DD
JF
JE
JD
1.40
GPM
EQ
JC
250 PSI
EB
LEFT
TEST
TANK
EKK
EOO
EII
LS
LS
P1
P1
3000 psi
EPP
2 SPD
2.00
GPM
ER
1.40
GPM
EW
EX
1.40
GPM
EQQ
ET
1800 psi
2.00
GPM
EMM
2.00
GPM
EE
EU
EA
ED
EZ
T
BRAKE
2.00
GPM
EV
ES
JB
EP
DN 0.030
DA
EJJ
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
G
3:1
600 PSI
H
3:1
3200 PSI
ELL
1.40
GPM
EJ
EY
FLA
DM
DO
EM
TP
FRONT
DG
DP
2 SPD
FRB
0.1GPM
JA
BRAKE
FLB
B
ENN
DE
DF
DB
AUXILIARY
DRIVE
OPTION
50%
50%
DC
2.0 GPM
50%
LB
LA
FLR
FLB
50%
REAR
LEFT
REAR LEFT STEERING
DH
DK
RA
RIGHT
FRA
EO
0.1GPM
T1
Manifold relief valve
EZ was removed at
Serial No. 522
EC
900 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
FOUR WHEEL STEER MANIFOLD
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-61
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 431 to serial number 1194)
6-61
6-62
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 1195 to serial number 2634)
6-63
6-64
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 1195 to serial number 2634)
PRIMARY 2 EXT.
18 GPM / 5 GPM
T
P1
CHARGE FILTER
87
PSI
G
K
HIGH
PRESS
FILTERS
E
3 gpm
G
F
CB
TEST
E
PRL
CD
CE
D
CO
A
0.030 CA
B
CC
100
PSI
100
PSI
PLATFORM MANIFOLD
S-125
P
3 gpm
PLATFORM ROTATE
0.3 GPM
PRIMARY 1 EXT.
18 GPM / 6 GPM
PRIMARY LIFT
11 GPM / 5 GPM
TURNTABLE ROTATE
3 GPM
PRR
T1
0.030
D
E
0.1GPM
D
A
CI
CF
B
PLU
C
CP
CH
C
CG
PLD
315
PSI
M5
3625
PSI
E
J
CJ
P3
T2
TRL
UP
TRR
1-2
EXT
DWN
9 17 10
3625
PSI
0-1
EXT
1-2
EXT
BN
AUX.
PUMP
H
P3A
.3 1.7
0-1
RET
CM
JD
BQ
CN
LS
BR
D
BC
CQ
BD
B
L1
M2
L2
D
CK
BH
M
TP3
JU
CL
BO
1800psi
BA
AE
1-2
RET
JIB
1.25 GPM / 0.75 GPM
A
M4
PLATFORM LEVEL
0.63 GPM
M1
S
500 psi
4.6 in.cu.
30psi BS
BG
BB
BF
3000 psi
25
PSI
25
PSI
P2
3
PSI
3
PSI
PLATFORM ROTATE
0.3 GPM
P1
AC
BJ
BL
0.030
TEST
BM
GE
GO
AF
TANK
P1
GD
GB
PRL
D
GA
AD
AG
GC
T1
AA
TP
PRR
0.030
BK
BP
0.040 DIA
D
GF
GI
GH
PLU
4
3
1
2
5
P2A
1
2A
2B
C
GG
230 psi
0.1GPM
BI
HYDRAULIC SWIVEL
3
4
AB
TP2
BE
2600 psi
PLD
GJ
5
T1
LS
J
P2 OUT
T3
LS
GQ
FUNCTION MANIFOLD
FRONT AXLE
EXTENSION
TEST
REAR
RIGHT
PLATFORM MANIFOLD
S-120
TO FUNCTION MANIFOLD T2
TO FUNCTION MANIFOLD P3
M7
FRONT
RIGHT
M8
FR
3 gpm
P
T
REAR AXLE
EXTENSION
B
A
X
T
FRONT LEFT
STEERING
FRONT RIGHT
STEERING
I
I
D
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
3 gpm
D
FH
REAR LEFT
STEERING
REAR RIGHT
STEERING
FE
CDR
FF
M6
M5
FN
FJ
2.0
GPM
280 PSI
2.0
GPM
FQ 50%
FLR
P
50%
50%
FP
FLB
EK
FRB
FAR
RAE
RAR
RLR
RLB
EG
EM
RRB
RRR
ENN
EJJ
EKK
EOO
EII
EPP
EH
EMM
ELL
COUNTERBALANCE VALVE
50%
FD
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
LS
F
3:1
P1
G
3:1
600 PSI
H
3:1
3200 PSI
2.0 GPM FM
FK
M3
1.40
GPM
EQ
M4
FG
FD
2.00
GPM
EV
2.00
GPM
ER
EB
EA
CDL
FI
FB
FC
FRONT
LEFT
M2
LBRAKE
LBRAKE
L2SPEED
L2SPEED
EP
R2SPEED
RBRAKE
RBRAKE
EO
0.1GPM
T
R2SPEED
EX
EQQ
1800 psi
1.40
GPM
ET
2.00
GPM
EE
2.00
GPM
EU
1.40
GPM
EJ
EY
0.030
FA
1.40
GPM
EW
ES
TP
M1
FAE
FL
50%
50%
REAR
LEFT
FRR
ED
EC
900 PSI
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
T1
FOUR WHEEL STEER MANIFOLD
4WD TRACTION MANIFOLD
6-64
S-100 • S-105 • S-120 • S-125
Part No. 102916
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 2635 to serial number 3145)
PRIMARY LIFT
11 GPM / 5 GPM
PRIMARY 2 (SECONDARY) EXT.
P1
18 GPM / 5 GPM
PRIMARY 1 EXT.
18 GPM / 6 GPM
T
P
3 gpm
3 gpm
CB
TEST
87
PSI
E
G
K
B
A
HIGH
PRESS
FILTERS
0.030 CA
E
CC
A
B
PRR
T1
0.030
D
0.1GPM
E
D
CO
100
PSI
100
PSI
M1
PRL
CD
CE
G
F
D
CI
CF
C
PLU
CP
C
CH
C
CG
PLATFORM LEVEL
0.63 GPM
CHARGE FILTER
PLATFORM ROTATE
0.3 GPM
TURNTABLE ROTATE
3 GPM
315
PSI
PLD
M5
3625
PSI
P3
E
T2
TRL
UP
TRR
1-2
EXT
DWN
9 17 10
3625
PSI
BN
AUX.
PUMP
J
CJ
0-1
RET
CM
JU
CL
BO
D
CK
1800psi
BA
AE
1-2
RET
0-1
EXT
1-2
EXT
BQ
JD
P3A
.3 1.7
BR
M
CN
BC
TP3
LS
BD
B
L1
M2
L2
D
S
30psi BS
BG
CQ
500 psi
4.6 in.cu.
BB
BF
PLATFORM MANIFOLD
S-125
3000 psi
25
PSI
25
PSI
AC
P2
3
PSI
3
PSI
P1
BJ
BL
AF
TANK
0.030
TEST
AD
GE
GO
BP
0.040 DIA
230 psi
3
1
2B
2A
GI
BE
GH
PLU
C
GG
T3
HYDRAULIC SWIVEL
4
D
GF
T1
5
D
PRR
0.1GPM
2600 psi
2
PRL
GA
0.030
BI
1
GB
GC
T1
AB
TP2
3
GD
BK
AA
P2A
PLATFORM ROTATE
0.3 GPM
P1
BM
AG
TP
4
JIB
1.25 GPM / 0.75 GPM
A
M4
P2 OUT
LS
PLD
FUNCTION MANIFOLD
GJ
LS
5
J
GQ
PLATFORM LEVEL
0.47 GPM
500 psi
4.6 in.cu.
3 gpm
3 gpm
P
T
TEST
B
A
X
T
REAR
RIGHT
FRONT AXLE
EXTENSION
M7
M8
FR
FRONT
RIGHT
FRONT LEFT
STEERING
FH
FRONT RIGHT
STEERING
I
TO FUNCTION MANIFOLD P3
I
D
PLATFORM MANIFOLD
S-120
TO FUNCTION MANIFOLD T2
REAR AXLE
EXTENSION
REAR LEFT
STEERING
D
REAR RIGHT
STEERING
COUNTERBALANCE VALVE
FE
CDR
FF
M6
RATIO
PRESS
A
5:1
5000 PSI
B
4.5:1
5000 PSI
C
1.5:1
3500 PSI
D
3:1
3000 PSI
E
4.5:1
3000 PSI
F
3:1
900 PSI
G
3:1
600 PSI
M5
50%
50%
FP
FN
FJ
2.0
GPM
280 PSI
2.0
GPM
FQ 50%
FLR
P
FL
EK
50%
ENN
50%
50%
FD
FK
M4
FG
1.40
GPM
EQ
FD
0.030
FA
FI
FRR
FAE
FAR
RAE
RAR
RLR
EJJ
EKK
RLB
EG
EM
2.00
GPM
EV
2.00
GPM
ER
EOO
EII
FB
FC
EPP
RRB
RRR
EH
EMM
ELL
LBRAKE
LBRAKE
L2SPEED
L2SPEED
R2SPEED
R2SPEED
RBRAKE
RBRAKE
EQQ
1800 psi
1.40
GPM
ET
2.00
GPM
EE
2.00
GPM
EU
1.40
GPM
EJ
EY
EB
FRONT
LEFT
M2
1.40
GPM
EW
EX
ES
TP
CDL
M1
FRB
2.0 GPM FM
M3
REAR
LEFT
FLB
EA
ED
EC
I
3:1
2200 PSI
J
1.5:1
2000 PSI
K
1:1
600 PSI
LS
P1
EP
Note: 'alpha' callouts refer
to components shown in the
manifold illustrations.
Refer to the Repair Section.
EO
0.1GPM
T
T1
4WD TRACTION MANIFOLD
FOUR WHEEL STEER MANIFOLD
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-65
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 2635 to serial number 3145)
6-65
6-66
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 3146 to S12514D-921)
6-67
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models
(from serial number 3146 to S12514D-921)
6-68
S-100 • S-105 • S-120 • S-125
Part No. 102916
October 2015
Section 6 • Schematics
Hydraulic Schematic, S-120 • S-125 Models
(from serial number S12514D-922)
Part No. 102916
S-100 • S-105 • S-120 • S-125
6-69
Section 6 • Schematics
October 2015
Hydraulic Schematic, S-120 • S-125 Models
(from serial number S12514D-922)
6-70
Electrical Schematic
P63LS-OR/RD
P53LS-WH/BK
31
24
31
24
J264 WAY1
2
31
3
24
31
4
24
31
24
31
24
31
AXLE EXTENTION
LIMIT SWITCHES
24
31
24
LIMIT SWITCHES
S-120/125
1
ENGINE BLOCK
P46HRN-WH
2
P33STR-BK
15 A
+BAT
1
30
WAS 10A BEFORE:
S100/105- SN 159
S120/125- SN 619
STARTER
2
86
87a 87 85
4
5
STARTER
RELAY
C61AXRT-GN
P264 WAY
C60AXEX-GN/WH
AUX.
PUMP
OTS1
N.O.
RD-HOLD
WH-PULL
+AUX
-BAT
COM
ALTERNATOR
BAT.
+
EXCT.
BAT.
-
IND.
1
30
2
86
HORN
87a 87 85 RELAY
5
4
1
REGULATOR
SERVICE
HORN
2
HI/LO
SPEED
SOLENOID
3
FLAMMSTART
2
RELAY
86
30
1
HYD COOLER
2
RELAY
86
85 87 87a
5
4
1
30
85 87 87a
5
4
2
86
1
30
85 87 87a
5
4
FUEL
SOLENOID
RELAY
STA.
FAN
FUEL
SOLENOID
RELAY
VLVRET6-BR
C27AUX-RD
P
P
2 86
85 5
J27
C08PBR-BK/WH
C07PBE-BK
C02PBD-RD/BK
C01PBU-RD
C06TRF-WH/RD
C09PERF-BK/RD
C03PBF-RD/WH
C27AUX-RD
VALVE RTN6
VALVE RTN7
C06TTR-WH/BK
C05TTL-WH
C113MFV-OR/RD
BATGND-BR
P1-01
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
P1-16
P1-15
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
P1-02
VALVE_RTN3
AC_GENERATOR
TT_TILT_Y_AXIS
TT_TILT_X_AXIS
ALT_FIELD_WIRE
ALTENATOR_RPM
VALVE_RTN2
TT_TILT_SNSR_PWR
TT_TILT_SNSR_GND
OIL/WATER_TEMP
OIL_PRESSURE
C30EDC-WH
C31EDC-WH/BK
STARTER_RELAY
SERVICE_HORN
REV
FWD
CHOKE/GLOW PLUG
VALVE_RTN4
BOOM_EXT/RET_VLV
BOOM_EXTEND_VLV
BOOM_RETRACT_VLV
P4-08
P4-09
P4-10
VALVE_RTN7
P4-27
P_11
P_12
P_14
P_18
OPER SW PWR
FST1S
LST10
P2-10
P2-11
P2-12
P2-13
P2-14
P2-15
C61AXRT-GN
S62BSTO-OR
P63LS-OR/RD
C64LS-OR/BL
C65LOFL-BL/WH
C66DREN-BL
J21
8 WAY
3
4
LIMIT SWITCHES
S-100/105
P54ENG-BK/WH
P20
12 WAY
P53LS-WH/BK
5
1
2
31
LSB3EO
P2-20
24
31
24
9 10 11 12 J20
12 WAY
31
24
31
31
24
24
31
1
2
3
VLVRET1-BR
C77AS-WH
G119SR-BL
4
P
4
C64LS-OR/BK
31
24
31
C64LS-OR/BK
P56PRV-RD
SJ3-WH
C68PBD-BL
S62BSTO-OR
P53LS-WH/BK
C60AXEX-GN/WH
3
S56PRV-RD
C77AS-WH
C64LS-OR/BK
24
C65LOFL-BL/WH
C64LS-OR/BK
C66DREN-BL
P57PBD-RD/WH
P58LS-RD/BK
P54ENG-BK/WH
P53LS-WH/BK
S56PRV-RD
SJ3-WH
LSB4EO
LSB13AO
LSB14AO
P2-28
P2-29
P2-30
P2-35
P2-34
P2-33
P2-32
VLV RET
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
PRI#2 LO
P2-22
P2-21
LSB3RO
P2-19
P2-25
C71PBE-BL/BK
LSB2RO
P2-18
SNSR GND-BR
C70PBE-BL/WH
LSB1DO
P2-17
C71PBE-BL/BK
8
PRI#1 LO
7
P2-24
6
P2-23
P57PBD-RD/WH
5
V75PRLO-RD/WH
C61AXRT-GN
4
C64LS-OR/BK
S62BSTO-OR
24
V74PRLO-RD
P63LS-OR/RD
3
C70PBE-BL/WH
C68PBD-RD
P_10
P2-09
C60AXEX-GN/WH
8
2
P2-16
P_9B
P2-08
S59CNBK-GN/WH
7
1
LSB6S
CHNBRK
P_9A
P2-07
P58LS-RD/BK
AUX_RELAY
P_7R
P4-35
P4-34
P4-33
P4-32
P4-31
P4-30
P4-29
VALVE_RTN6
ROTATE_CCW_VLV
P4-26
P4-28
ROTATE_CW_VLV
P4-25
P4-24
P4-23
P4-22
P4-21
P4-20
MULTI_FUNCT_VLV
BOOM REVERSE LOAD
P4-18
P4-19
HYD_FILTER2
BOOM OVERLOAD
HYD_FILTER1
P4-15
P4-17
VALVE_RTN5
P4-14
P4-16
DRIVE LIGHTS RELAY
P4-13
P4-12
P4-11
BOOM_UP_VLV
BOOM_DOWN_VLV
P4-07
P4-06
P4-05
6
FUSE
4
2
1
K8 86
30
87 87a
85
5
4
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO PLD
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
1
30
87 87a
TO MICRO
P4-04 TURNTABLE_ROTATE_VLV
P4-03
P4-02 BOOM_UP/DOWN_VLV
P4-01
THROTTLE
IGNITION/FUEL
5
85
2
K7 86
AUX/START_BAT_GND
AUX/START_BAT_PWR
P1-03
P1-04
P2-06
C14LS-BK/RD
C15LS-RD/BK
VLVRET5-BR
R49LP - WT/BK
J31-TILT
SNSR
P31-ENG
HARN
VLVRET3-BR
C45GEN-GN/WH
C84TAY-GN/BK
C83TAX-GN/WH
C107AF-RD
C41RPM-OR/BK
VLVRET2-BR
P85TTSR-GN
RET85TTSR-BR
C26TSR-WH/RD
C25PSR-WH/BK
C30EDC-WH
C31EDC-WH/BK
C33STR-BK
C46HRN-WH
V31REV-WH/BK
V30FWD-WH
C34SA-BK/WH
C21IGN-WH
R35RPM-BK/RD
VLVRET1-BR
BATECU-RD
SYS_BAT_PWR
SYS_BAT_GND
P1-01
TO MICRO
TO PLD
TO MICRO
P1-02
P57PBD-RD/WH
3-10A
BATVLV-RD
P_6R2
P21
8 WAY
P2-05
P56PRV-RD
S56PRV-RD
P56PRV-RD
P27
P_6R1
P53LS-WH/BK
P2-04
P63LS-OR/RD
P54ENG-BK/WH
C60AXEX-GN/WH
DCON ECU PWR
C61AXRT-GN
P2-03
P21DCON-RD
P53LS-WH/BK
P57PBD-RD/WH
DCON ECU GND
S56PRV-RD
P2-02
GNDDCON-BR
P2-01
J32-ENG HARN
P21DCON-RD
J1 BLACK 23 PIN
GNDDCON-BR
31
2
LSB1DO
10 DEG
P
1
LSB7DS
11 DEG
P116HYD-OR
FAN
BELT
BREAK
SWITCH
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
5
1
30
85 87 87a
4
2
K1 86
5
1
30
85 87 87a
4
2
K2 86
J11
J10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
5
85
87a
87
K5 86
30
2
1
TO MICRO
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
5
85
4
1
30
87 87a
2
K6 86
5
5
85
85 87
87a
87a
87
30
30
K4 86
K3 86
2
1
2
1
Y
LSB13AO
53 DEG
P56PRV-RD
4
FST1S
LOW
FUEL FS
87
LST1O
DRV
ENABLE
1 30
LSB8AS
50 DEG
P56PRV-RD
TO DRIVELAMPS
C64LS-OR/BK
24
87a 3
SJ3-WH
FUSE
12 VOLT
S56PRV-RD
S56PRV-RD
31
DEUTZ F4L913
86
C70PBE-BL/WH
24
TROMBETTA
TIME DELAY
MOM N.O.
4.5 DEGREE
TURNTABLE
TILT
SENSOR
30
P57PBD-RD/WH
31
FUSE
86
P58LS-RD/BK
P27
P
LSB20LO
NO
86
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,
85 87 87a K8
TURNTABLE ROTATE VLV.
K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH
86
30
85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES:
PRIMARY VALVES 1 & 2, THROTTLE (IGN),
86
GLOW PLUG, STARTER RELAY, AC GENERATOR,
30
BOOM RETRACT, MULTIFUNCTION VALVE,
ROTATE CW, AND ROTATE CCW.
85 87 87a 85 87 87a 85 87 87a
K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY
86
86
86
K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.
30
30
30
(FUEL ON/OFF SOLENOID AND ALT FIELD)
K3
K5
K2
K7 POWERS THROTTLE OR HI/LOW SOLENOID
85 87 87a K6 85 87 87a K1
(CKT C35RPM-BK/RD)
K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
87 87a
P54ENG-BK/WH
20 A
85
P53LS-WH/BK
24
P7R
C61AXRT-GN
P
31
SEE OPTIONS FOR OTHER ENGINES
1
X
P57PBD-RD/WH
DIAG/TETHER PWR
BATGND-BR
P2-35
P2-34
P2-33
P2-32
TO MICRO
TO PLD
P10
P63LS-OR/RD
C61AXRT-GN
3
W
S62BSTO-OR
J24
V
C64LS-OR/BK
4
DEUTZ ENGINE
4
TO AUX HYD RELAY PR1
P29 ENG HARN
3
P58LS-RD/BK
DIAG/TETHER GND
SEE GENERATOR OPTIONS
TURNTABLE ROT CCW VLV
P53LS-WH/BK
3
MULTI FUNC VLV
85
P114BAT-RD
TURNTABLE ROT CW VLV
C47OUT-WH/BK
1
MANIFOLD HARN
BOOM RET VLV
GNDDCON-BR
C45GEN-GN/WH 1
2
BAT GND-BR
U
C71PBE-BL/BK
3
P9A
P6R1
BOOM EXTEND VLV
P63LS-OR/RD
J4 WHITE 35 PIN
BOOM UP VLV
P21DCON-RD
RET85TTSR-BR
VLVRET4-BR
BOOM HARN
TCON
BOOM DWN VLV
S56PRV-RD
P11
BOOM EXT/RET F.C.
J29 PWR HARN
P10
TURNTABLE CW/CCW F.C.
P57PBD-RD/WH
P85TTSR-GN
BOOM UP/DWN F.C.
C83TAX-GN/WH
BAT GND-BR
P
4
C84TAY-GN/BK
OIL TEMP SENDER
LSB14AO
P2-30
C78PS-WH/BK
J2 BLACK 35 PIN
LIMIT SWITCH HARNESS
C26TSR-WT/RD
3
OPTIONAL HYDRAULIC
PRESSURE SENSOR
ENGINE HARN
BAT CBL(A)-RD
LSB13AO
P2-29
C77AS-WH
VLV RET
LSB4EO
P2-28
C76PBE-BL
VLVRET1-BR
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
PRI#2 LO
P2-25
SNSR GND-BR
G119SR-BL
PRI#1 LO
P2-24
V75PRLO-RD/WH
P2-22
P2-23
V74PRLO-RD
POWER HARN
P33STR-BK
LSB3EO
P2-20
C71PBE-BL/BK
TO MICRO
TO PLD
TO MICRO
P_22
C116HYD-OR
LSB3RO
P2-19
C70PBE-BL/WH
J5 BLACK 4 PIN
TO MICRO
P116HYD-OR
LSB2RO
P2-18
C69PBE-BK
P2-21
LSB1DO
P2-17
C68PBD-RD
P11
70 A FUSE
WAS 40A BEFORE
S100/105- SN 134
S120/125- SN 369
CB
P2-15
C66DREN-BL
TCON
25A
LST10
P2-14
C65LOFL-BL/WH
TCON
BAT CBL(A)-RD
TO WORK LIGHTS 87a
AUX MAIN
FST1S
P2-13
C64LS-OR/BL
P6R1
C34SA-BK/WH
C60AXEX-GN/WH
P114BAT-RD
OPER SW PWR
P2-12
P63LS-OR/RD
BM U/D FC O
BM E/R FC O
TN
PK
GR
BOOM UP/DWN FC RECOVERY SIGNAL
OIL PRESSURE
24
C64LS-OR/BK
P_18
P2-11
S62BSTO-OR
BM RET O
BM DWN O
YL
BL
PR
BOOM UP/DWN FC RECOVERY SIGNAL
C25PSR-WT/BK
D81CAN- -GN
31
C64LS-OR/BK
P_14
P2-10
C61AXRT-GN
BM 3' I
BM 100' I
PRI LO#1 O
PWR IN SERV OR BM DWN ST I
RECOVERY
PROVIDES PWR AUX HYD O
TO MINIMAL
MLT FNC VLV O
HARDWARE
SERVICE OR
RECOVERY
MODE
PWR TO TCON ESTOP 1
TCON ESTOP 2
TETHER ESTOP 3
TCON OR PCON MODE 4
PCON MODE 5
GY
BR
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
C21IGN-WH
D80SHLD-N/A
24
C65LOFL-BL/WH
P_12
P2-09
C60AXEX-GN/WH
P6R1
WT
OR
BOOM DWN RECOVERY SIGNAL
E35ESPK-BK/RD
31
C64LS-OR/BK
P_11
P2-08
S59CNBK-GN/WH
7
LT GR
BOOM EXT/RET FC RECOVERY SIGNAL
HOLD
P20
12 WAY
C66DREN-BL
P_10
P2-07
P58LS-RD/BK
8
OUTPUT PWR ENABLE 6
9
P7R
10
SERV. OR OPER. REC.
P22
BOOM DWN RECOVERY SIGNAL
PULL IN
D82CAN+ -YL
J20
12 WAY
P56PRV-RD
P_9B
P2-06
P57PBD-RD/WH
12
BOOM DWN RECOVERY SIGNAL
BAT GND-BR
9 10 11 12
SJ3-WH
P_9A
P2-05
S56PRV-RD
13
P7
FUEL TYPE
SPARE 2
COORD STEER
CRAB STEER
REAR STEER
FRONT STEER
DRIVE SPEED
AXLE EXTEND
ENGINE SPEED
AXLE RETRACT
SPARE 1
BOOM EXT/RET FC RECOVERY SIGNAL
R116HYD-OR
8
C68PBD-BL
P_7R
P2-04
P54ENG-BK/WH
14
P11
10
9
8
7
6
START
DRIVE ENABLE
6
5
4
H4_THUMB_RT
H4_THUMB_LT
3
BOOM RET RECOVERY SIGNAL
BAT GND-BR
7
S62BSTO-OR
P_6R1
P_6R2
P2-03
P53LS-WH/BK
TO PLD
DCON ECU PWR
P2-02
P21DCON-RD
P2-16
DCON ECU GND
P2-01
GNDDCON-BR
P15
SERV. OR
OPER. REC.
TO MICRO
P15
15
TCON MODE
OPER. REC. 11
16
ALARM GND
ALARM PWR
GR/WT
YL/WT
PR
LT BL
BK
RD
P2
P2
P2
P2
P2
5
4
3
2
1
10
9
8
7
6
START ASSIST
AUXILIARY
AC GENERATOR
HORN
H4_PWR
H4_XOUT
H4_YOUT
P4
P3
P2
P1
BOOM RET RECOVERY SIGNAL
BAT GND-BR
6
P53LS-WH/BK
P1-23
P1-22
P1-21
P2
P2
P2
P2
P2
P1
P1
P1
P1
P1
5
4
3
2
1
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
P4
P3
P2
P1
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
R34SA-RD
5
C60AXEX-GN/WH
P1-19
10
9
8
7
6
5
4
3
2
1
P1
P1
P1
P1
P1
H4_GND
H3_YOUT
H3_PWR
H3_GND
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
MULTI FUNCTION VLV RECOVERY SIGNAL
FLAMMSTART
IGNITOR
4
S56PRV-RD
CANRS232_GND
P1-18
P9A
VLVRET2-BR
3
C64LS-OR/BK
CAN+
P1-17
PWR-PCON ESTOP
HRN RLY CNTRL
P1-16
P1-20
OUT PWR ENBL
P1-15
PCON POWER
P11
C30EDC-WH
2
P9A
P6R1
FWD VLV A
SOLENOID
1
C64LS-OR/BK
P1-13
P10
C31EDC-WH/BK
8
SJ1-WH/RD
RS232_TXD
BOOT
P1-12
P1-14
CAN SHIELD
RS232_RXD
P1-11
P22
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P7
PCON PWR
P1-02
P1-03
PCON GND
P1-01
PCON POWER
REV VLV B
SOLENOID
7
C78AS-WH/BK
SAFE PL TILT PWR
P1-23
U20
P7R
VLVRET2-BR
6
P54ENG-BK/WH
SAFE PL TILT GND
P1-22
U32
RD-HOLD
5
P53LS-WH/BK
PL TILT SNSR PWR
P1-21
P7R
WH-PULL IN
4
P57PBD-RD/WH
PL TILT SNSR
P1-20
PWR-PCON ESTOP
BATGND(A)-BK
3
P58LS-RD/BK
PL TILT SNSR GND
P1-19
P_22
RD
2
SJ1-WH/RD
FOOT SW RTN
P1-17
P_7
WH
J21
1
8 WAY
S56PRV-RD
FOOT SW PWR
P1-16
TCON MODE
BK
P56PRV-RD
C71PBE-BL/BK
FUSE
3-10A
SAFE PL TILT OUT
P1-15
TCON MODE
HOLD
P21
8 WAY
C64LS-OR/BK
TET ESTOP RET
RS232 GND
CAN HIGH
CAN LOW
CAL FREQ 2
TET ESTOP PWR
CAL FREQ 1
BOOT
RS232 TXD
RS232 RXD
CAN SHIELD
FLASHING BEACON
WORK LT
P_22
P_7
LOAD SNSR PWR
P1-14
P_7
PULL IN
TETHER ESTOP RET
P57PBD-RD/WH
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
P1-16
P1-15
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
PWR-PCON ESTOP
OUT PWR ENBL
LOAD SNSR OUT
P1-13
OUT PWR ENABLE
VLVRET2-BR
TETHER ESTOP PWR
C61AXRT-GN
P95TET-OR
P96TET-RD
TETGND-BR
TETFUNC-WH
D82CAN+ -YL
D81CAN- -GN
P97TET-BK
D80SHLD-N/A
R49LP-WH/BK
R48LP-WH/RD
P56PRV-RD
S56PRV-RD/WH
P1-05
P1-04
LOAD SNSR GND
P1-12
P_9B
C107AF-RD
TETHER FUNC ENABLE
S62BSTO-OR
C47OUT-WH/BK
PROX KILL CMD
P1-11
P1-18
PROX KILL GND
P1-10
H1_GND
ESTOP_1
H4_THUMB_RT
ESTOP_2
H4_THUMB_LT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
H1_GND
S3-3
S3-2
S3-1
S2-3
S2-2
S2-1
S1-3
S1-2
S1-1
AUXILIARY HYD RECOVERY SIGNAL
T
LSB3RO
3' EXT
P57PBD-RD/WH
P23PCON-BK
PROP VLV1_B
P1-08
P_6R2
S
LSB4ES
75.5'
(before serial number 921)
P27-LIMIT SW
OUT PWR ENABLE
R46HRN-WH
P21DCON-RD
HORN RELAY COIL
PROP VLV1_A
P1-07
PRI BOOM DOWN STATUS
BAT GND-BR
Genie S-120/125
PCON POWER
P23PCON-BK
D81CAN- -YL
D82CAN+ -GR
C46HN-WH
C47OUT-WHT/BLK
P56PRV-RD
S56PRV-RD/WH
PROP VLV2_B
P1-06
P1-09
PROP VLV2_A
P1-05
PRI BOOM LENGTH 100' STATUS
C41RPM-OR/BK
J27-BOOM HARN
P_9B
C27AUX-RD
GNDDCON-BR
P1-03
5A
FUSE
P52PCON-WH
GNDPCON-BR
SAFE PL TILT OUT
FOOT SW PWR
P1-15
P87PTS-RD
PTSRET-BR
P85PTS-GN
C84TAY-GN/BK
PLATRET-BR
C56PTS-RD
R56PTS-RD
C88PTS-RD/BK
P1-16
BK
WH
GN
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
C14PLU-OR
C44JD-GN/BK
C43JU-GN
LOCKOUT VALVE #1 SIG
VLVRET6-BR
(before serial number 231)
P1-02
P1-01
PCON GND
C56PTS-RD
R56PTS-RD
OUT FRM TILT SWITCH
PWR TO TILT SWITCH
TILT SWITCH GND
TILT SENSOR PWR
TILT SENSOR SIG OUT
PLAT SENSOR GND
NOT USED
PLAT LEVEL DN
PLAT LEVEL UP
JIB DOWN
JIB UP
PRI BOOM LENGTH 3' STATUS
R
LSB3RS
3.5 EXT
Genie Part Number 228879 Rev A
CAN SHIELD
Q
LSB3EO
75' EXT
ES105SD Rev C ES125SD Rev G
CAN SHIELD
PR1
Genie S-100/105
AMP
BAT GND-BR
6
CAN LOW
P
P33STR-BK
6
AUXILIARY HYD RECOVERY SIGNAL
START BAT
5
MULTI FUNCTION VLV RECOVERY SIGNAL
MAIN (SYS)
BAT
GN
5
D81CAN- -GN
V75PRLO-RD/WH
YL
P6R1
4
CAN HIGH
VLVRET1-BR
P11
88
4
D82CAN+ -YL
4
V74PRLO-RD
88
3
3
PRI 2 LO
YL
GN
3
P7-LIMIT SW HARN
O
PRI 1 LO
BL
2
J27
2
FST1S
LOW
FUEL FS
P18
BR
1
2
TETHER INTERFACE
1
LST1O
DRV
ENABLE
88
P12
J7
1
P6R1
LSB1DO
10 DEG
BL
88
OR
P24
P7R
LSB7DS
11 DEG
P9A
86
PWR TO TCON ESTOP
C77AS-WH
DCON PWR RD
88
2
30
PWR TO TCON ESTOP
SJ2-BK/RD
88
1
2
87
SJ2-BK/RD
RD
OR
WH
P8-LIMIT SW HARN
TO FLASHING BEACON 87a
SJ3-WH
BR
GNDPCON-BR
TO HORN BUTTON
LSB13AO
53 DEG
6
DCON GND BK
S56PRV-RD/WH
85
N
LSB14AO
68 DEG
6
P7R
88
J8
1
30
TO HORN BUTTON
LSB9AS
65 DEG
5
88
BK
C
87
LSB8AS
50 DEG
5
WH
C
C46HN-WH
P_7
C64LS-OR/BK
4
CAN SHIELD
B
P52PCON-WH
86
P_22
SJ3-WH
4
88
B
P23PCON-BK
S56PRV-RD
3
GRN
FOOTSWITCH
PCON POWER
C70PBE-BL/WH
3
FOOTSWITCH
12 VOLT
P57PBD-RD/WH
2
CAN LOW
P6-BOOM HARN
5A FUSE ADDED
S100/105- SN 188
S120/125- SN 584
TCON
P58LS-RD/BK
P17
1
88
A
OPTIONAL
PROXIMITY
KILL WIRING
P11
SJ2-BK/RD
1
2
GRN
J6
A
2
J1 BLACK 23 PIN
BOOM HARN
P63LS-OR/RD
2
YEL
PROX
KILL
1
4
C70PBE-BL/WH
2
(SLIP RING)
2
85 5
SJ1-WH/RD
24
ON/OFF VLV3_B
TCON MODE
LSB3RO
3' EXT
AXLE NOT EXT
LIMIT SWITCHES
31
P18
1
1
PLATFORM
TILT SENSOR
ASSEMBLY
87
C61AXRT-GN
24
C
24
87a 3
PLD
P57PBD-RD/WH
P53LS-WH/BK
C
CAN HIGH
J31-TILT SNSR
5A
(SLIP RING)
5A FUSE ADDED
S100/105- SN 188
S120/125- SN 584
4
P63LS-OR/RD
C60AXEX-GN/WH
ON/OFF VLV3_A
1 30
85 5
S62BSTO-OR
P63LS-OR/RD
P1-04
87
S59CNBK-GN/WH
D80SHLD-N/A
88
J2 WHITE 23 PIN
PCON MANIFOLD
87a 3
C64LS-OR/BK
C61AXRT-GN
P1-03
P6R
C76PBE-BL
P21DCON-RD
C18PRR-GN/BK
P7R
C71PBE-BL/BK
J3-OR/BL
C17PRL-GN
OUT PWR ENABLE
SJ2-BK/RD
P57PBD-RD/WH
PLAT ROT CW
VLV RTN
ECU
SJ1-WH/RD
J17-DRIVE CHASSIS HARN
B
YEL
PCON
MEMBRANE/LED INTERFACE CARD
C64LS-OR/BK
J2-BL/RD
P1-02
P1-01
30
29
28
PCON MEMBRANE PANEL
C76PBE-BL
11
PLAT ROT CCW
VLVRET-BRN
6
2 86
C46HN-WH
P1-23
P1-22
P1-21
27
26
25
24
23
22
21
20
19
18
17
16
15
J3 10PIN
GNDPCON-BR
RS232 GND
P1-19
AXLE NOT EXT PWR
CAN HIGH
P1-18
P1-20
CAN LOW
P1-17
P1-16
P1-15
K2
J2 10PIN
P52PCON-WH
BOOT
P1-13
1 30
TCON
C69PBE-BK
S56PRV-RD
B
WH
RD
BK
RS232 TXD
P1-12
2 86
PCON
RECOVERY
LSB4ES
75.5'
WHEN AXLES
ARE EXTENDED
TERM 3 & 4
ARE CLOSED
GN
RS232 RXD
P1-11
K1
SERV. BYPASS
M
LSB3RS
3.5 EXT
P
P61LS(A)-GN
CAN SHIELD
P1-10
AXLE NOT EXT SIG
AXLE NOT RET PWR
P1-09
P1-14
AXLE NOT RET SIG
P1-08
14
13
12
11
10
9
8
7
6
5
4
3
2
1
P20
J1 10PIN
FUSE
LOAD SENSOR
ASSEMBLY OPTION
24
Joystick Adaptor Harness
3
P54ENG-BK/WH
GNDDCON-BR
P16
A
31
Deutsch
1
LSB3EO
75' EXT
P
D82CAN+ -YL
D81CAN- -GN
C61LS(A)-GN
P12
P1-06
P1-07
P_7R
P1-05
10 WAY ENGINE HARN TO ENGINE
2
RUN
P53LS-WH/BK
D81CAN- -GN
A
1
3
4
OFF
P58LS-RD/BK
D82CAN+ -YL
NO
6
4
5
P54ENG-BK/WH
J16-DRIVE CHASSIS HARN
NC
5
2
6
P63LS
C
P63LS-OR/RD
PROX
KILL SW.
OPTIONAL
4
5
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
LSB4EO
100' EXT
P
31
DCON
3
P33-PCON
MANIFOLD
1
GND
PWR
XOUT
YOUT
RKOUT
S59CNBK
4
C60AXEX-GN/WH
P57PBD-RD/WH
10
J18-DRIVE CHASSIS HARN
JOYSTICK CONNECTORS (after serial number S120- 1616; S100- 419)
6
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
C64LS-OR/BK
3
31
2
DRIVE & STEERING
JOYSTICK
L
C69PBE-BK
4
1
NOT USED
K
LSB6S
CHNBRK
AXLE RETRACTION
LIMIT SWITCHES
3
J1 BLACK 23 PIN
DRIVE CHASSIS HARN
BOOM EXT/RET
JOYSTICK
J
LSB2RO
100'
WHEN AXLES
ARE RETRACTED
TERM 3 & 4
ARE CLOSED
4
D80SHLD-N/A
P_6R1
P1-03
7
BOOM UP/DWN &
TURNTABLE ROTATE
JOYSTICK
I
SJ1-WH/RD
3
P61LS-GN
DCON ECU PWR
P1-02
2 WAY DEUTSCH-PWR HARN/ENG HARN
PCON
E-STOP
H
SJ2-BK/RD
4
J4-GN/BK
DRIVE & STEERING
JOYSTICK
G
P53LS-WH/BK
3
NOT USED
F
LSB2RS
101'
J1-BL/BK
BOOM EXT/RET
JOYSTICK
LSAX2ES
12
P1-04
DCON ECU GND
P1-01
J20
ALARM+
ALARM-
BOOM UP/DWN &
TURNTABLE ROTATE JOYSTICK
LSAX1ES
P
LSAX2EO
B
LSAX1EO
A
J2 WHITE 23 PIN
DRIVE CHASSIS HARN
C61LS-GN
LF STEER LEFT
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR
6 WAY ENGINE HARN TO TILT SENSOR
4 WAY ENGINE HARN-AC GENERATOR
PCON MANIFOLD/TILT SENSOR
JIB
C61AXRT-GN
LF STEER RIGHT
P2-23
J30
J31
J32
J33
LSAX2RO
RF STEER LEFT
P2-22
P30
P31
P32
P33
9 WAY DEUTSCH TETHER CONNECTOR
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN
2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
S56PRV-RD
STEER SNSR PWR
P2-21
12 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
P53LS-RD
STEER SNSR GND
P2-20
J20
J21
J23
J24
J25
J26
J27
J28
J29
P21DCON-WH
RF STEER RIGHT
P2-19
P20
P21
P23
P24
P25
P26
P27
P28
P29
GND-DCON-BR
LR STEER LEFT
P2-18
PCON PCB TO MEMBRANE SWITCH
PCON PCB TO MEMBRANE SWITCH
LSAX1RO
LR STEER RIGHT
P2-17
J1
J2
LF STEER LEFT
BRAKE
P2-16
P1
P2
LF STEER RIGHT
VALVE RTN2
P2-15
TCON PCB TO MEMBRANE SWITCH
TCON PCB TO MEMBRANE SWITCH
RF STEER LEFT
LR STEER SNSR
P2-14
J10
J11
RF STEER RIGHT
RF STEER SNSR
P2-13
P10
P11
LR STEER LEFT
LR STEER SNSR
P2-12
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
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
LR STEER RIGHT
RR STEER SNSR
P2-11
J6
J7
J8
J16
J17
J18
RR STEER LEFT
RR STEER LEFT
P2-10
P6
P7
P8
P16
P17
P18
RR STEER RIGHT
RR STEER RIGHT
P2-09
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN
WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN
V37LFS-BL/BK
AUX REVERSE
P2-07
J1
J2
V36LFS-BL
AUX FORWARD
P2-06
P2-08
P1
P2
V37RFS-BL/BK
MOTOR SPEED
P2-04
BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
BK
C
P109ANG-GN/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BRN
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
V52AREV-BL/RD
V52AFV-BL/RD
AXLE EXTEND
P2-03
P2-05
AXLE RETRACT
P2-02
P_6R2
J1
J2
BL
RD
B
LF STEER RIGHT
A
BK
C
BL
RD
B
BK
A
BL
RD
C
RF STEER RIGHT
LR STEER RIGHT
B
BK
A
BL
RD
VALVE RTN1
P2-01
J144
V29MS-RD/WH
V60AXEX-GN/WH
V61AXRT-GN
VLVRET-BRN
9
BRAKE
5
AUX REVERSE
8
AUX FORWARD
MOTOR SPEED
4
AXLE EXTEND
RR STEER RIGHT
13
AXLE RETRACT
OUT PWR ENABLE
P1
P2
PLATFORM PLATFORM
ROTATE
LEVEL
E
-
PCON
ALARM
D
-
3
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 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
C
+
2
PLUG NO JACK NO
J1
P1
J2
P2
J3
P3
J4
P4
J5
P5
B
+
A
Z
1
7
AUXILIARY HYD RECOVERY SIGNAL
TO HORN BUTTON
PWR TO TCON ESTOP
U95
TCON MEMBRANE PANEL
TO HORN BUTTON
TO MICRO
P_22R
DETAIL E - TCON RELAY PARKING
30
K7
30
TCON
J2 BLACK 35 PIN
LIMIT SWITCH HARNESS
OPTIONAL HYDRAULIC
PRESSURE SENSOR
24
31
24
J264 WAY1
2
31
3
24
31
4
24
31
24
31
24
31
AXLE EXTENTION
LIMIT SWITCHES
24
31
24
ENGINE BLOCK
-BAT
LIMIT SWITCHES
S-120/125
AUX.
PUMP
BR-COM
87a 87 85
4
5
15A
CB7 ADDED
S100- S/N 710
S120- S/N 2589
P57PBD-RD/WH
BAT.
+
BAT.
-
IND.
1
30
ALTERNATOR
EXCT.
2
86
HORN
87a 87 85 RELAY
4
5
GLOW PLUG2
RELAY
86
P21DCON-RD
1
REGULATOR
SERVICE
HORN
2
HI/LO
SPEED
SOLENOID
3
30
1
HYD COOLER
2
RELAY
86
85 87 87a
5
4
1
30
85 87 87a
5
4
STA.
FAN
FUEL
SOLENOID
RELAY
VLVRET6-BR
C27AUX-RD
C27AUX-RD
VALVE RTN6
VALVE RTN7
C06TTR-WH/BK
C05TTL-WH
C113MFV-OR/RD
P63LS-OR/RD
P53LS-WH/BK
P27
P56PRV-RD
2
3
24
4
5
6
7
8
LIMIT SWITCHES
S-100/105
1
LSB3RO
LSB3EO
P2-19
P2-20
C70PBE-BL/WH
C71PBE-BL/BK
LSB13AO
LSB14AO
P2-29
P2-30
C77AS-WH
C78PS-WH/BK
FUSE
3-10A
BATVLV-RD
REV
P1-06
2
3
4
5
6
31
7
8
24
31
24
9 10 11 12 J20
12 WAY
31
24
31
31
24
24
31
24
3
4
P
31
24
31
C64LS-OR/BK
P56PRV-RD
SJ3-WH
C68PBD-BL
S62BSTO-ORN
P53LS-WH/BK
C60AXEX-GN/WH
P5-03
P5-04
AUX/START_BAT_GND
FWD
REV
SERVICE_HORN
P3-05
P3-06
P3-07
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
VALVE_RTN2
P3-14
P3-15
P3-16
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC_GENERATOR
VALVE_RTN3
P3-20
P3-22
P3-23
P3-19
P3-21
ALTENATOR_RPM
ALT_FIELD_WIRE
P3-18
P3-17
OIL_PRESSURE
OIL/WATER_TEMP
P3-12
P3-13
C31EDC-WH/BK
C30EDC-WH
P3-10
P3-11
STARTER_RELAY
P3-09
P3-08
IGNITION/FUEL
CHOKE/GLOW PLUG
P3-03
P3-04
THROTTLE
BOOM_EXT/RET_VLV
P4-02
P4-03
BOOM_DOWN_VLV
BOOM_EXTEND_VLV
BOOM_RETRACT_VLV
P4-08
P4-09
P4-10
VALVE_RTN7
P4-27
DCON ECU PWR
P_6R1
P_6R2
P_7R
P_9A
P_9B
P_10
P_11
P_12
P_14
P_18
OPER SW PWR
FST1S
LST10
P2-03
P2-04
P2-05
P2-06
P2-07
P2-08
P2-09
P2-10
P2-11
P2-12
P2-13
P2-14
P2-15
P53LS-WH/BK
P54ENG-BK/WH
S56PRV-RD
P57PBD-RD/WH
P58LS-RD/BK
S59CNBK-GN/WH
C60AXEX-GN/WH
C61AXRT-GN
S62BSTO-OR
P63LS-OR/RD
C64LS-OR/BL
C65LOFL-BL/WH
C66DREN-BL
AUX_RELAY
DCON ECU GND
P4-35
P4-34
P4-33
P4-32
P4-31
P4-30
P4-29
VALVE_RTN6
ROTATE_CCW_VLV
P4-26
P4-28
ROTATE_CW_VLV
P4-25
P4-24
P4-23
P4-22
P4-21
P4-20
MULTI_FUNCT_VLV
BOOM REVERSE LOAD
P4-18
P4-19
HYD_FILTER2
BOOM OVERLOAD
C77AS-WH
G119SR-BL
SNSR GND-BR
LSB1DO
LSB2RO
LSB3RO
LSB3EO
P2-17
P2-18
P2-19
P2-20
PRI#2 LO
P2-24
LSB4EO
LSB13AO
LSB14AO
P2-28
P2-29
P2-30
P2-35
P2-34
P2-33
P2-32
VLV RET
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
P2-25
PRI#1 LO
P2-23
P2-22
TO MICRO
TO MICRO
TO MICRO
TO PLD
HYD_FILTER1
P4-15
P4-17
VALVE_RTN5
P4-14
P4-16
TO MICRO
TO PLD
DRIVE LIGHTS RELAY
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
2
1
K8 86
30
87 87a
85
5
4
TO MICRO
P4-13
P4-12
P4-11
BOOM_UP_VLV
P4-07
P4-06
P4-05
P2-02
P2-21
4
P4-04 TURNTABLE_ROTATE_VLV
VALVE_RTN4
BOOM_UP/DOWN_VLV
P4-01
P2-01
P2-16
5
85
1
30
87 87a
TO MICRO
TO MICRO
TO PLD
TO MICRO
2
K7 86
AUX/START_BAT_PWR
P3-02
P3-01
SYS_BAT_PWR
SYS_BAT_GND
P21DCON-RD
C64LS-OR/BK
2
S56PRV-RD
1
4
C77AS-WH
C64LS-OR/BK
P20
12 WAY
C65LOFL-BL/WH
C64LS-OR/BK
C66DREN-BL
P57PBD-RD/WH
P58LS-RD/BK
P54ENG-BK/WH
P53LS-WH/BK
S56PRV-RD
SJ3-WH
C71PBE-BL/BK
C64LS-OR/BK
P57PBD-RD/WH
C61AXRT-GN
S62BSTO-OR
P5-01
P5-02
TO MICRO
TO PLD
TO MICRO
TO PLD
TO MICRO
GNDDCON-BR
C14LS-BK/RD
C15LS-RD/BK
VLVRET5-BR
R49LP - WH/BK
J31-TILT
SNSR
P31-ENG
HARN
VLVRET3-BR
C45GEN-GN/WH
C84TAY-GN/BK
C83TAX-GN/WH
C107AF-RD
C41RPM-OR/BK
VLVRET2-BR
P85TTSR-GN
RET85TTSR-BR
C26TSR-WH/RD
C25PSR-WH/BK
C30EDC-WH
C31EDC-WH/BK
C33STR-BK
C46HRN-WH
DETAIL B
C34SA-BK/WH
C21IGN-WH
R35RPM-BK/RD
FWD
P1-05
BATECU-RD
BATGND-BR
BATGND-BR
P2-35
P2-34
P2-33
P2-32
VLV RET
LSB4EO
P2-28
C76PBE-BL
VLVRET1-BR
PRI ANG
P2-27
P2-31
SNSR GND
P2-26
PRI#2 LO
P2-25
SNSR GND-BR
G119SR-BL
PRI#1 LO
P2-24
V75PRLO-RD/WH
P2-22
P2-23
V74PRLO-RD
C71PBE-BL/BK
C60AXEX-GN/WH
P63LS-OR/RD
C61AXRT-GN
C70PBE-BL/WH
P21DCON-RD
C70PBE-BL/WH
P57PBD-RD/WH
C68PBD-RD
S56PRV-RD
P54ENG-BK/WH
GNDDCON-BR
3
LSB1DO
10 DEG
C08PBR-BK/WH
C07PBE-BK
C02PBD-RD/BK
C01PBU-RD
C06TRF-WH/RD
J32-ENG HARN
2
LSB7DS
11 DEG
1
1
LSB13AO
53 DEG
J21
8 WAY
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
5
1
30
85 87 87a
4
2
K1 86
YL
BL
PR
GY
BR
WT
LT GN
5
BK
RD
J11
J10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
85
87a
87
K5 86
30
2
1
5
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P1
P1
P1
P1
TO MICRO
OR
GN/WH
YL/WH
PR
LT BL
85 87 87a
4
1
30
2
K2 86
TN
PK
GN
10
9
8
7
6
5
4
3
2
1
P1
P1
P1
P1
P1
P1
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
5
85
2
K6 86
4
1
30
87 87a
FUEL TYPE
SPARE 2
COORD STEER
CRAB STEER
REAR STEER
FRONT STEER
DRIVE SPEED
AXLE EXTEND
ENGINE SPEED
AXLE RETRACT
SPARE 1
DRIVE ENABLE
START
START ASSIST
AUXILIARY
AC GENERATOR
HORN
5
85
85 87
87a
87a
87
30
30
K4 86
K3 86
2
1
2
1
5
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
NOT USED
H4_RKOUT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
P4
P3
P2
P1
Y
FST1S
LOW
FUEL FS
P21
8 WAY
LST1O
DRV
ENABLE
P56PRV-RD
LSB8AS
50 DEG
CB 7
C64LS-OR/BK
2
+AUX
SJ3-WH
1
WH-PULL
S56PRV-RD
GNDDCON-BR
24
2
86
RD-HOLD
31
86
C70PBE-BL/WH
S56PRV-RD
31
+BAT
OTS1
N.O.
J27
30
P57PBD-RD/WH
24
P34SA-RD
85 5
P53LS-WH/BK
2 86
86
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,
85 87 87a K8
TURNTABLE ROTATE VLV.
K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH
86
30
85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES:
PRIMARY VALVES 1 & 2, THROTTLE (IGN),
86
GLOW PLUG, STARTER RELAY, AC GENERATOR,
30
BOOM RETRACT, MULTIFUNCTION VALVE,
ROTATE CW, AND ROTATE CCW.
85 87 87a 85 87 87a 85 87 87a
K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY
86
86
86
K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.
30
30
30
(FUEL ON/OFF SOLENOID AND ALT FIELD)
K3
K5
K2
K7 POWERS THROTTLE OR HI/LOW SOLENOID
85 87 87a K6 85 87 87a K1
(CKT C35RPM-BK/RD)
K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
87 87a
P58LS-RD/BK
P46HRN-WH
87a 3 TO DRIVE
LAMPS
4
1 30
87
85
P54ENG-BK/WH
31
70 A FUSE
86
P53LS-WH/BK
24
1
30
TO MICRO
C61AXRT-GN
P
31
STARTER
RELAY
TO HORN BUTTON
P57PBD-RD/WH
4
TROMBETTA
TIME DELAY
MOM N.O.
12 VOLT
P63LS-OR/RD
D81CAN- -GN
P
LSB20LO
NO
X
S62BSTO-OR
P116HYD-OR
P
1
C64LS-OR/BK
20 A
4.5 DEGREE
TURNTABLE
TILT
SENSOR
C71PBE-BL/BK
FUSE
P
W
LSB6S
CHNBRK
P56PRV-RD
3
P58LS-RD/BK
P27
4
TO AUX HYD RELAY PR1
DEUTZ BF4L-2011/TD2011-L04I
ENGINES SHOWN
3
TURNTABLE ROT CW VLV
P
BOOM RET VLV
S56PRV-RD
TURNTABLE ROT CCW VLV
D82CAN+ -YL
MULTI FUNC VLV
P7-LIMIT SW HARN
SEE GENERATOR
OPTION PAGE
BOOM DWN VLV
P63LS-OR/RD
P9A
P6R1
BOOM EXTEND VLV
C60AXEX-GN/WH
3
BAT GND-BR
P114BAT-RD
BOOM UP VLV
GNDDCON-BR
C45GEN-GN/WH 1
2
BAT GND-BR
OIL TEMP SENDER
P56PRV-RD
RET85TTSR-BR
C09PERF-BK/RD
P85TTSR-GR
C26TSR-WH/RD
C47OUT-WH/BK
C83TAX-GR/WH
OIL PRESSURE
BOOM HARN
C84TAY-GR/BK
J4 WHITE 35 PIN
MANIFOLD HARN
BOOM EXT/RET F.C.
P53LS-WH/BK
DETAIL B
HIGH CURRENT
VALVE PROPEL
OUTPUT
TCON
TURNTABLE CW/CCW F.C.
C61AXRT-GN
P11
C03PBF-RD/WH
LSB2RO
P2-18
C69PBE-BK
P2-21
LSB1DO
P2-17
C68PBD-RD
J2 BLACK 35 PIN
LIMIT SWITCH HARNESS
P10
C25PSR-WH/BK
3
OPTIONAL HYDRAULIC
PRESSURE SENSOR
J3 WHITE 23 PIN
ENGINE HARN
VLVRET4-BR
P2-15
C66DREN-BL
J5 BLACK 4 PIN
POWER HARN
BOOM UP/DWN F.C.
LST10
P2-14
C65LOFL-BL/WH
P11
C21IGN-WH
P21DCON-RD
P6R1
BAT GND-BR
FST1S
P2-13
C64LS-OR/BL
TCON
R116HYD-OR
P57PBD-RD/WH
P7R
BAT GND-BR
OPER SW PWR
P2-12
P63LS-OR/RD
BM U/D FC O
BM E/R FC O
BM DWN O
BM RET O
PWR IN SERV OR BM DWN ST I
RECOVERY
PROVIDES PWR AUX HYD O
TO MINIMAL
MLT FNC VLV O
HARDWARE
BM 3' I
BM 100' I
PRI LO#1 O
PWR TO TCON ESTOP 1
TCON ESTOP 2
TETHER ESTOP 3
TCON OR PCON MODE 4
PCON MODE 5
OUTPUT PWR ENABLE 6
7
P6R1
10
8
P22
P10
P116HYD-OR
P_18
P2-11
S62BSTO-OR
P11
C116HYD-OR
P_14
P2-10
C61AXRT-GN
P6R1
V31REV-WH/BK
P_12
P2-09
C60AXEX-GN/WH
P9A
R34SA-RD
J1 BLACK 23 PIN
V30FWD-WH
CB
P_11
P2-08
S59CNBK-GN/WH
TCON
25A
P_10
P2-07
P58LS-RD/BK
12
9
SERVICE OR
RECOVERY
MODE
PCON POWER
C34SA-BK/WH
TO WORK LIGHTS 87a
AUX MAIN
P_9B
P2-06
P57PBD-RD/WH
13
P7
P7R
P9A
P6R1
VLVRET2-BR
85
P114BAT-RD
P_9A
P2-05
S56PRV-RD
14
P11
SERV. OR OPER. REC.
P10
C30EDC-WH
P
4
C64LS-OR/BK
P_7R
P2-04
P54ENG-BK/WH
15
TCON MODE
OPER. REC. 11
16
ALARM GND
ALARM PWR
PCON POWER
BAT GND-BR
C60AXEX-GN/WH
3
C64LS-OR/BK
P_6R1
P_6R2
P2-03
P53LS-WH/BK
TO PLD
DCON ECU PWR
P2-02
P21DCON-RD
P2-16
DCON ECU GND
P2-01
GNDDCON-BR
P15
SERV. OR
OPER. REC.
TO MICRO
P15
P7R
GLOW PLUG
P264 WAY
24
C65LOFL-BL/WH
P1-23
P1-22
P1-21
U32
FWD VLV A
SOLENOID
C61AXRT-GN
31
C64LS-OR/BK
P1-19
P7R
C31EDC-WH/BK
D81CAN- -GN
24
C66DREN-BL
CANRS232_GND
P1-18
P_22
C41RPM-OR/BK
31
P56PRV-RD
CAN+
P1-17
PWR-PCON ESTOP
HRN RLY CNTRL
P1-16
P1-20
OUT PWR ENBL
P1-15
PWR-PCON ESTOP
REV VLV B
SOLENOID
D82CAN+ -YL
J20
12 WAY
C68PBD-BL
P1-13
P_22
VLVRET2-BR
9 10 11 12
S62BSTO-OR
RS232_TXD
BOOT
P1-12
P1-14
CAN SHIELD
RS232_RXD
P1-11
P22
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P7
PCON PWR
P1-02
P1-03
PCON GND
P1-01
P_7
BK-COM
8
P_7
BK
7
P53LS-WH/BK
SAFE PL TILT PWR
P1-23
U20
BOOM EXT/RET FC RECOVERY SIGNAL
RD-HOLD
6
C60AXEX-GN/WH
SAFE PL TILT GND
P1-22
BOOM EXT/RET FC RECOVERY SIGNAL
WH-PULL IN
5
S56PRV-RD
PL TILT SNSR PWR
P1-21
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
RD
4
C64LS-OR/BK
PL TILT SNSR
P1-20
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
WH
3
C64LS-OR/BK
PL TILT SNSR GND
P1-19
TCON MODE
TCON MODE
VLVRET2-BR
2
SJ1-WH/RD
P1-17
P_6R2
R46HRN-WH
1
C78AS-WH/BK
FOOT SW RTN
P1-16
OUT PWR ENABLE
J144-8
8
P54ENG-BK/WH
FOOT SW PWR
P1-15
P_9B
C107AF-RD
7
P53LS-WH/BK
SAFE PL TILT OUT
P1-14
PWR TO TCON ESTOP
J144-2
6
P57PBD-RD/WH
LOAD SNSR PWR
P1-13
P_6R2
J144-1
5
P58LS-RD/BK
FUSE
3-10A
LOAD SNSR OUT
OUT PWR ENABLE
HOLD
P63LS-OR/RD
4
SJ1-WH/RD
TET ESTOP RET
RS232 GND
CAN HIGH
CAN LOW
CAL FREQ 2
TET ESTOP PWR
CAL FREQ 1
BOOT
RS232 TXD
RS232 RXD
CAN SHIELD
FLASHING BEACON
WORK LT
P_22
P_7
PWR-PCON ESTOP
OUT PWR ENBL
HORN RELAY COIL
PCON POWER
LOAD SNSR GND
P1-12
H1_XOUT
H1_PWR
H1_GND
P4
P3
P2
P1
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
V
LSB3RO
3' EXT
24
3
S56PRV-RD
P1-23
P1-22
P1-21
P1-20
P1-19
P1-18
P1-17
P1-16
P1-15
P1-14
P1-13
P1-12
P1-11
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
PCON GND
P23PCON-BK
D81CAN- -YL
D82CAN+ -GR
C46HN-WH
C47OUT-WH/BK
P56PRV-RD
S56PRV-RD/WH
P52PCON-WH
PROX KILL CMD
P1-11
P1-18
PROX KILL GND
P1-10
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
U
LSB4ES
75.5'
31
2
C71PBE-BL/BK
P95TET-OR
D82CAN+ -YL
D81CAN- -GN
P97TET-BK
R117FB-RD
R48LP-WH/RD
P56PRV-RD
S56PRV-RD/WH
P23PCON-BK
C47OUT-WH/BK
C46HN-WH
P1-02
P1-01
5A
FUSE
FOOT SW PWR
P1-16
GNDPCON-BR
SAFE PL TILT OUT
P1-15
P87PTS-RD
PTSRET-BR
P85PTS-GN
C84TAY-GN/BK
C56PTS-RD
R56PTS-RD
C88PTS-RD/BK
PLATRET-BR
BK
PROP VLV1_B
P1-09
PROP VLV1_A
P1-08
P_9B
C27AUX-RD
J21
1
8 WAY
C64LS-OR/BK
GNDPCON-BR
C56PTS-RD
R56PTS-RD
OUT FRM TILT SWITCH
PWR TO TILT SWITCH
TILT SWITCH GND
TILT SENSOR PWR
TILT SENSOR SIG OUT
PLAT SENSOR GND
NOT USED
WH
GN
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
PROP VLV2_B
P1-07
ESTOP_1
NOT USED
ESTOP_2
H4_RKOUT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
H1_GND
S3-3
BOOM UP/DWN FC RECOVERY SIGNAL
T
LSB3RS
3.5 EXT
ES0427G
Genie Part Number 228880 Rev A
P53LS-WH/BK
TO HORN BUTTON
S
LSB3EO
75' EXT
Electrical Schematic
P56PRV-RD
P20
12 WAY
R
PULL IN
(from s/n 921 to s/n 2709)
LOCKOUT VALVE #1 SIG
VLVRET6-BR
P21
8 WAY
Q
BAT GND-BR
Genie S-120/125
P27-LIMIT SW
P33STR-BK
J27-BOOM HARN
PR1
(from s/n 231 to s/n 809)
PRI BOOM DOWN STATUS
BAT GND-BR
Genie S-100/105
PRI BOOM LENGTH 100' STATUS
START BAT
6
PRI BOOM LENGTH 3' STATUS
MAIN (SYS)
BAT
6
V75PRLO-RD/WH
5
P
VLVRET1-BR
GN
5
V74PRLO-RD
YL
P6R1
4
PRI 2 LO
P11
88
3
4
PRI 1 LO
88
3
4
FST1S
LOW
FUEL FS
YL
GN
2
3
LST1O
DRV
ENABLE
BL
1
2
J27
2
SJ3-WH
BR
J7
1
87
1
LSB1DO
10 DEG
P12
2
86
O
LSB7DS
11 DEG
88
2
P8-LIMIT SW HARN
30
C77AS-WH
BR
S56PRV-RD/WH
TO FLASHING BEACON 87a
LSB13AO
53 DEG
P18
GNDPCON-BR
LSB14AO
68 DEG
OR
C
P6R1
SJ2-BK/RD
P9A
C
P7R
LSB9AS
65 DEG
DCON PWR RD
88
C46HN-WH
P52PCON-WH
85
SJ2-BK/RD
88
1
30
SJ3-WH
RD
OR
B
P_7
C64LS-OR/BK
88
DCON GND BK
J8
1
87
LSB8AS
50 DEG
6
BL
WH
A
B
86
P_22
SJ3-WH
6
(SLIP RING)
P23PCON-BK
PCON POWER
S56PRV-RD
5
PLAT LEVEL DN
PROP VLV2_A
P1-06
TCON MODE
C70PBE-BL/WH
5
C14PLU-OR
C44JD-GN/BK
OUT PWR ENABLE
P57PBD-RD/WH
3
4
PLAT LEVEL UP
JIB DOWN
ON/OFF VLV3_B
P1-05
30
29
28
27
PWR TO TCON ESTOP
P58LS-RD/BK
3
4
CAN SHIELD
J6
A
P6-BOOM HARN
FOOTSWITCH
P57PBD-RD/WH
2
88
P7R
GN
PROX
KILL
2
C61AXRT-GN
2
24
12 VOLT
S62BSTO-OR
P17
1
1
BK
88
PLATFORM
TILT SENSOR
ASSEMBLY
5A
(SLIP RING)
OPTIONAL
PROXIMITY
KILL WIRING
TCON
P63LS-OR/RD
2
WH
FOOTSWITCH
1
J1 BLACK 23 PIN
BOOM HARN
SJ2-BK/RD
C
2
88
CAN LOW
J31-TILT SNSR
P11
SJ1-WH/RD
24
P18
1
88
YL
P33-PCON
MANIFOLD
FUSE
LOAD SENSOR
ASSEMBLY OPTION
24
TO HORN BUTTON
LSB3RO
3' EXT
AXLE NOT EXT
LIMIT SWITCHES
31
1
GN
CAN HIGH
31
85 5
C61AXRT-GN
24
C
88
2
4
P57PBD-RD/WH
J3-OR/BL
P1-04
2 86
87
P63LS-OR/RD
P53LS-WH/BK
C
YL
6
87a 3
PLD
S62BSTO-OR
C60AXEX-GN/WH
C43JU-GN
1 30
85 5
C64LS-OR/BK
P63LS-OR/RD
C18PRR-GR/BK
K2
4
C71PBE-BL/BK
C61AXRT-GN
JIB UP
87
C70PBE-BL/WH
P21DCON-RD
B
J2 WHITE 23 PIN
PCON MANIFOLD
87a 3
C76PBE-BL
P57PBD-RD/WH
PLAT ROT CW
P6R
SJ2-BK/RD
J17-DRIVE CHASSIS HARN
ON/OFF VLV3_A
P7R
SJ1-WH/RD
GNDDCON-BR
P1-03
OUT PWR ENABLE
S59CNBK-GN/WH
S56PRV-RD
C17PRL-GN
VLV RTN
ECU
C64LS-OR/BK
J2-BL/RD
P1-02
P1-01
6
MEMBRANE/LED INTERFACE CARD
C76PBE-BL
11
PLAT ROT CCW
VLVRET-BR
2 86
P52PCON-WH
P1-23
P1-22
P1-21
26
25
24
23
22
21
J3 10PIN
C69PBE-BK
J18-DRIVE CHASSIS HARN
P16
A
B
WH
RD
BK
RS232 GND
P1-19
AXLE NOT EXT PWR
CAN HIGH
P1-20
CAN LOW
P1-18
1 30
J2 10PIN
N
LSB4ES
75.5'
WHEN AXLES
ARE EXTENDED
TERM 3 & 4
ARE CLOSED
P1-17
P1-16
P1-15
20
19
18
PCON MEMBRANE PANEL
LSB3RS
3.5 EXT
P
31
GN
P1-13
K1
TCON
LSB3EO
75' EXT
P
P61LS(A)-GN
BOOT
P1-12
17
16
15
14
13
12
11
10
J1 10PIN
RECOVERY
LSB4EO
100' EXT
P
D82CAN+ -YL
RS232 TXD
P1-11
AXLE NOT EXT SIG
RS232 RXD
P1-10
P1-14
AXLE NOT RET PWR
CAN SHIELD
P1-09
10 WAY ENGINE HARN TO ENGINE
AMP
P54ENG-BK/WH
D81CAN- -GN
A
NO
PCON
1
PCON
P53LS-WH/BK
D82CAN+ -YL
JOYSTICK CONNECTORS (before serial number S120- 1617; S100- 420)
Joystick Adaptor Harness
RUN
SERV. BYPASS
P58LS-RD/BK
J16-DRIVE CHASSIS HARN
NC
5
Deutsch
3
2
OFF
P63LS
4
P63LS-OR/RD
PROX
KILL SW.
OPTIONAL
1
4
3
5
M
S59CNBK
3
DCON
3
4
4
C64LS-OR/BK
4
31
2
2
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
C69PBE-BK
J4-GN/BK
J1 BLACK 23 PIN
DRIVE CHASSIS HARN
1
1
5
GND
PWR
XOUT
YOUT
RKOUT
L
SJ1-WH/RD
3
D81CAN- -GN
C61LS(A)-GN
P61LS-GN
AXLE NOT RET SIG
P1-08
P1-07
P12
P1-06
7
6
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
K
LSB6S
CHNBRK
AXLE RETRACTION
LIMIT SWITCHES
C61LS-GN
C61AXRT-GN
P_7R
P1-05
P1-04
2 WAY DEUTSCH-PWR HARN/ENG HARN
DRIVE & STEERING
JOYSTICK
J
LSB2RO
100'
WHEN AXLES
ARE RETRACTED
TERM 3 & 4
ARE CLOSED
4
C60AXEX-GN/WH
P57PBD-RD/WH
10
DRIVE & STEERING
JOYSTICK
NOT USED
I
SJ2-BK/RD
3
NOT USED
BOOM EXT/RET
JOYSTICK
H
P54ENG-BK/WH
4
9
S3-2
S3-1
S2-3
S2-2
S2-1
S1-3
S1-2
S1-1
BOOM UP/DWN &
TURNTABLE ROTATE JOYSTICK
G
P53LS-WH/BK
J1-BL/BK
BOOM EXT/RET
JOYSTICK
PCON
E-STOP
F
LSB2RS
101'
3
S56PRV-RD
P_6R1
P1-03
8
7
6
5
4
3
2
1
P20
BOOM UP/DWN &
TURNTABLE ROTATE
JOYSTICK
LSAX2ES
12
P53LS-RD
J20
ALARM+
ALARM-
JIB
LSAX1ES
P
LSAX2EO
B
LSAX1EO
A
LSAX2RO
C
J2 WHITE 23 PIN
DRIVE CHASSIS HARN
DCON ECU PWR
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR
6 WAY ENGINE HARN TO TILT SENSOR
4 WAY ENGINE HARN-AC GENERATOR
PCON MANIFOLD/TILT SENSOR
P1-02
J30
J31
J32
J33
P21DCON-WH
P30
P31
P32
P33
9 WAY DEUTSCH TETHER CONNECTOR
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN
2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
DCON ECU GND
12 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
P1-01
J20
J21
J23
J24
J25
J26
J27
J28
J29
GND-DCON-BR
P20
P21
P23
P24
P25
P26
P27
P28
P29
LSAX1RO
LF STEER LEFT
PCON PCB TO MEMBRANE SWITCH
PCON PCB TO MEMBRANE SWITCH
LF STEER LEFT
LF STEER RIGHT
P2-23
J1
J2
LF STEER RIGHT
RF STEER LEFT
P2-22
TCON PCB TO MEMBRANE SWITCH
TCON PCB TO MEMBRANE SWITCH
RF STEER LEFT
STEER SNSR PWR
P2-21
J10
J11
RF STEER RIGHT
STEER SNSR GND
P2-20
P10
P11
LR STEER LEFT
RF STEER RIGHT
P2-19
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
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
LR STEER RIGHT
LR STEER LEFT
P2-18
J6
J7
J8
J16
J17
J18
RR STEER LEFT
LR STEER RIGHT
P2-17
P6
P7
P8
P16
P17
P18
V37LFS-BL/BK
BRAKE
P2-16
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN
WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN
BK
VALVE RTN2
P2-15
J1
J2
V36LFS-BL
LR STEER SNSR
P2-14
P1
P2
V37RFS-BL/BK
RF STEER SNSR
RR STEER SNSR
P2-10
P2-13
RR STEER LEFT
P2-09
LR STEER SNSR
RR STEER RIGHT
P2-08
P2-12
AUX REVERSE
P2-07
P2-11
AUX FORWARD
P2-06
P1
P2
P109ANG-GN/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BR
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
V52AREV-BL/RD
V52AFV-BL/RD
MOTOR SPEED
P2-04
P2-05
AXLE EXTEND
P2-03
BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
BL
RD
B
LF STEER RIGHT
A
BK
C
BL
RD
B
BK
A
BL
RD
C
RF STEER RIGHT
LR STEER RIGHT
B
BK
A
BL
RD
AXLE RETRACT
P2-02
J144
V29MS-RD/WH
VALVE RTN1
P2-01
P1
P2
J1
J2
RR STEER RIGHT
13
RR STEER RIGHT
V60AXEX-GN/WH
V61AXRT-GN
VLVRET-BR
9
BRAKE
5
AUX REVERSE
8
AUX FORWARD
MOTOR SPEED
4
AXLE EXTEND
AXLE RETRACT
3
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 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
PLATFORM PLATFORM
ROTATE
LEVEL
E
-
PCON
ALARM
D
-
1
C
+
2
PLUG NO JACK NO
J1
P1
J2
P2
J3
P3
J4
P4
J5
P5
B
+
A
Z
6
7
TO HORN BUTTON
BOOM UP/DWN FC RECOVERY SIGNAL
U95
PWR TO TCON ESTOP
TCON MEMBRANE PANEL
TO MICRO
DETAIL E - TCON RELAY PARKING
30
K7
30
P_22R
P_22R
P7R
J2 BLACK 35 PIN
LIMIT SWITCH HARNESS
OPTIONAL HYDRAULIC
PRESSURE SENSOR
24
AXLE RETRACTION
LIMIT SWITCHES
AXLE EXTENTION
LIMIT SWITCHES
5 31
24 6
31
24
31
24
31
24
31
24
31
24
5 31
24 6
31
24
LIMIT SWITCHES
S-120/125
ENGINE BLOCK
C61AXRT-GR
AUX.
PUMP
87a 87 85
5
4
P57PBD-RD/WH
P264 WAY
BAT.
+
BAT.
-
IND.
1
30
ALTERNATOR
EXCT.
2
86
GLOW PLUG2
RELAY
86
HORN
87a 87 85 RELAY
4
5
P21DCON-RD
1
REGULATOR
2
HI/LO
SPEED
SOLENOID
3
SERVICE
HORN
S7PLE1-BL/BK
S2PLD2-GR/BK
1
30
HYD COOLER
2
RELAY
86
85 87 87a
5
4
FUEL
SOLENOID
2
RELAY
86
1
30
85 87 87a
5
4
STA.
FAN
1
30
85 87 87a
5
4
FUEL
SOLENOID
RELAY
2
3
4
C27AUX-RD
S2PLD1-BL/RD
VLVRET6-BR
S7PLE2-GR/WH
ES0509C
C27AUX-RD
VALVE RTN6
VALVE RTN7
C06TTR-WH/BK
C05TTL-WH
12 VOLT
P56PRV-RD
24
5
6
7
8
1
REV
FWD
FUSE
3-10A
2
LIMIT SWITCHES
S-100/105
3
4
5
6
31
7
8
24
31
24
9 10 11 12 J20
12 WAY
5 31
24 6
5 31
31
24 6
3 1
24
3
4
P
31
24
31
C64LS-OR/BK
P56PRV-RD
SJ3-WH
C68PBD-BL
S62BSTO-ORN
P53LS-WH/BK
C60AXEX-GN/WH
SERVICE_HORN
P3-07
TT_TILT_SNSR_GND
TT_TILT_SNSR_PWR
VALVE_RTN2
P3-14
P3-15
P3-16
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC_GENERATOR
VALVE_RTN3
P3-20
P3-22
P3-23
P3-19
P3-21
ALTENATOR_RPM
ALT_FIELD_WIRE
P3-18
P3-17
OIL_PRESSURE
OIL/WATER_TEMP
P3-12
P3-13
C31EDC-WH/BK
C30EDC-WH
P3-10
P3-11
STARTER_RELAY
P3-09
P3-08
FWD
REV
P3-05
CHOKE/GLOW PLUG
P3-04
P3-06
THROTTLE
IGNITION/FUEL
P3-03
P3-01
BOOM_EXT/RET_VLV
P2-09
C77AS-WH
G119SR-BL
SNSR GND-BR
P2-35
P2-34
P2-33
P2-32
P2-31
P2-30
P2-29
P2-28
P2-27
P2-26
P2-25
P2-24
P2-23
P2-22
P2-21
P2-20
P2-19
P2-18
P2-17
P2-16
P2-15
P2-14
C66DREN-BL
P2-13
C65LOFL-BL/WH
P2-12
P2-11
C64LS-OR/BL
P63LS-OR/RD
S62BSTO-OR
P2-10
P2-08
P2-06
P2-05
P2-04
P2-03
P2-02
P2-01
AUX_RELAY
VALVE_RTN6
VALVE_RTN7
ROTATE_CCW_VLV
ROTATE_CW_VLV
MULTI_FUNCT_VLV
LSB4ES MONITOR INPUT
LSB8RS MONITOR INPUT
LSB9AS MONITOR INPUT
LSB2RS MONITOR INPUT
DRIVE LIGHTS RELAY
BOOM_RETRACT_VLV
BOOM_EXTEND_VLV
BOOM_DOWN_VLV
BOOM_UP_VLV
C60AXEX-GR/WH
P4-35
P4-34
P4-33
P4-32
P4-31
P4-30
P4-29
P4-28
P4-27
P4-26
P4-25
P4-24
P4-23
P4-22
P4-21
P4-20
P4-19
P4-18
P4-17
P4-16
P4-15
P4-14
P4-13
P4-12
P4-11
P4-10
P4-09
P4-08
P4-07
P4-06
P4-05
P4-04 TURNTABLE_ROTATE_VLV
P4-03
VALVE_RTN4
BOOM_UP/DOWN_VLV
P4-02
P4-01
P2-07
C61AXRT-GR
5
85
2
K7 86
4
TO MICRO
3
TETHER ESTOP
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO PLD
BM 3' I
BM 100' I
PRI LO#1 O
PWR TO TCON ESTOP
1
BM U/D FC O
BM E/R FC O
BM DWN O
BM RET O
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO MICRO
TO MICRO
TO MICRO
TO PLD
YL
BL
PR
GY
BR
WT
LT GR
5
1
30
85 87 87a
4
2
K1 86
PWR IN SERV OR BM DWN ST I
RECOVERY
PROVIDES PWR AUX HYD O
TO MINIMAL
MLT FNC VLV O
HARDWARE
TO MICRO
TO MICRO
4
TCON OR PCON MODE
SERVICE OR
RECOVERY
MODE
TO MICRO
TO PLD
TO MICRO
TO MICRO
2
1
K8 86
30
87 87a
85
5
4
TO MICRO
1
30
87 87a
AUX/START_BAT_PWR
AUX/START_BAT_GND
SYS_BAT_GND
SYS_BAT_PWR
P3-02
S59CNBK-GR/WH
C64LS-OR/BK
2
S56PRV-RD
1
4
C77AS-WH
C64LS-OR/BK
P20
12 WAY
C65LOFL-BL/WH
C64LS-OR/BK
C66DREN-BL
P57PBD-RD/WH
S7PLE1-BL/BK
P58LS-RD/BK
P54ENG-BK/WH
P53LS-WH/BK
S56PRV-RD
SJ3-WH
C71PBE-BL/BK
C64LS-OR/BK
P57PBD-RD/WH
C61AXRT-GN
S62BSTO-OR
P5-04
P58LS-RD/BK
P57PBD-RD/WH
S56PRV-RD
P54ENG-BK/WH
P53LS-WH/BK
P21DCON-RD
GNDDCON-BR
S2PLD1-BL/RD
S7PLE1-BL/BK
S7PLE2-GR/WH
S2PLD2-GR/BK
R49LP - WH/BK
J31-TILT
SNSR
P31-ENG
HARN
VLVRET3-BR
C45GEN-GR/WH
C84TAY-GR/BK
C83TAX-GR/WH
C107AF-RD
C41RPM-OR/BK
VLVRET2-BR
P85TTSR-GR
RET85TTSR-BR
C26TSR-WH/RD
C25PSR-WH/BK
C30EDC-WH
C31EDC-WH/BK
C33STR-BK
C46HRN-WH
(DETAIL B )
C34SA-BK/WH
C21IGN-WH
R35RPM-BK/RD
P3-06
P3-05
C71PBE-BL/BK
P53LS-WH/BK
P63LS-OR/RD
C60XES-GR/WH
C70PBE-BL/WH
C61AXRT-GR
C70PBE-BL/WH
P63LS-OR/RD
C68PBD-RD
P21DCON-RD
P57PBD-RD/WH
P54ENG-BK/WH
S56PRV-RD
3
LSB1DO
10 DEG
S2PLD1-BL/RD
LSB6S
CHNBRK
C08PBR-BK/WH
C07PBE-BK
C02PBD-RD/BK
C01PBU-RD
C06TRF-WH/RD
C09PERF-BK/RD
C03PBF-RD/WH
GNDDCON-BR
2
LSB7DS
11 DEG
4
1
LSB13AO
53 DEG
3
TN
PK
GR
5
1
30
5
TO MICRO
OR
GR/WH
YL/WH
PR
LT BL
BK
RD
J11
J10
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P1
P1
P1
P1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P10
85
87a
87
K5 86
30
2
1
85 87 87a
4
2
K2 86
10
9
8
7
6
5
4
3
2
1
P1
P1
P1
P1
P1
P1
FUEL TYPE
SPARE 2
COORD STEER
CRAB STEER
REAR STEER
FRONT STEER
DRIVE SPEED
AXLE EXTEND
ENGINE SPEED
AXLE RETRACT
SPARE 1
DRIVE ENABLE
START
START ASSIST
AUXILIARY
AC GENERATOR
HORN
BOOM CW
PLTFRM CW
JIB DOWN
PLTFRM DOWN
PLTFRM UP
JIB UP
PLTFRM CCW
BOOM CCW
TURTLE
SEC. DOWN
RABBIT
BOOM EXT
BOOM DOWN
ROOM RET
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
+ BUTTON
- BUTTON
SCRL F/ENT
SCROLL R
STRT ASST
START
5
85
4
1
30
87 87a
2
K6 86
5
85
85 87
87a
87a
87
30
30
K4 86
K3 86
2
1
2
1
5
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
P4
P3
Y
FST1S
LOW
FUEL FS
2
LST1O
DRV
ENABLE
1
1
C64LS-OR/BK
15A
J21
8 WAY
SJ3-WH
CB 7
P21
8 WAY
S56PRV-RD
BR-COM
LSB8AS
50 DEG
P34SA-RD
C70PBE-BL/WH
+AUX
31
P57PBD-RD/WH
S2PLD1-BL/RD
P116HYD-OR
P27
P58LS-RD/BK
RD-HOLD
RELAY ADDED
S100- S/N 865
S120- S/N 2782
85 5
J27
P54ENG-BK/WH
WH-PULL
P
86
P53LS-WH/BK
P53LS-WH/BK
-BAT
OTS1
N.O.
TO DRIVELAMPS
S56PRV-RD
30
C61AXRT-GN
2 86
4
TO AUX HYD RELAY PR1
87
X
P57PBD-RD/WH
TROMBETTA
TIME DELAY
MOM N.O.
86
P53LS-WH/BK
1 30
P58LS-RD/BK
P56PRV-RD
TURNTABLE ROT CCW VLV
87a 3
TURNTABLE ROT CW VLV
85
C113MFV-OR/RD
12 VOLT
MULTI FUNC VLV
P46HRN-WH
P
BOOM RET VLV
P
BOOM DWN VLV
FUSE
BOOM EXTEND VLV
S56PRV-RD
VLVRET4-BR
V31REV-WH/BK
V30FWD-WH
HIGH CURRENT VALVE PROPEL OUTPUT
BATECU-RD
P5-03
P5-02
P5-01
TO MICRO
TO MICRO
TO PLD
5
PCON MODE
P9A
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,
85 87 87a K8
TURNTABLE ROTATE VLV.
K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH
86
30
85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES:
PRIMARY VALVES 1 & 2, THROTTLE (IGN),
GLOW PLUG, STARTER RELAY, AC GENERATOR,
86
30
BOOM RETRACT, MULTIFUNCTION VALVE,
ROTATE CW, AND ROTATE CCW.
85 87 87a 85 87 87a 85 87 87a
K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY
K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.
86
86
86
30
30
30
(FUEL ON/OFF SOLENOID AND ALT FIELD)
K3
K5
K2
K7 POWERS THROTTLE OR HI/LOW SOLENOID
85 87 87a K6 85 87 87a K1
(CKT C35RPM-BK/RD)
K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
87 87a
P63LS-OR/RD
2
2
86
SEE GENERATOR OPTIONS
BOOM UP VLV
P63LS-OR/RD
DEUTZ BF4L-2011/TD2011-LO4I
ENGINES SHOWN
S2PLD1-BL/RD
J32-ENG HARN
BOOM EXT/RET F.C.
C60AXEX-GR/WH
4.5 DEGREE
TURNTABLE
TILT
SENSOR
86
S62BSTO-OR
S56PRV-RD
1
BATGND-BR
MANIFOLD HARN
85
C64LS-OR/BK
GNDDCON-BR
24
1
30
J4 WHITE 35 PIN
TURNTABLE CW/CCW F.C.
C61AXRT-GR
BOOM UP/DWN F.C.
20 A
TCON
W
C71PBE-BL/BK
31
+BAT
P10
J23
4WAY
D82CAN+ -YL
3
P23
4WAY
P114BAT-RD
S7PLE2-GR/WH
GNDDCON-BR
C45GEN-GR/WH 1
2
BAT GND-BR
S7PLE1-BL/BK
KILL
PROX
S2PLD2-GR/BK
BOOM HARN
BAT GND-BR
24
STARTER
RELAY
RET85TTSR-BR
C26TSR-WH/RD
31
70 A FUSE
P85TTSR-GR
OIL TEMP SENDER
D81CAN- -GR
C83TAX-GR/WH
OIL PRESSURE
P7-LIMIT SW HARN
DETAIL B
J1 BLACK 23 PIN
C84TAY-GR/BK
P21IGN-WH
30
BATGND-BR
LIMIT SWITCH HARNESS
C25PSR-WH/BK
24
BATVLV-RD
P2-35
P2-34
P2-33
P2-32
J2 BLACK 35 PIN
J144-7
87
ENGINE HARN
C21IGN-WH
TO FLASHING BEACON 87a
J3 WHITE 23 PIN
C116HYD-OR
CB
OPTIONAL HYDRAULIC
PRESSURE SENSOR
25A
LSB14AO
P2-30
POWER HARN
R21IGN-WH
31
P11
VLVRET2-BR
4
P11
P116HYD-OR
AUX MAIN
LSB13AO
P2-29
VLV RET
LSB4EO
P2-28
P2-31
AUX HYD PRESS SIG
P2-27
J5 BLACK 4 PIN
C34SA-BK/WH
P53LS-WH/BK
P114BAT-RD
P21DCON-RD
P6R1
R116HYD-OR
P
C64LS-OR/BK
P57PBD-RD/WH
P9A
P6R1
GLOW PLUG
3
C64LS-OR/BK
SNSR GND
P2-25
TCON
P_22R
R34SA-RD
4
C65LOFL-BL/WH
PRI#2 LO
P2-24
P2-26
PRI#1 LO
P2-23
P2-22
TO PLD
TO MICRO
6
OUTPUT PWR ENABLE
P_22
VLVRET2-BR
P
C64LS-OR/BK
LSB3EO
P2-20
P11
C30EDC-WH
P20
12 WAY
C66DREN-BL
LSB3RO
P2-19
TO MICRO
7
P6R1
2
8
TCON ESTOP
9
P7R
10
P22
SERV. OR OPER. REC.
12
13
11
14
P11
OPER. REC.
15
TCON MODE
P7
16
ALARM GND
ALARM PWR
P7R
FWD VLV A
SOLENOID
3
P56PRV-RD
LSB2RO
P2-18
P2-21
LSB1DO
P2-17
TO PLD
LST10
P2-16
FST1S
P2-15
P_12
OPER SW PWR
P_11
P2-10
P2-14
P_10
P2-09
P_18
P_9B
P2-08
P2-13
P_9A
P2-07
P_14
P_7R
P2-06
P2-12
P_6R2
P2-05
P2-11
P_6R1
P2-04
DCON ECU PWR
DCON ECU GND
P2-03
P2-02
P2-01
P15
SERV. OR
OPER. REC.
TO MICRO
P15
P6R1
C31EDC-WH/BK
Genie S-100/105
24 6
C68PBD-BL
VLVRET1-BR
C78PS-WH/BK
C77AS-WH
C76PBE-BL
G119SR-BL
SNSR GND-BR
V75PRLO-RD/WH
V74PRLO-RD
C71PBE-BL/BK
C70PBE-BL/WH
C69PBE-BK
C68PBD-RD
C66DREN-BL
C65LOFL-BL/WH
C64LS-OR/BL
P63LS-OR/RD
S62BSTO-OR
C61AXRT-GR
C60AXEX-GR/WH
S59CNBK-GR/WH
P58LS-RD/BK
P57PBD-RD/WH
S56PRV-RD
P54ENG-BK/WH
P53LS-WH/BK
P21DCON-RD
GNDDCON-BR
P1-23
P1-22
P1-21
P6R1
REV VLV B
SOLENOID
D81CAN- -GR
24 6
4
S62BSTO-OR
FUSE
3-10A
P1-19
P9A
VLVRET2-BR
5 31
3
P53LS-WH/BK
P1-23
P1-22
P1-21
CANRS232_GND
P1-18
PCON POWER
BK-COM
J20
12 WAY
2
C60AXEX-GN/WH
RS232 GND
P1-19
CAN+
P1-17
PWR-PCON ESTOP
HRN RLY CNTRL
P1-16
P1-20
OUT PWR ENBL
P1-15
PCON POWER
BK
9 10 11 12
1
S56PRV-RD
CAN HIGH
P1-18
P1-13
U32
RD-HOLD
8
C64LS-OR/BK
CAN LOW
P1-17
RS232_TXD
BOOT
P1-12
P1-14
CAN SHIELD
RS232_RXD
P1-11
P22
P1-10
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P7
PCON PWR
P1-02
P1-03
PCON GND
P1-01
U20
P_22
WH-PULL IN
7
C77AS-WH
NOT USED
P1-16
P1-23
PWR-PCON ESTOP
RD
6
C64LS-OR/BK
TET ESTOP PWR
P1-15
SAFE PL TILT GND
SAFE PL TILT PWR
P1-22
P_7
V
LSB3RO
3' EXT
4
5
SJ1-WH/RD
S7PLE2-GR/WH
LOAD SENSOR INPUT
P1-14
PL TILT SNSR PWR
P1-21
P_7
WH
D82CAN+ -YL
C78AS-WH/BK
BOOT
P1-13
PL TILT SNSR
P1-20
TCON MODE
VLVRET2-BR
4
5 31
SJ2-BK/RD
RS232 TXD
P1-12
PL TILT SNSR GND
P1-19
TCON MODE
R46HRN-WH
3
P54ENG-BK/WH
RS232 RXD
P1-11
FOOT SW RTN
P1-17
P_6R2
U
LSB3RS
3.5 EXT
3
2
P53LS-WH/BK
P53LS-WH/BK
CAN SHIELD
P1-10
FOOT SW PWR
P1-16
OUT PWR ENABLE
T
LSB3EO
75' EXT
2
1
P57PBD-RD/WH
S7PLE1-BL/BK
FLASHING BEACON
P1-09
SAFE PL TILT OUT
P1-15
P_9B
TO MICRO
BAT GND-BR
J264 WAY1
8
P58LS-RD/BK
WORK LT
P1-08
LOAD SNSR PWR
P1-14
P_6R2
C107AF-RD
7
SJ2-BK/RD
P_22
P1-07
LOAD SNSR OUT
P1-13
LOCKOUT VALVE #1 SIG
J144-2
6
P53LS-WH/BK
SJ1-WH/RD
P_7
P1-06
LOAD SNSR GND
P1-12
PRI BOOM DOWN STATUS
C41RPM-OR/BK
5
S56PRV-RD
PWR-PCON ESTOP
P1-05
P23PCON-BK
D81CAN- -YL
D82CAN+ -GR
C46HN-WH
C47OUT-WH/BK
P56PRV-RD
S56PRV-RD/WH
P52PCON-WH
PROX KILL CMD
P1-11
P1-18
PROX KILL GND
P1-10
6
5
4
3
2
1
6
5
4
3
2
1
P2
P1
BOOM UP/DWN FC RECOVERY SIGNAL
HOLD
P63LS-OR/RD
4
C71PBE-BL/BK
OUT PWR ENBL
P1-04
TET ESTOP RET
HORN RELAY COIL
P1-03
P1-20
PCON POWER
P1-02
SAFE PL TILT OUT
FOOT SW PWR
PROP VLV1_B
OUT PWR ENABLE
J144-1
3
C64LS-OR/BK
P95TET-OR
D82CAN+ -YL
D81CAN- -GR
P97TET-BK
S132LDS-BL/WH
R117FB-RD
R48LP-WH/RD
P56PRV-RD
S56PRV-RD/WH
PCON GND
P1-01
5A
FUSE
C56PTS-RD
GNDPCON-BR
P1-15
P1-16
R56PTS-RD
P87PTS-RD
PTSRET-BR
P85PTS-GR
PROP VLV1_A
P1-08
P1-09
PROP VLV2_B
P1-07
ESTOP_1
ESTOP_2
NOT USED
H4_RKOUT
H4_YOUT
H4_XOUT
H4_PWR
H4_GND
H3_YOUT
H3_PWR
H3_GND
6
5
4
3
2
1
6
5
4
3
2
1
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
BAT GND-BR
C60AXEX-GR/WH
2
P57PBD-RD/WH
C47OUT-WH/BK
P23PCON-BK
OUT FRM TILT SWITCH
PWR TO TILT SWITCH
TILT SWITCH GND
TILT SENSOR PWR
C84TAY-GR/BK
C56PTS-RD
R56PTS-RD
C88PTS-RD/BK
PLATRET-BR
BK
OR
GR/YL
C90PXS-RD/BK
R90PXS-RD/BK
C15PLD-OR/BK
C14PLU-OR
PROP VLV2_A
P1-06
30
29
28
H2_YOUT
H2_PWR
H2_GND
H1_YOUT
H1_XOUT
H1_PWR
H1_GND
S3-3
S3-2
BOOM EXT/RET FC RECOVERY SIGNAL
S
LSB4ES
75.5'
ES0509C
Genie Part Number 228882 Rev A
P53LS-WH/BK
P_9B
PRI BOOM LENGTH 100' STATUS
R
BAT GND-BR
Electrical Schematic
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
PULL IN
(from serial number 2710)
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
J144-8
Genie S-120/125
P27-LIMIT SW
J21
1
8 WAY
P9A
Q
BAT GND-BR
(from serial number 810)
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
C27AUX-RD
J27-BOOM HARN
PR1
P56PRV-RD
AUXILIARY HYD RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
VLVRET6-BR
P21
8 WAY
P
BAT GND-BR
6
PCON POWER
P33STR-BK
5
6
PRI BOOM LENGTH 3' STATUS
START BAT
5
P10
MAIN (SYS)
BAT
GR
P7R
P10
V75PRLO-RD/WH
P6R1
P7R
VLVRET1-BR
88
P_22
PRI 2 LO
YL
GR
BL
P_7
V74PRLO-RD
P11
O
PRI 1 LO
P18
88
4
PWR TO TCON ESTOP
FST1S
LOW
FUEL FS
88
YL
3
4
PWR TO TCON ESTOP
LST1O
DRV
ENABLE
BL
3
TO HORN BUTTON
SJ3-WH
BR
P27
TO HORN BUTTON
LSB1DO
10 DEG
P12
2
TILT SENSOR SIG OUT
PLAT SENSOR GND
BK
RD
PLAT LEVEL DN
PLAT LEVEL UP
C44JD-GR/BK
ON/OFF VLV3_B
TCON MODE
LSB7DS
11 DEG
88
1
2
J27
LSB13AO
53 DEG
BR
2
P56PRV-RD
N
LSB14AO
68 DEG
OR
86
LSB9AS
65 DEG
P9A
P56PRV-RD
C64LS-OR/BK
DCON PWR RD
88
J7
1
S132LDS-BL/WH
SJ3-WH
88
P8-LIMIT SW HARN
SJ3-WH
RD
OR
2
1
C61AXRT-GN
C47OUT-WH/BK
85
S62BSTO-OR
DCON GND BK
J8
1
86
P63LS-OR/RD
88
S56PRV-RD/WH
C70PBE-BL/WH
BK
WH
C
30
C76PBE-BL
P7R
C
87
C70PBE-BL/WH
6
88
C46HN-WH
P52PCON-WH
LSB8AS
50 DEG
5
6
(SLIP RING)
B
P57PBD-RD/WH
S2PLD1-BL/RD
5
WH
A
B
TO WORK LIGHTS 87a
P58LS-RD/BK
3
4
GNDPCON-BR
SJ2-BK/RD
P23PCON-BK
S56PRV-RD
C
3
4
CAN SHIELD
J157
SJ2-BK/RD
24
2
GR
J6
A
P6-BOOM HARN
2
LSB3RO
3' EXT
AXLE NOT EXT
LIMIT SWITCHES
31
2
2
88
CAN LOW
YEL
FOOTSWITCH
SJ1-WH/RD
(SLIP RING)
P157
1
TCON
LSB4ES
75.5'
24
P17
1
1
88
CAN HIGH
2
24
J1 BLACK 23 PIN
P53LS-WH/BK
SJ1-WH/RD
12
2
P18
1
GR
FOOTSWITCH
LOAD SENSOR OPTION
S132LDS-BL/WH
31
BOOM HARN
C61AXRT-GN
J3-OR/BL
C
88
PLATFORM
TILT SENSOR
ASSEMBLY
OPTIONAL
PROXIMITY
KILL WIRING
P11
P57PBD-RD/WH
P53LS-WH/BK
C
YEL
J31-TILT SNSR
85 5
P63LS-OR/RD
P63LS-OR/RD
B
P33-PCON
MANIFOLD
4
S62BSTO-OR
C60AXEX-GR/WH
P16
A
B
6
87
C64LS-OR/BK
C61AXRT-GR
A
1
5
87a 3
PLD
S2PLD2-GR/BK
9
24
4
85 5
C71PBE-BL/BK
P21DCON-RD
P1-05
87
C64LS-OR/BK
P57PBD-RD/WH
1
JIB DOWN
DCON
3
PCON MANIFOLD
5A
OPTIONAL
PROX KILL SW.
2
J2 WHITE 23 PIN
4
S2PLD1-BL/RD
GNDDCON-BR
P1-04
2 86
FUSE
31
1
PCON
87a 3
C76PBE-BL
J17-DRIVE CHASSIS HARN
C43JU-GR
J20
S59CNBK-GN/WH
S56PRV-RD
C18PRR-GR/BK
P6R
C69PBE-BK
J18-DRIVE CHASSIS HARN
JIB UP
P7R
P54ENG-BK/WH
D81CAN- -GR
PLAT ROT CW
OUT PWR ENABLE
P53LS-WH/BK
D82CAN+ -YL
ON/OFF VLV3_A
ECU
P58LS-RD/BK
J16-DRIVE CHASSIS HARN
P1-03
1 30
C46HN-WH
DRIVE CHASSIS HARN
C17PRL-GR
VLV RTN
P20
P63LS
J2-BL/RD
P1-02
P1-01
K2
GNDPCON-BR
J1 BLACK 23 PIN
PLAT ROT CCW
VLVRET-BR
AXLE NOT EXT PWR
5
2 86
P52PCON-WH
P1-23
P1-22
27
26
25
24
23
22
21
20
19
18
17
16
PCON MEMBRANE PANEL
S59CNBK
31
WH
P61LS(A)-GR
P1-21
P1-20
1 30
TCON
M
LSB3RS
3.5 EXT
WHEN AXLES
ARE EXTENDED
TERM 3 & 4
ARE CLOSED
RS232 GND
K1
RECOVERY
LSB3EO
75' EXT
P
P1-19
10 WAY ENGINE HARN TO ENGINE
MEMBRANE/LED INTERFACE CARD
PCON
LSB4EO
100' EXT
P
CAN HIGH
CAN LOW
7
RUN
OFF
LSB6S
CHNBRK
P
P1-18
6
PCON
E-STOP
C64LS-OR/BK
4
P1-17
AXLE NOT EXT SIG
BOOT
RS232 TXD
RS232 RXD
15
14
13
J3 10PIN
SERV. BYPASS
L
LSB2RO
100'
3
D82CAN+ -YL
P1-16
P1-15
P1-14
P1-13
AXLE NOT RET SIG
CAN SHIELD
2 WAY DEUTSCH-PWR HARN/ENG HARN
J2 10PIN
K
C69PBE-BK
4
P1-12
P1-11
P1-10
P1-09
AXLE NOT RET PWR
12
11
10
J1 10PIN
J
SJ1-WH/RD
S2PLD2-GR/BK
3
D81CAN- -GR
C61LS(A)-GR
C61LS-GR
P1-08
P12
P_7R
9
BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
I
SJ2-BK/RD
J4-GR/BK
P63LS-OR/RD
10
DRIVE & STEERING
JOYSTICK
H
LSB2RS
101'
WHEN AXLES
ARE RETRACTED
TERM 3 & 4
ARE CLOSED
4
C60AXEX-GR/WH
P57PBD-RD/WH
11
NOT USED
G
P54ENG-BK/WH
J1-BL/BK
BOOM EXT/RET
JOYSTICK
F
P53LS-WH/BK
P53LS-WH/BK
3
P1-07
P1-06
P1-05
P1-04
P_6R1
8
S3-1
1
P61LS-GR
C61AXRT-GR
S56PRV-RD
P1-03
DCON ECU PWR
7
S2-3
S2-2
S2-1
S1-3
S1-2
S1-1
BOOM UP/DWN &
TURNTABLE ROTATE
JOYSTICK
LSAX2ES
4
P53LS-RD
P1-02
DCON ECU GND
6
5
4
3
2
1
ALARM+
ALARM-
JIB
LSAX1ES
P
LSAX2EO
3
P21DCON-WH
P1-01
J2 WHITE 23 PIN
LSAX1EO
B
DRIVE CHASSIS HARN
LSAX2RO
A
GND-DCON-BR
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR
6 WAY ENGINE HARN TO TILT SENSOR
4 WAY ENGINE HARN-AC GENERATOR
PCON MANIFOLD/TILT SENSOR
LSAX1RO
J30
J31
J32
J33
LF STEER LEFT
P30
P31
P32
P33
9 WAY DEUTSCH TETHER CONNECTOR
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN
2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
LF STEER RIGHT
12 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN
RF STEER LEFT
J20
J21
J23
J24
J25
J26
J27
J28
J29
RF STEER RIGHT
P20
P21
P23
P24
P25
P26
P27
P28
P29
LR STEER LEFT
PCON PCB TO MEMBRANE SWITCH
PCON PCB TO MEMBRANE SWITCH
LR STEER RIGHT
J1
J2
RR STEER LEFT
P1
P2
LF STEER LEFT
TCON PCB TO MEMBRANE SWITCH
TCON PCB TO MEMBRANE SWITCH
RR STEER RIGHT
J10
J11
LF STEER RIGHT
P10
P11
P2-23
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
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
V37LFS-BL/BK
J6
J7
J8
J16
J17
J18
RF STEER LEFT
P6
P7
P8
P16
P17
P18
P2-22
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN
WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN
2 WAY DEUTSCH LOAD SENSE LIMIT SWITCH TO BOOM HARN
V36LFS-BL
STEER SNSR PWR
J2
J157
P2-21
STEER SNSR GND
RF STEER RIGHT
LR STEER LEFT
LR STEER RIGHT
BRAKE
VALVE RTN2
LR STEER SNSR
RF STEER SNSR
LR STEER SNSR
RR STEER SNSR
RR STEER LEFT
RR STEER RIGHT
J1
V37RFS-BL/BK
P2-20
P2-19
P2-18
P2-17
P2-16
P2-15
P2-14
P2-13
P2-12
P2-11
P2-10
P2-09
P2-08
P2-07
MOTOR SPEED
P_6R2
P1
P2
P157
BK
C
P109ANG-GR/WH
P110RT-BK
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
V32BRK-WH/RD
VLVRET2-BR
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
P2-06
P2-05
AXLE EXTEND
AXLE RETRACT
VALVE RTN1
OUT PWR ENABLE
J1
J2
BL
RD
B
LF STEER RIGHT
A
BK
C
BL
RD
B
BK
A
BL
RD
C
RF STEER RIGHT
LR STEER RIGHT
B
BK
A
BL
RD
P2-04
P2-03
P2-02
P2-01
J144
V29MS-RD/WH
V60AXEX-GR/WH
V61AXRT-GR
VLVRET-BR
8
BRAKE
MOTOR SPEED
4
AXLE EXTEND
RR STEER RIGHT
13
AXLE RETRACT
3
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 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
PLATFORM PLATFORM
ROTATE
LEVEL
E
-
PCON
ALARM
D
-
2
P1
P2
C
+
PLUG NO JACK NO
J1
P1
J2
P2
J3
P3
J4
P4
J5
P5
B
+
A
Z
PWR TO TCON ESTOP
U95
TCON MEMBRANE PANEL
TO MICRO
TO HORN BUTTON
TO MICRO
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
P10
P_22R
P7R
30
K7
30
DETAIL E - TCON RELAY PARKING
LIMIT SWITCH HARNESS
J2 BLACK 35 PIN
OPTIONAL HYDRAULIC
PRESSURE SENSOR
24
24
S2PLD1-BL/RD
S7PLE1-BL/BK