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Service Manual
Part No. 62401
Rev A1
October 2004
Introduction
First Edition • First Printing
Important
Contact us:
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.
http://www.genielift.com
e-mail: [email protected]
This service manual covers the Genie S-100 and
Genie S-105 and Genie S-120 and Genie S-125
models.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at a Genie
dealer service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore product specifications are subject
to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-0069 U.S.A.
If you have any questions, please contact Genie
Industries.
®
Copyright © 2001 by Genie Industries
First Edition:
First Printing, January 2001
"Genie" and "S" are Registered Trademarks
of Genie Industries in the USA and many other
countries.
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
ii
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
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. 62401
Genie S-100 & S-105 & S-120 & S-125
iii
First Edition • First Printing
Section 1 - Safety Rules
SAFETY RULES
Personal Safety
Workplace 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.
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.
Read each procedure thoroughly. This
manual and the decals, on the machine,
use signal words to identify the following:
Indicates the presence of
a hazard that will cause
death or serious injury.
Indicates the presence of
a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.
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, and lifting or
placing loads. Always wear approved steel-toed
shoes.
iv
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 that your workshop or work area
is properly ventilated and well lit.
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.
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One
Safety Rules
General Safety Rules ..................................................................................................... iii
Section Two
Specifications
Machine Specifications, S120 and S-125 Models ...................................................... 2 - 1
Performance Specifications, S120 and S-125 Models ............................................... 2 - 2
Machine Specifications, S100 and S-105 Models ...................................................... 2 - 3
Performance Specifications, S100 and S-105 Models ............................................... 2 - 5
Hydraulic Specifications ............................................................................................ 2 - 6
Perkins Engine 1004-42 Specifications ..................................................................... 2 - 7
Cummins Engine B3.9L Specifications ..................................................................... 2 - 8
Deutz Engine F4L 913 Specifications ........................................................................ 2 - 9
Hydraulic Hose and Fitting Torque Specifications ................................................... 2 - 10
Section Three
Theory of Operation
Theory of Operation .................................................................................................. 3 - 1
Section Four
Scheduled Maintenance Procedures
Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................. 4 - 3
Part No. 62401
A-1
Inspect the Manuals ........................................................................................ 4 - 5
A-2
Inspect the Decals and Placards ..................................................................... 4 - 5
A-3
Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6
A-4
Check the Engine Oil Level ............................................................................. 4 - 6
Genie S-100 & S-105 & S-120 & S-125
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First Edition • First Printing
TABLE OF CONTENTS
Section Four
Scheduled Maintenance Procedures, continued
A-5
Check the Engine Coolant Level - Liquid Cooled Models ................................. 4 - 7
A-6
Check the Engine Belt(s) - Cummins Models .................................................. 4 - 8
A-7
Check the Engine Cooling Fan - Liquid Cooled Models .................................... 4 - 9
A-8
Drain the Inline Fuel Filter/Water Separator ................................................... 4 - 10
A-9
Inspect the Engine Air Filter .......................................................................... 4 - 11
A-10 Check for Fuel Leaks .................................................................................... 4 - 12
A-11 Check the Hydraulic Oil Level ....................................................................... 4 - 12
A-12 Check for Hydraulic Leaks ............................................................................. 4 - 13
A-13 Check the Hydraulic Filter Condition Indicators .............................................. 4 - 13
A-14 Test the Platform and Ground Controls .......................................................... 4 - 15
A-15 Test the Auxiliary Power Operation .............................................................. 4 - 16
A-16 Test the Tilt Sensor and Alarm ...................................................................... 4 - 17
A-17 Test the Operating Envelope ......................................................................... 4 - 18
A-18 Perform 30 Day Service ................................................................................ 4 - 19
A-19 Check the Engine Fasteners - Deutz Models ................................................. 4 - 20
A-20 Check the Batteries ....................................................................................... 4 - 21
vi
B-1
Check the Radiator - Liquid Cooled Models ................................................... 4 - 23
B-2
Check the Oil Cooler and Cooling Fins - Deutz Models .................................. 4 - 24
B-3
Check the Engine Belt(s) - Deutz and Perkins Models ................................... 4 - 25
B-4
Replace the Inline Fuel Filter/Water Separator Element ................................. 4 - 26
B-5
Replace the Air Filter ..................................................................................... 4 - 32
B-6
Inspect the Air Intake System ....................................................................... 4 - 33
B-7
Check the Exhaust System ........................................................................... 4 - 33
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
TABLE OF CONTENTS
Section Four
Scheduled Maintenance Procedures, continued
B-8
Replace the Hydraulic Tank Return Filters ..................................................... 4 - 35
B-9
Replace the Hydraulic Tank Breather Filter .................................................... 4 - 36
B10 Replace the Medium and High Pressure Hydraulic Filters .............................. 4 - 37
B-11 Inspect the Electrical Wiring .......................................................................... 4 - 38
B-12 Confirm the Proper Brake Configuration ......................................................... 4 - 39
B-13 Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 39
B-14 Check the Oil Level in the Drive Hubs ........................................................... 4 - 40
B-15 Check and Adjust the Engine RPM ............................................................... 4 - 41
B-16 Test the Key Switches .................................................................................. 4 - 44
B-17 Test the Emergency Stop Buttons ................................................................. 4 - 46
B-18 Test the Ground Control Override .................................................................. 4 - 46
B-19 Test the Safety Envelope and Circuits .......................................................... 4 - 47
B-20 Test the Platform Self-leveling ...................................................................... 4 - 53
B-21 Test the Horn ................................................................................................ 4 - 54
B-22 Test the Foot Switch ..................................................................................... 4 - 54
B-23 Test the Engine Idle Select ........................................................................... 4 - 55
B-24 Test the Drive Enable System ....................................................................... 4 - 56
B-25 Test the Drive Brakes .................................................................................... 4 - 57
B-26 Test the Drive Speed - Stowed Position ........................................................ 4 - 58
B-27 Test the Drive Speed - Raised or Extended Position ..................................... 4 - 58
B-28 Test the Alarm Package (if equipped) ............................................................ 4 - 60
B-29 Replace the Engine Oil and Filter - Cummins Models .................................... 4 - 61
B-30 Inspect the Fuel Tank Cap Venting System .................................................. 4 - 62
B-31 Perform Hydraulic Oil Analysis ...................................................................... 4 - 63
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
vii
First Edition • First Printing
TABLE OF CONTENTS
Section Four
Scheduled Maintenance Procedures, continued
C-1
Check the Engine Valve Clearances - Deutz Models ..................................... 4 - 64
C-2
Clean the Fuel Pump Strainer - Perkins Models ............................................ 4 - 64
C-3
Replace the Fuel Filter Element - Perkins and Cummins Models ................... 4 - 66
C-4
Replace the Engine Oil and Filter - Deutz and Perkins Models ...................... 4 - 68
C-5
Check the Specific Gravity of the Coolant - Liquid Cooled Models ................. 4 - 70
C-6
Inspect the Boom Extend/Retract Cables ...................................................... 4 - 71
D-1
Check the Boom Wear Pads ......................................................................... 4 - 73
D-2
Check the Extendable Axle Wear Pads ......................................................... 4 - 74
D-3
Check the Free-wheel Configuration .............................................................. 4 - 75
D-4
Check the Turntable Rotation Bearing Bolts .................................................. 4 - 76
D-5
Check the Turntable Rotation Gear Backlash ................................................ 4 - 77
D-6
Grease the Turntable Rotation Bearing and Rotate Gear ................................ 4 - 78
D-7
Replace the Drive Hub Oil ............................................................................. 4 - 78
D-8
Inspect the Engine Belt(s) - Cummin Models ................................................. 4 - 82
D-9
Replace the Fuel Filter/Water Separator - Deutz Models ................................ 4 - 84
D-10 Check the Engine Valve Clearances - Perkins and Cummins Models ............ 4 - 85
viii
E-1
Test or Replace the Hydraulic Oil .................................................................. 4 - 86
E-2
Change or Recondition the Engine Coolant - Liquid Cooled Models ................ 4 - 89
E-3
Change the Fuel Hoses ................................................................................. 4 - 90
E-4
Check the Engine Valve Clearances - Cummins Models ............................... 4 - 92
E-5
Check the Fuel Injectors - Deutz Models ....................................................... 4 - 92
E-6
Remove and Inspect the Boom Extend/Retract Cables ................................. 4 - 93
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
TABLE OF CONTENTS
Section Five
Troubleshooting Flow Charts
Introduction ............................................................................................................... 5 - 1
Fault Code Chart ....................................................................................................... 5 - 3
Part No. 62401
1
Display Not Active ......................................................................................... 5 - 11
2
Engine Will Not Crank Over ........................................................................... 5 - 16
3
Engine Cranks Over But Will Not Start .......................................................... 5 - 22
4
Engine Starts and Runs for 3 Seconds and Dies ........................................... 5 - 25
5
Engine High Idle Inoperative .......................................................................... 5 - 28
6
Engine Low Idle Inoperative ........................................................................... 5 - 30
7
All Functions Inoperative, Engine Starts and Runs ........................................ 5 - 31
8
Boom Up/Down, Extend/Retract, Turntable Rotate and
Platform Functions Inoperative,
Drive, Steer and Axle Extend/Retract Functions Operational ......................... 5 - 32
9
All Platform, Steering and Axle Functions Inoperative,
All Other Functions Operational ..................................................................... 5 - 33
10
Ground Controls Inoperative, Platform Controls Operate Normally ................. 5 - 38
11
Platform Controls Inoperative, Ground Controls Operate Normally ................. 5 - 40
12
Boom Angle Switch Fault .............................................................................. 5 - 42
13
Boom Up Function Inoperative ...................................................................... 5 - 45
14
Boom Down Function Inoperative .................................................................. 5 - 49
15
Boom Length Switch Fault ............................................................................. 5 - 54
16
Boom Extend Function Inoperative ................................................................ 5 - 58
17
Boom Retract Function Inoperative ............................................................... 5 - 67
18
Boom Envelope Operational Switch Failure, S-100 and S-105 Models ........... 5 - 72
19
Boom Envelope Operational Switch Failure, S-120 and S-125 Models ........... 5 - 77
20
Boom Envelope Safety Switch Failure, S-100 and S-105 Models .................. 5 - 86
Genie S-100 & S-105 & S-120 & S-125
ix
First Edition • First Printing
TABLE OF CONTENTS
Section Five
x
Troubleshooting Flow Charts, continued
21
Boom Envelope Safety Switch Failure, S-120 and S-125 Models ................. 5 - 104
22
Turntable Rotate Clockwise Function Inoperative ......................................... 5 - 128
23
Turntable Rotate Counter Clockwise Function Inoperative ............................ 5 - 133
24
Platform Level Function Inoperative ............................................................. 5 - 138
25
Platform Level Up Function Inoperative ........................................................ 5 - 140
26
Platform Level Down Function Inoperative .................................................... 5 - 144
27
Platform Level Safety Fault .......................................................................... 5 - 148
28
Platform Rotate Clockwise Function Inoperative ........................................... 5 - 151
29
Platform Rotate Counter Clockwise Function Inoperative .............................. 5 - 154
30
Jib Up Function Inoperative .......................................................................... 5 - 157
31
Jib Down Function Inoperative ...................................................................... 5 - 160
32
Auxiliariy Functions Inoperative .................................................................... 5 - 163
33
Axle Extend Function Inoperative ................................................................. 5 - 168
34
Axle Retract Function Inoperative ................................................................. 5 - 174
35
Blue End Blue Side Steering Function Inoperative ........................................ 5 - 178
36
Blue End Yellow Side Steering Function Inoperative .................................... 5 - 181
37
Yellow End Blue Side Steering Function Inoperative .................................... 5 - 184
38
Yellow End Yellow Side Steering Function Inoperative ................................. 5 - 187
39
Drive Forward Function Inoperative .............................................................. 5 - 190
40
Drive Reverse Function Inoperative .............................................................. 5 - 196
41
Drive Enable Fault ........................................................................................ 5 - 202
42
Drive Mode Select Inoperative ...................................................................... 5 - 204
43
Engine Start Assist Inoperative .................................................................... 5 - 210
44
Auxiliary Drive Function Inoperative ............................................................. 5 - 213
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
TABLE OF CONTENTS
Section Six
Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Wire Circuit 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
Electrical Schematic Legend Drive Chassis (DCON) and Platform Controls (PCON) ............................................ 6 - 14
Electrical Schematic Legend - Ground Controls (TCON) ......................................... 6 - 15
Electric Symbols Legend ........................................................................................ 6 - 16
Electrical Schematic Drive Chassis and Platform Controls (Sheet 1 of 2) ................... located at end of manual
Electrical Schematic Ground Controls (Sheet 2 of 2) ................................................... located at end of manual
Limit Switch Harness Schematic, S-100 & S-105 Models ....................................... 6 - 17
Limit Switch Harness Schematic, S-120 & S-125 Models ....................................... 6 - 18
Safety Circuit Schematic ........................................................................................ 6 - 19
Electrical Schematic - Generators ........................................................................... 6 - 20
Electrical Schematic - Deutz Models ...................................................................... 6 - 21
Electrical Schematic - Cummins and Perkins Models ............................................. 6 - 22
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
xi
First Edition • First Printing
TABLE OF CONTENTS
Section Six
Schematics, continued
Hydraulic Symbols Legend ...................................................................................... 6 - 24
Hydraulic Schematic, S-100 Models with 2 Wheel Steer ......................................... 6 - 25
Hydraulic Schematic, S-100 Models with 4 Wheel Steer ......................................... 6 - 27
Hydraulic Schematic, S-105 Models with 2 Wheel Steer ......................................... 6 - 29
Hydraulic Schematic, S-105 Models with 4 Wheel Steer ......................................... 6 - 31
Hydraulic Schematic, S-120 Models ....................................................................... 6 - 33
Hydraulic Schematic, S-125 Models ....................................................................... 6 - 35
Section Seven
Repair Procedures
Introduction ............................................................................................................... 7 - 1
Display Module ......................................................................................................... 7 - 2
Platform Controls
1-1
Circuit Boards .................................................................................................. 7 - 5
1-2
Membrane Decal ............................................................................................. 7 - 6
1-3
Joystick Controllers ......................................................................................... 7 - 7
1-4
Foot Switch ................................................................................................... 7 - 10
1-5
Toggle Switches ............................................................................................ 7 - 10
Platform Components
xii
2-1
Platform ........................................................................................................ 7 - 12
2-2
Platform Leveling Cylinder ............................................................................. 7 - 12
2-3
Platform Rotator ............................................................................................ 7 - 14
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
TABLE OF CONTENTS
Section Seven
Repair Procedures, continued
Jib Boom Components, S-105 and S-125 Models
3-1
Jib Boom, S-105 and S-125 Models .............................................................. 7 - 18
3-2
Jib Boom Lift Cylinder, S-105 and S-125 Models ........................................... 7 - 20
Boom Components
4-1
Cable Track ................................................................................................... 7 - 23
4-2
Boom ............................................................................................................ 7 - 26
4-3
Boom Lift Cylinder ......................................................................................... 7 - 37
4-4
Extension Cylinders ...................................................................................... 7 - 39
4-5
Boom Extend/Retract Cables ........................................................................ 7 - 43
Turntable Covers
5-1
Turntable Covers ........................................................................................... 7 - 47
Engines
6-1
RPM Adjustment ........................................................................................... 7 - 49
6-2
Flex Plate ...................................................................................................... 7 - 49
6-3
Oil Pressure and Coolant Temperature Sending Units,
Cummins and Perkins Models ....................................................................... 7 - 50
6-4
Oil Pressure and Temperature Sending Units, Deutz Models ......................... 7 - 51
Ground Controls
7-1
Circuit Boards ................................................................................................ 7 - 52
7-2
Membrane Decal ........................................................................................... 7 - 53
7-3
Control Relays ............................................................................................... 7 - 54
Limit Switches
8-1
Part No. 62401
Limit Switches ............................................................................................... 7 - 57
Genie S-100 & S-105 & S-120 & S-125
xiii
First Edition • First Printing
TABLE OF CONTENTS
Section Seven
Repair Procedures, continued
Hydraulic Pumps
9-1
Function Pumps ............................................................................................ 7 - 60
9-2
Drive Pump ................................................................................................... 7 - 61
9-3
Auxiliary Pump .............................................................................................. 7 - 64
9-4
Power Relay .................................................................................................. 7 - 65
Manifolds
10-1 Function Manifold Components, S-100 and S-105 Models ............................. 7 - 66
10-2 Valve Adjustments - Function Manifold, S-100 and S-105 Models ................. 7 - 70
10-3 Proportional Valves - Function Manifold ........................................................ 7 - 71
10-4 Function Manifold Components, S-120 and S-125 Models ............................. 7 - 72
10-5 Valve Adjustments - Function Manifold, S-120 and S-125 Models ................. 7 - 76
10-6 Proportional Valves - Function Manifold ........................................................ 7 - 77
10-7 Distribution Manifold Components ................................................................. 7 - 78
10-8 Valve Adjustments - Distribution Manifold ..................................................... 7 - 80
10-9 Platform Manifold Components, S-100 and S-120 Models ............................. 7 - 82
10-10 Platform Manifold Components, S-105 and S-125 Models ............................. 7 - 84
10-11 Proportional Valves - Platform Manifolds ....................................................... 7 - 86
10-12 Platform Rotate Counterbalance Valve Manifold ............................................ 7 - 86
10-13 Turntable Rotation Manifold Components ...................................................... 7 - 87
10-14 Steer and Axle Extend/Retract Manifold Components - View 1 ...................... 7 - 88
10-15 Steer and Axle Extend/Retract Manifold Components - View 2 ...................... 7 - 92
10-16 Valve Adjustments - Steer and Axle Extend/Retract Manifold ....................... 7 - 96
10-17 Drive Manifold Components ........................................................................... 7 - 98
10-18 Valve Adjustments - Drive Manifold .............................................................. 7 - 102
xiv
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
TABLE OF CONTENTS
Section Seven
Repair Procedures, continued
.
Fuel and Hydraulic Tanks
11-1 Fuel Tank ..................................................................................................... 7 - 103
11-2 Hydraulic Tank ............................................................................................. 7 - 104
Turntable Rotation Components
12-1 Turntable Rotation Hydraulic Motor and Drive Hub ........................................ 7 - 106
Axle Components
13-1 Steer Sensors .............................................................................................. 7 - 110
13-2 Yoke and Hub ............................................................................................... 7 - 112
13-3 Drive Motor ................................................................................................... 7 - 114
13-4 Drive Hub ..................................................................................................... 7 - 115
13-5 Steering Cylinders ........................................................................................ 7 - 116
13-6 Extendable Axles ......................................................................................... 7 - 117
Appendix
Electrical Schematic , Genie part number 62304
Drive Chassis and Platform Control ............................................................... Sheet 1 of 2
Ground Controls ............................................................................................ Sheet 2 of 2
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
xv
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TABLE OF CONTENTS
This page intentionally left blank.
xvi
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 2 • Specifications
Specifications
Machine Specifications,
S-120 and S-125 Models
Stowed dimensions
Turning radius, inside,
axles retracted
16 ft 4 in
4.9 m
16 ft 4 in
4.9 m
Turning radius, outside,
axles extended
20 ft 8 in
6.3 m
20 ft 8 in
6.3 m
Turning radius, inside,
axles extended
10 ft 1 in
3.1 m
10 ft 1 in
3.1 m
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
14 m
8 ft 6 in
259 cm
8 ft 6 in
259 cm
11 ft 6 in
351 cm
11 ft 6 in
351 cm
10 ft 1 in
308 cm
10 ft 1 in
308 cm
44,340 lbs
20,112 kg
44,640 lbs
20,248 kg
153/4 in
40 cm
153/4 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
Overall tire diameter
Maximum load capacity
750 lb
340 kg
500 lb
227 kg
Wheel diameter
22.5 in
57 cm
Turntable tailswing,
axles retracted
66 in
168 cm
66 in
168 cm
Wheel width
13 in
33 cm
Turntable tailswing
axles extended
48 in
122 cm
48 in
122 cm
Wheel lugs
Wheelbase
12 ft
366 cm
12 ft
366 cm
24 ft 4 in
7.4 m
24 ft 4 in
7.4 m
Length, transport position
Length, stowed
Turntable rotation (degrees)
Platform rotation
Width, axles retracted
Width, axles extended
Height, stowed maximum
Weight
Ground clearance
Maximum allowable
side force (ANSI and CSA)
Maximum allowable
side force (CE)
Controls
Part No. 62401
160°
150 lbs
667 N
90 lbs
400 N
12V DC proportional
Platform dimensions
Length
96 in
244 cm
Width
36 in
91 cm
Operational dimensions
Turning radius, outside,
axles retracted
360° continuous
Tires and wheels
Tire size
Tire ply rating
18 x 22.5, 18 pr FF
18
46.5 in
118 cm
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
569.5 Nm
Lug nut torque, lubricated
320 ft-lbs
433.9 Nm
Genie S-100 & S-105 & S-120 & S-125
2-1
Section 2 • Specifications
First Edition • First Printing
SPECIFICATIONS
Fluid capacities
Hydraulic tank capacity
55 gallons
208 liters
Hydraulic system capacity
(including tank)
80 gallons
303 liters
Fuel tank capacity
40 gallons
151 liters
Performance Specifications,
S-120 and S-125 Models
Drive speeds, maximum
Airborne noise emissions
80 dB
Maximum sound level at normal operating workstations
(A-weighted)
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
Drive speed, stowed
3 mph
4.8 km/h
40 ft/9.1 sec 12.2 m/9.1 sec
Drive speed,
raised or extended
0.7 mph
1.1 km/h
40 ft/40 sec 12.2 m/40 sec
Drive speed,
fully extended
0.4 mph
0.6 km/h
40 ft/70 sec 12.2 m/70 sec
Gradeability (boom stowed)
40%
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)
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
50 to 55 seconds
Boom extended to >100 ft (>30.5 m) 24 to 28 seconds
(time between 68° envelope
limit and a fully raised position)
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)
80 to 88 seconds
100 to 110 seconds
50 to 55 seconds
Boom extended to >100 ft (>30.5 m) 24 to 28 seconds
(time between fully raised and
the 65° envelope limit)
2-2
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 2 • Specifications
SPECIFICATIONS
Boom extend
horizontal, 0 to 80 ft (0 to 24.4 m)
vertical, 0 to 120 ft (0 to 36.6 m)
75 to 83 seconds
170 to 190 seconds
Boom retract
horizontal, 80 ft to 0 (24.4 m to 0)
vertical, 120 ft to 0 (36.6 m to 0)
75 to 83 seconds
170 to 190 seconds
Turntable rotate, 360°
boom horizontal and
fully retracted
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 6 in
259 cm
8 ft 6 in
259 cm
Width, axles extended
11 ft 6 in
351 cm
11 ft 6 in
351 cm
Height, stowed maximum
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
24 ft 4 in
7.4 m
24 ft 4 in
7.4 m
Turning radius, inside,
axles retracted
16 ft 4 in
4.9 m
16 ft 4 in
4.9 m
Length, transport position
Length, stowed
170 to 190 seconds
Turntable rotate, 360°
boom horizontal and
extended >0 ft (>0 m)
285 to 315 seconds
Turntable rotate, 360°
boom horizontal and
extended >80 ft (>24.4 m)
490 to 540 seconds
Platform rotate, 160°
Machine Specifications,
S-100 and S-105 Models
18 to 22 seconds
Weight
Ground clearance
Operational dimensions
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
2-3
Section 2 • Specifications
First Edition • First Printing
SPECIFICATIONS
Turning radius, outside,
axles extended
20 ft 8 in
6.3 m
20 ft 8 in
6.3 m
Turning radius, inside,
axles extended
10 ft 1 in
3.1 m
10 ft 1 in
3.1 m
Turntable rotation (degrees)
Platform rotation
Maximum allowable
side force (ANSI and CSA)
Maximum allowable
side force (CE)
Controls
360° continuous
160°
150 lbs
667 N
90 lbs
400 N
12V DC proportional
Platform dimensions
Length
96 in
244 cm
Width
36 in
91 cm
Fluid capacities
Hydraulic tank capacity
55 gallons
208 liters
Hydraulic system capacity
(including tank)
80 gallons
303 liters
Fuel tank capacity
40 gallons
151 liters
Airborne noise emissions
80 dB
Maximum sound level at normal operating workstations
(A-weighted)
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
Tires and wheels
Tire size
Tire ply rating
Overall tire diameter
Wheel diameter
Wheel width
Wheel lugs
15 x 22.5, 18 pr FF
18
43.1 in
109.5 cm
22.5 in
57 cm
11.75 in
30 cm
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
569.5 Nm
Lug nut torque, lubricated
320 ft-lbs
433.9 Nm
2-4
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 2 • Specifications
SPECIFICATIONS
Performance Specifications,
S-100 and S-105 Models
Boom extend, boom fully raised
0 to 100 ft (0 to 30.5 m)
120 to 140 seconds
Drive speeds, maximum
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)
285 to 315 seconds
Turntable rotate, 360°
boom fully raised and
extended >80 ft (>24.4 m)
490 to 540 seconds
Drive speed, stowed
3 mph
4.8 km/h
40 ft/9.1 sec 12.2 m/9.1 sec
Drive speed,
raised or extended
0.7 mph
1.1 km/h
40 ft/40 sec 12.2 m/40 sec
Drive speed,
fully extended
0.4 mph
0.6 km/h
40 ft/70 sec 12.2 m/70 sec
Gradeability (boom stowed)
42%
Boom function speeds, maximum
from platform controls
Platform rotate, 160°
Jib boom up (S-105 models)
28 to 32 seconds
Jib boom down (S-105 models)
28 to 32 seconds
18 to 22 seconds
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
50 to 55 seconds
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)
Part No. 62401
80 to 88 seconds
100 to 110 seconds
50 to 55 seconds
Genie S-100 & S-105 & S-120 & S-125
2-5
Section 2 • Specifications
First Edition • First Printing
SPECIFICATIONS
Hydraulic Specifications
Function pump
Hydraulic fluid
Type: two-section gear pump
Dexron equivalent
Displacement (Pump 1)
Drive pump
Type: bi-directional, variable displacement piston pump
Displacement @ 2350 rpm
Maximum drive pressure
28 gpm
106 L/min
4250 psi
293 bar
1.75 cu in
28.7 cc
Displacement @ 2350 rpm (Pump 1)
Displacement (Pump 2)
1 cu in
16.4 cc
Displacement @ 2350 rpm (Pump 2)
Charge pump
Charge pump pressure
5.2 gpm
19.7 L/min
290 psi
20 bar
Type: two section gear pump
Displacement (Section 1)
0.159 cu in
2.61 cc
Displacement @ 2687 rpm (Section 1)
Function manifold
Function relief
valve pressure
2600 psi
179.3 bar
Displacement (Section 2)
Boom extend relief
valve pressure
1800 psi
124.1 bar
Displacement @ 2687 rpm (Section 2)
Four wheel steer and axle extend/retract manifold
Steer/axle extend
flow regulator
10.2 gpm
38.5 L/min
Auxiliary pump
Type: gear
Displacement @ 2350 rpm
17.8 gpm
67.4 L/min
3 gpm
11.4 L/min
Auxiliary pump relief pressure
Section 1
Section 2
1.85 gpm
7 L/min
0.051 cu in
0.84 cc
0.59 gpm
2.2 L/min
2500 psi 172.4 bar
3000 psi 206.8 bar
Hydraulic filters
Drive manifold
Brake relief pressure
250 psi
17.2 bar
High pressure filter
B3-200
High pressure filter
bypass pressure
100 psi
6.9 bar
Medium pressure filter
B3-200
Medium pressure filter
bypass pressure
87 psi
6 bar
Drive motors
Displacement
per revolution, variable
0.73 to 2.75 cu in
12 cc to 45 cc
Hydraulic tank circuit
return line filter
Drive motor case drain filter
2-6
Genie S-100 & S-105 & S-120 & S-125
10 micron with 25 psi
(1.7 bar) bypass
10 micron
Part No. 62401
First Edition • First Printing
Section 2 • Specifications
SPECIFICATIONS
Perkins Engine 1004-42
Displacement
Injection system
258 cu in
4.23 liters
Number of cylinders
Bore & stroke
Zexel
Injector opening pressure
2204 psi
152 bar
4
4.06 x 5 inches
103.1 x 127 mm
Horsepower
81 @ 2200 rpm
Firing order
1-3-4-2
Compression ratio
Injection pump make
18.5:1
Compression pressure
pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle - no load
1300 rpm
High idle - no load
2350 rpm
Fuel requirement
Summer grade
Winter grade
diesel number 2-D
At operating temperatures below
32°F (0°C), use a special winter fuel.
Alternator output
55A, 12V
Battery - System
Type
Quantity
AH rating
Cold cranking ampere
Reserve capacity @ 25A rate
12V, Group 27TM
1
109AH
630A
160 minutes
Battery - Engine starting
Valve clearance, cold
Intake
0.008 in
0.20 mm
Exhaust
0.018 in
0.45 mm
Oil capacity
(including filter)
51 psi
3.45 bar
8.9 quarts
8.4 liters
Engine capacity
9.5 quarts
9 liters
System capacity
20 quarts
18.9 liters
Fan belt deflection
Oil viscosity requirements
below 32°F / 0°C
12V, Group 4D
1
190AH
1020A
325 minutes
Cooling system
Lubrication system
Oil pressure
Type
Quantity
AH rating
Cold cranking ampere
Reserve capacity @ 25A rate
3 /8
to 1/2 inch
9 to 12 mm
0W
-13°F to 68°F / -25°C to 20°C
5W-20
10°F to 104°F / -12°C to 40°C
10W-30
14°F to 122°F / -10°C to 50°C
15W-40
above 23°F / -5°C
20W-50
Engine oil should have properties of API classification
CF4 grade OR ACEA classification E3.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
2-7
Section 2 • Specifications
First Edition • First Printing
SPECIFICATIONS
Cummins Engine B3.9L
Displacement
Injection system
238 cu in
3.9 liters
Number of cylinders
Bore and stroke
Injection pump make
Injection pump pressure
4
4.02 x 4.72 inches
102 x 120 mm
Injector opening pressure
Fuel requirement
Horsepower
75 @ 2200 rpm
Firing order
1-3-4-2
Alternator output
16.5:1
Battery - System
Compression ratio
Low idle - no load
1300 rpm
Type
Quantity
AH rating
Cold cranking ampere
Reserve capacity @ 25A rate
High idle - no load
2350 rpm
Battery - Engine starting
Intake
0.010 in
0.254 mm
Exhaust
0.020 in
0.508 mm
Type
Quantity
AH rating
Cold cranking ampere
Reserve capacity @ 25A rate
Compression pressure
pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Valve clearance, cold
Lubrication system
Oil pressure
Oil capacity
(including filter)
50 psi
3.45 bar
Bosch
5500 psi
379.2 bar
3480 psi
240 bar
diesel number 2-D
63A, 12V
12V, Group 27TM
1
109AH
630A
160 minutes
12V, Group 4D
1
190AH
1020A
325 minutes
Cooling system
Engine capacity
8.8 quarts
8.3 liters
System capacity
20 quarts
18.9 liters
9.5 quarts
9 liters
Oil viscosity requirements
below 68°F / 20°C
5W-30
-10° to 68°F / -23° to 20°C
10W-30
above 15°F / -9°C
15W-40
Use oils meeting API classification CE (labeled CE/SG).
2-8
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 2 • Specifications
SPECIFICATIONS
Deutz Engine F4L 913
Displacement
Injection system
249.3 cu in
4.086 liters
Number of cylinders
Bore and stroke
Injection pump make
Injection pump pressure
8702 psi
600 bar
Injector opening pressure
3626 psi
250 bar
4
4.02 x 4.92 inches
102 x 125 mm
Fuel requirement
Horsepower
77 @ 2200 rpm
Firing order
1-3-4-2
Alternator output
18:1
Battery - System
Compression ratio
Low idle - no load
1300 rpm
Type
Quantity
AH rating
Cold cranking ampere
Reserve capacity @ 25A rate
High idle - no load
2350 rpm
Battery - Engine starting
Compression pressure
pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Valve clearance, cold
Intake
0.006 in
0.15 mm
Exhaust
0.006 in
0.15 mm
Type
Quantity
AH rating
Cold cranking ampere
Reserve capacity @ 25A rate
Fan belt deflection
Lubrication system
Oil pressure
Oil capacity
(including filter)
IMSA
diesel number 2-D
55A, 12V
12V, Group 27TM
1
109AH
630A
160 minutes
12V, Group 4D
1
190AH
1020A
325 minutes
3 /8
to 1/2 inch
9 to 12 mm
40 to 60 psi
2.75 to 4.14 bar
14.3 quarts
13.5 liters
Oil viscosity requirements
below 60°F / 15.5°C (synthetic)
5W-30
-10°F to 90°F / -23°C to 32°C
10W-40
above -4°F / -34°C
15W-40
Engine oil should have properties of API classification
CC/SE or CC/SF grades OR ACEA classification E1-96.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
2-9
Section 2 • Specifications
First Edition • First Printing
SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications
Your machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines that
utilize Parker Seal-Lok® O-ring face seal hoses and fittings require that the fittings and hose ends be
torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Hydraulic Hose and Fitting Torque Specifications
SAE O-ring Boss Port - tube fitting
SAE Dash
Installing
Size
into...
ft. lbs.
-4
Aluminum
11
Steel
16
-6
Aluminum
23
Steel
35
-8
Aluminum
40
Steel
60
-10
Aluminum
69
Steel
105
-12
Aluminum
93
Steel
140
-16
Aluminum
139
Steel
210
-20
Aluminum
172
Steel
260
-24
Aluminum
208
Steel
315
Nm
14.9
21.7
31.2
47.5
54.2
81.3
93.6
142.4
126.1
190
188.5
284.7
233.2
352.5
282
427.1
Seal-Lok® - hose end
SAE Dash
Size
ft. lbs.
-4
18
-6
27
-8
40
-10
63
-12
90
-16
120
-20
140
-24
165
Nm
24.4
36.6
54.2
85.4
122
162.7
190
223.7
Torque Procedure
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.
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).
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
above.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
be sure that there are no leaks.
2 Lubricate the O-ring before installation.
2 - 10
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 3 • Theory of Operation
Theory of Operation
Power Source
The Genie S-100, S-105, S-120 and S-125 are
powered by one of three diesel engines:
the Cummins B3.9L, the Deutz F4L 913 and the
Perkins 1004-42.
Auxiliary power is supplied by a hydraulic pump
powered by a 12V battery.
Hydraulic System
All machine functions are performed by the
hydraulic system. The hydraulic system can be
divided into two groups: Boom and Steer/Axle
functions and Drive functions.
Boom and Steer/Axle functions are powered by
two-section gear pumps, rated at 17 gpm (64.4 L/
min) and 10 gpm (37.9 L/min). When the engine is
running, these pumps supply hydraulic fluid under
pressure to function manifolds, where the
directional and flow control valves are located. To
protect from over-pressurization of the systems,
each manifold is provided with a pressure relief
valve. The Steer and Axle extend/retract manifold
relief valve is set at 3000 psi (206.8 bar); the
Function manifold relief valve is set at 2600 psi
(179.3 bar); the Platform manifold relief valve is
located in the Distribution manifold and is set at
3000 psi (206.8 bar).
Drive functions are powered by a bi-directional,
variable displacement piston pump rated at 28 gpm
(106 L/min) @ 2350 rpm. Two internal 4250 psi
(293 bar) relief valves are used to prevent overpressurization of the closed loop drive system.
Part No. 62401
The boom lift cylinder, boom extend cylinders,
platform leveling slave cylinder, platform rotator
and jib boom cylinder (S-105 and S-125 models)
incorporate counterbalance valves to prevent
movement in the event of a hydraulic line failure.
A regeneration circuit is used to increase the
performance of the primary boom extension
function. This circuit transfers hydraulic fluid from
one end of the primary cylinder into the other end
when the cylinder is extending or retracting.
The auxiliary pump is a two-section gear pump.
One section is rated at 1.85 gpm (7 L/min) and the
other is rated at 0.59 gpm (2.2 L/min).
The 1.7 gpm (7 L/min) section is supplied with a
2500 psi (172.4 bar) relief valve and the 0.59 gpm
(2.2 L/min) section is supplied with a 3000 psi
(206.8 bar) relief valve.
Electrical System
Two separate 12V batteries are used for this
system. The larger, Group 4D, battery is used to
start the engine and power the auxiliary pump. The
smaller, Group 31, battery is used to power the
three Electronic Control Modules (ECM's) which
manage boom functions and engine controls. The
batteries are charged through a common engine
driven alternator. A battery separator is used to
charge the smaller battery before charging the
larger battery. The control system is protected by
two circuit breakers that may be manually reset.
Genie S-100 & S-105 & S-120 & S-125
3-1
Section 3 • Theory of Operation
First Edition • First Printing
THEORY OF OPERATION
Service Bypass/Recovery
Key Switch
The Service Bypass/Recovery key switch is only to
be used by properly trained service personnel.
When the Service Bypass/Recovery key switch is
turned to the service bypass position, the 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. 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 unit will turn on and fully retract the
boom, and then lower the boom to a stowed
position. 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.
Machine Controls
Three ECMs manage the boom functions. They
are located at the turntable (ground controls or
TCON), the platform (platform controls or PCON)
and the drive chassis (drive chassis controller or
DCON). Communication between the controllers is
maintained via a high speed data bus (CAN bus).
For example, steering inputs from PCON are sent
to DCON via the high speed data bus using
multiplexed signals.
3-2
A series of proximity switches and mechanical limit
switches provide information to the controllers.
These proximity and mechanical switches maintain
and define the safe operating parameters of the
machine. In addition, there is a back-up safety
system using mechanical limit switches which will
cut power to selected portions of the controllers
should the operational system fail to operate
properly.
The ground controls (TCON) have membrane
operated switches. They are non-tactile touch
switches for greater durability. When one button is
pressed there is an audible beep indicating
operation. In addition, there is a display on the
ground control box that is used to show fault
codes, engine condition, machine status and
setup, and the display language selected. Boom
speeds, turntable rotation and ramp rates are
adjustable. Also, various options and operating
limitations can be programmed. For example, the
boom extension can be limited to 80 ft (24.4 m) or
100 ft (30.5 m).
The platform controls (PCON) has three joystick
controllers for operational control. Drive and steer
functions are controlled through one dual-axis
joystick, boom up/down and turntable rotate
functions are controlled through another dual-axis
joystick, and the boom extend/retract functions are
controlled through a single axis joystick. Standard
toggle switches are used to control the platform
level up/down, platform rotate and jib boom up/
down functions (S-105 and S-125 models).
Membrane type switches are used to select the
various steering and operating modes.
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 3 • Theory of Operation
THEORY OF OPERATION
The drive chassis controller (DCON) has no
operator accessible controls. The various steering
controls, axle status, brake and motor speed is
managed by this controller. There are status LED's
on this module to indicate power, data link
communications, system fault and sensor power.
Platform leveling is accomplished with
electrohydraulic controls. An angle sensor is
mounted on the platform rotator which senses the
level of the platform. This signal is processed by
PCON and sent to TCON using the data bus. The
signal from the tilt sensor on the turntable is
compared to the PCON signal and adjustments are
made to level the platform.
For safety, machine drive speed is reduced relative
to the steer angle of the wheels and boom length.
Steering is accomplished using hydraulic cylinders
at each wheel. Correct steering geometry is
maintained through the use of four steering
sensors, one at each wheel. Steering angles are
sent from the primary steering sensor to DCON
and the appropriate adjustments are made to the
other three wheels to correspond with the steer
mode selected. If the machine is equipped with
four wheel steering, there are four steering modes
available: 2 wheel front steer, 2 wheel rear steer, 4
wheel coordinated steer and crab steer. Having
independent control over each wheel allows the
machine to determine the correct wheel geometry
in each steering mode.
Washing electronic components is
not suggested. Instead, use low
pressure compressed air to
remove debris from these
components.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
3-3
Section 3 • Theory of Operation
First Edition • First Printing
This page intentionally left blank.
3-4
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • 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, semi-annually,
annually and every 2 years as specified on the
Maintenance Inspection Report.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
· Machine parked on a flat, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the circle-end (yellow arrow) wheels
· Turntable secured with the turntable rotation
lock
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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
· Key switch in the OFF position with the
key removed
· Wheels chocked
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4-1
Section 4 • Scheduled Maintenance Procedures
First Edition • First Printing
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Schedule
Maintenance Symbols Legend
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.
Indicates that tools will be required to
perform this procedure.
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two year.
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.
Inspection
Table or Checklist
Daily or every 8 hours
Indicates that new parts will be required
to perform this procedure.
Quarterly or every 250 hours
Semi-annually or every 500 hours
Annual or every 1000 hours
Indicates that a cold engine will be
required to perform this procedure.
Indicates that a warm engine will be
required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
4-2
Two year 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. Store completed forms
for three years.
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Checklist A
A-1 Manuals
Serial number
A-2 Decals and placards
Date
A-3 Damage and loose or
missing parts
Hour meter
A-4 Engine oil level
Machine owner
A-5 Engine coolant level Liquid cooled models
Inspected by (print)
A-6 Engine belt(s) Cummins models
A-7 Engine cooling fan Liquid cooled models
A-8 Drain inline fuel
filter/water separator
Inspector signature
Inspector title
Inspector company
A-9 Inspect air filter
Instructions
· Make copies of this report to use for
each inspection.
A-10 Fuel leaks
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
A-13 Hydraulic filter
condition indicators
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
Y N R
A-11 Hydraulic oil level
A-12 Hydraulic leaks
A
A+B
Semi-annual or 500 hour
Inspection:
A+B+C
Annual or 1000 hour
Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E
Checklist B
B-1 Check radiator Liquid cooled models
B-2 Oil cooler and fins Deutz models
B-3 Engine belt(s) - Deutz
and Perkins models
B-4 Replace inline fuel
filter/water separator
B-5 Replace air filter
B-6 Air intake system
B-7 Exhaust system
B-8 Hydraulic tank return
filters
B-9 Hydraulic tank
breather filter
B-10 Medium and high
pressure filters
B-11 Electrical wiring
B-12 Brake configuration
A-14 Platform and
ground controls
B-13 Tires and wheels
A-15 Auxiliary power
B-15 Engine RPM
A-16 Tilt sensor and alarm
B-16 Key switches
A-17 Operating envelope
B-17 Emergency Stop
Perform after 40 hours:
A-18 Perform 30 day service
A-19 Engine fasteners Deutz models
Perform every 125 hours:
A-20 Batteries
Y N R
B-14 Drive hub oil level
B-18 Ground control override
B-19 Safety envelope
B-20 Platform self leveling
B-21 Horn
B-22 Foot switch
B-23 Engine idle select
· 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.
B-24 Drive enable system
· 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.
B-28 Alarm package
Legend
Y = yes, acceptable
N = no, remove from service
B-31 Hydraulic oil analysis
B-25 Drive brakes
B-26 Drive speed - stowed
B-27 Drive speed - raised or
extended
B-29 Engine oil and filter Cummins models
B-30 Fuel tank cap vent
R = repaired
Comments
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4-3
Section 4 • Scheduled Maintenance Procedures
First Edition • First Printing
MAINTENANCE INSPECTION REPORT
Model
Checklist C
Refer to Table C
C-1 Valves - Deutz models
C-2 Fuel pump strainer Perkins models
C-3 Fuel filter element Perkins and Cummins
C-4 Engine oil and filter Deutz and Perkins
C-5 Check the coolant Liquid cooled models
C-6 Boom extend/retract
cables
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Y N R
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:
Quarterly or 250 hour
Inspection:
A
A+B
Semi-annual or 500 hour
Inspection:
A+B+C
Checklist D
Y N R
Refer to Table D
D-1 Boom wear pads
D-2 Axle wear pads
D-3 Free-wheel configuration
D-4 Turntable bearing bolts
D-5 Turntable gear backlash
D-6 Grease rotation bearing
D-7 Drive hub oil
D-8 Engine Belt(s) Cummins models
D-9 Fuel filter - Deutz models
D-10 Valves Cummins and Perkins
Checklist E
Y N R
Refer to Table E
E-1 Hydraulic oil
E-2 Engine coolantLiquid cooled models
E-3 Fuel hoses
E-4 Valves Cummins models
Perform every 3000 hours:
E-5 Fuel injectorsDeutz models
Perform every 5 years:
E-6 Remove and inspect
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.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
4-4
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
Table A Procedures
A-1
Inspect the Manuals
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.
1 Check to be sure that the storage container is
present and in good condition.
2 Check to make sure that the operator's,
responsibilities and safety manuals are present
and complete in the storage container in the
platform.
3 Examine the pages of each manual to be sure
that they are legible and in good condition.
4 Always return the manuals to the storage
container after use.
Contact your authorized Genie
distributor or Genie Industries if
replacement manuals are needed.
Part No. 62401
A-2
Inspect the
Decals and Placards
Maintaining all of the safety and instructional
decals and placards 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.
1 Refer to the Decals section in the Genie S-100 &
Genie S-105 Operator's Manual or the Genie
S-120 & Genie S-125 Operator's Manual and
use the decal list and illustrations to determine
that all decals and placards are in place.
2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
immediately.
Contact your authorized Genie
distributor or Genie Industries if
replacement decals are needed.
Genie S-100 & S-105 & S-120 & S-125
4-5
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
A-3
Inspect for Damage and Loose or
Missing Parts
Daily machine condition inspections are essential
to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
1 Visually inspect the entire machine for damage
and improperly installed or missing parts
including:
· Electrical components, wiring and electrical
cables
· Hydraulic hoses, fittings, cylinders and
manifolds
· Fuel and hydraulic tanks
· Drive and turntable motors and drive hubs
· Boom and axle wear pads
· Dents or damage to machine
· Tires and wheels
· Engine and related components
· Limit switches and horn
· Alarms and beacon (if equipped)
· Nuts, bolts and other fasteners
A-4
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Check the oil level with the
engine off.
1 Check the engine oil dipstick. Add oil as
needed.
Cummins models:
Result: The oil level should be within the "L" and
"H" marks on the dipstick.
Deutz models:
Result: The oil level should be within the two
marks on the dipstick.
Perkins models:
Result: The oil level should be within the two
notches on the dipstick.
Cummins B3.9L Engine
Oil capacity (including filter)
11.5 quarts
10.9 liters
Cummins B3.9L Engine
Engine oil viscosity requirements
below 68°F / 20°C
5W-30
· Platform entry mid-rail or gate
· Cracks in welds or structural components
-13° to 68°F / -25° to 20°C
10W-30
· Compartment covers and latches
above 15°F / -9°C
15W-40
Use oils meeting API classification CE (labeled CE/SG).
4-6
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
Deutz F4L 913 Engine
Oil capacity (including filter)
14.3 quarts
13.5 liters
Deutz F4L 913 Engine
Engine oil viscosity requirements
below 60°F / 15.5°C (synthetic)
A-5
Check the Engine Coolant Level Liquid Cooled Models
5W-30
-10°F to 90°F / -23°C to 32°C
10W-40
above -4°F / -34°C
15W-40
Engine oil should have properties of API classification
CC/SE or CC/SF grades OR ACEA classification E1-96.
Maintaining the engine coolant at the proper level
is essential to engine service life. Improper coolant
level will affect the engine's cooling capability and
can damage engine components. Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed.
Perkins 1004-42 Engine
Oil capacity (including filter)
8.9 quarts
8.4 liters
Perkins 1004-42 Engine
Engine oil viscosity requirements
below 32°F / 0°C
0W
-13°F to 68°F / -25°C to 20°C
5W-20
10°F to 104°F / -12°C to 40°C
10W-30
14°F to 122°F / -10°C to 50°C
15W-40
above 23°F / -5°C
20W-50
Result: The fluid level should be in the
NORMAL range.
Bodily injury hazard. Fluids in the
radiator are under pressure and
extremely hot. Use caution when
removing cap and adding fluids.
Engine oil should have properties of API classification
CF4 grade OR ACEA classification E3.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4-7
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
A-6
Check the Engine Belt(s) Cummins Models
Maintaining the engine belt(s) is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
belt(s) and continued use may cause component
damage.
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.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
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 Inspect the engine belt for:
· Cracking
· Glazing
· Separation
· Breaks
5 Replace the belt if any damage is found. See
D-8, Inspect the Engine Belt(s).
6 Inspect the generator belt (if equipped) for:
· Cracking
· Glazing
· Separation
· Breaks
a
b
a
b
a
b
4-8
engine pivot plate anchor hole
engine pivot plate retaining fastener
a
b
Genie S-100 & S-105 & S-120 & S-125
generator (option)
generator belt
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
7 Replace the belt if any damage is found. See
D-8, Inspect the Engine Belt(s).
Cummins engines are equipped
with a serpentine belt and
incorporate a self-adjusting pulley
tensioner. No adjustment is
required.
8 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
9 Swing the engine pivot plate in towards the
machine.
A-7
Check the Engine Cooling Fan Liquid Cooled Models
Maintaining the engine cooling fan is essential to
good engine performance and service life. The
machine will not operate properly with a loose or
defective cooling fan and continued use may
cause component damage.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.
10 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.
Belts - Genie part numbers
Cummins engine belt
Cummins generator belt
62437
60725
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
1 Open the engine side turntable cover and locate
the engine cooling fan.
2 Inspect the engine cooling fan for:
· Cracking
· Loose rivets (if equipped)
· Bent or loose blades
3 Check the fan to make sure it is securely
mounted. Tighten the cooling fan mounting
fasteners if necessary.
4 Replace the cooling fan if any damage is found.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4-9
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
A-8
Drain the Inline Fuel Filter/ Water
Separator
2 Loosen the vent plug located on the fuel filter/
water separator head.
Proper maintenance of the fuel filter/water
separator is essential for good engine
performance. Failure to perform this procedure can
lead to poor engine performance and component
damage.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Poor fuel quality or very wet
conditions may necessitate
performing this procedure more
often.
Perform this procedure with the
engine off.
1 Open the engine side turntable cover and locate
the fuel filter/water separator.
a
b
c
d
e
f
head bolt
vent plug
drain plug
filter bowl
filter element
separator head
3 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
Do not completely drain the fuel
bowl.
4 Tighten the vent plug.
5 Clean up any diesel fuel that may have spilled
during the procedure.
6 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
If the engine will not start or runs
erratically, the fuel system may
need to be bled. Refer to B-4,
Replace The Fuel Filter/Water
Separator.
4 - 10
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
A-9
Inspect the Engine Air Filter
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.
Perform this procedure with the
engine off.
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
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.
Air filter element
Genie part number
62425
Genie S-100 & S-105 & S-120 & S-125
4 - 11
clamp
cannister end cap
dust discharge valve
2 Release the clamps from the end cap of the air
filter canister. Remove the end cap.
Part No. 62401
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
A-10
Check for Fuel Leaks
A-11
Check the Hydraulic Oil Level
Failure to detect and correct fuel leaks will result in
an unsafe condition. An explosion or fuel fire could
result in death or serious injury.
Maintaining the hydraulic oil at the proper level is
essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
system problems.
Explosion and fire hazard. Engine
fuels are combustible. Inspect the
machine in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
1 Perform a visual inspection around the following
areas:
· Fuel tank, shutoff valve, hoses and fittings,
fuel pump, fuel filter, fuel injection pumps and
fuel injectors.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
4 - 12
Perform this procedure with the
boom in the stowed position and
the axles extended.
1 Visually inspect the sight gauge located on the
side of the hydraulic oil tank.
Result: The hydraulic oil level should be 3/4 inch
(19 mm) from the top of the sight gauge.
Hydraulic oil specifications
Hydraulic oil type
Dexron equivalent
Tank capacity
55 gallons
208 liters
Hydraulic system
(including tank)
80 gallons
303 liters
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
A-12
Check for Hydraulic Leaks
Detecting hydraulic fluid leaks is essential to
operational safety and good machine performance.
Undiscovered leaks can develop into hazardous
situations, impair machine functions and damage
machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
· Hydraulic tank—filter, fittings, hoses,
auxiliary power unit and turntable surface
· Engine compartment—fittings, hoses,
pumps, filters and turntable surface
· All hydraulic cylinders
· All hydraulic manifolds
· Boom
· The underside of the turntable
· The underside of the drive chassis
A-13
Check the Hydraulic Filter
Condition Indicators
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.
There are five hydraulic filters
located on the machine. There is
two tank return filters, one medium
pressure filter and two high
pressure filters. All the filters have
condition indicators on them,
except the drive motor case drain
return filter.
1 Start the engine from the platform controls.
· Axles
· Ground area under the machine
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 13
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
Medium and High Pressure Filters
2 Change the engine idle to high rpm (rabbit
symbol).
a
b
The medium and high pressure
filters are mounted to the engine
side bulkhead. A filter condition
indicator is located on the top of
each filter.
c
4 Inspect the filter condition indicators.
d
a
b
c
d
foot switch activated high idle
indicator light
low idle indicator light
high idle indicator light
engine idle speed select button
b
Press the engine idle speed select
button until the indicator light next
to foot switch activated high idle
(rabbit symbol) is on.
Tank Return Filter
c
a
b
c
3 Inspect the filter condition indicator gauge.
a
a
a
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 should be
replaced. See B-10, Replace the Medium and
High Pressure Hydraulic Filters.
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 should be
replaced. See B-8, Replace the Hydraulic Tank
Return Filters.
4 - 14
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
3 Push and hold a function enable/speed select
button and push the boom up button.
A-14
Test the Platform and
Ground Controls
Testing the machine functions and the Emergency
Stop buttons for malfunctions is essential for safe
machine operation. An unsafe working condition
exists if any function fails to operate properly or
either Emergency Stop button fails to stop all the
machine functions and shut off the engine. Each
function should activate, operate smoothly and be
free of hesitation, jerking and unusual noise.
Tip-over hazard. Do not raise or
extend the boom unless both
axles are extended. If the axle
extension system is not operating
correctly, the stability of the
machine is compromised and it
may tip over.
Be sure the axles are retracted
before performing this procedure.
1 Turn the key switch to ground controls and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls.
Result: The LCD screen will come on and
display no error messages. The beacon
(if equipped) should flash.
In cold climates, the LCD readout
screen will need to warm up
before the display appears.
Result: The boom should raise to 10° above
horizontal and then stop. The boom should not
raise above the limit switch unless both axles
are extended.
4 Push and hold a function enable/speed select
button and push the boom down button.
Result: The boom should lower and return to
the stowed position.
5 Push and hold a function enable/speed select
button and press the boom extend button.
Result: The boom will extend approximately 3
feet (1 m) and stop. The boom should not
extend further unless both axles are extended.
6 Push and hold a function enable/speed select
button and push the boom retract button.
Result: The boom should retract.
7 Turn the key switch to platform controls.
8 Press down the foot switch.
9 Move the drive control handle in the forward
direction and push the extend axle button.
Result: The machine should drive and the axles
should extend. The indicator light will flash
while the axles are moving and stay on when
the axles are fully extended.
The extend axle function will only
work while the machine is moving.
2 Start the engine.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 15
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
10 Stop the machine when the axles are fully
extended.
Test the Ground Controls
11 Turn the key switch to ground controls.
12 Do not press and hold a function enable/speed
select button. Attempt to activate each boom
and platform function button.
Result: No boom and platform functions should
operate.
13 Press and hold a function enable/speed select
button and activate each boom and platform
function button.
Result: All boom and platform functions should
operate through a full cycle. Descent alarm
(if equipped) should sound while boom is
lowering.
Test the Platform Controls
14 Turn the key switch to platform controls.
15 Do not press down the foot switch.
16 Attempt to activate each machine function
control handle, toggle switch or button.
Result: No boom and platform functions should
operate.
A-15
Test the Auxiliary Power
Operation
Detection of auxiliary power system malfunctions is
essential for safe machine operation. An unsafe
working condition exists if the auxiliary powered
functions do not operate in the event of a main
power loss. When operating the machine on
engine power, selecting auxiliary power will stop
the engine immediately. Auxiliary power is
designed for short term use only and excessive
use will result in battery drain and component
damage.
Perform this procedure with the
axles extended and the engine off.
1 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Simultaneously push and hold the auxiliary
power button and push each boom function
button.
To conserve battery power, test
each function through a partial
cycle.
Result: All boom functions should operate.
17 Press down the foot switch.
18 Activate each machine function control handle,
toggle switch or button.
Result: All functions should operate through a
full cycle. Descent alarm (if equipped) should
sound while boom is lowering.
3 Turn the key switch to platform controls.
4 Press down the foot switch.
5 Simultaneously press and hold the auxiliary
power button and activate each function control
handle, toggle switch or button.
To conserve battery power, test
each function through a partial
cycle.
Result: All boom functions should operate.
4 - 16
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
A-16
Test the Tilt Sensor and Alarm
The tilt sensor sounds an alarm located in the
platform when the incline of the turntable exceeds
the rating on the serial plate.
Select a level test area. The tilt
alarm should not be sounding prior
to the test.
Be sure the engine is off.
4 Push one of the LCD
screen buttons shown until
PLATFORM LEVEL
appears.
Result: The LCD screen should display the
angle in degrees.
5 Turn the key switch to platform controls.
6 Push a button, such as the engine RPM button
or the fuel select button.
Result: The alarm should sound at the platform
controls.
1 Turn the key switch to ground controls and pull
out the Emergency Stop buttons out to the ON
position at both the ground and platform
controls.
2 Push one of the LCD
screen buttons shown until
TURNTABLE LEVEL X
AXIS appears.
Result: The LCD screen should display the
angle in degrees.
3 Push one of the LCD
screen buttons shown until
TURNTABLE LEVEL Y
AXIS appears.
Result: The LCD screen should display the
angle in degrees.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 17
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
A-17
Test the Operating Envelope
Testing the machine operating envelope is critical
to safe machine operation. If the boom is allowed
to operate outside of the operating envelope, the
machine stability is compromised and may tip over.
1 Turn the key switch to ground controls and pull
out the Emergency Stop buttons out to the ON
position at both the ground and platform
controls.
6 Extend the boom and observe the LCD screen.
Result: The LCD screen should display:
at 0
>0
>80
= 100
>100
7 Retract the boom.
8 Lower the boom.
2 Simultaneously push the
LCD screen buttons
shown to activate status
mode.
3 Push one of the LCD
screen buttons shown until
BOOM ANGLE is
displayed.
4 Raise the boom and observe the LCD screen.
Result: The LCD screen should display:
<10
>10
>50
>65
5 Push one of the LCD
screen buttons shown until
BOOM LENGTH is
displayed.
4 - 18
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
A-18
Perform 30 Day Service
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 tables for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
Deutz models:
· A-3 Inspect for Damage and Loose or
Missing Parts
· A-19 Check the Engine Fasteners Deutz Models
· B-3 Check the Engine Belt(s) - Deutz and
Perkins Models
· B-5 Replace the Air Filter
· B-8 Replace the Hydraulic Tank Return
Filters
· B-13 Inspect the Tires and Wheels
(including lug nut torque)
· C-1 Check the Engine Valve Clearances Deutz Models
· C-6 Inspect the Boom Extend/Retract
Cables
· D-4 Check the Turnable Rotation Bearing
Bolts
· D-9 Replace the Fuel Filter/Water
Separator - Deutz Models
· B-15 Check and Adjust the Engine RPM
· C-4 Replace the Engine Oil and Filter Deutz and Perkins Models
Part No. 62401
Cummins models:
· A-3 Inspect for Damage and Loose or
Missing Parts
· A-5 Check the Engine Coolant Level Liquid Cooled Models
· B-5 Replace the Air Filter
· B-8 Replace the Hydraulic Tank Return
Filters
· B-13 Inspect the Tires and Wheels
(including lug nut torque)
· C-3 Replace the Fuel Filter Element Perkins and Cummins Models
· C-6 Inspect the Boom Extend/Retract
Cables
· D-4 Check the Turnable Rotation Bearing
Bolts
· D-8 Check the Engine Belt(s) Cummins Models
· D-10 Check the Engine Valve Clearances Cummins and Perkins Models
· B-15 Check and Adjust the Engine RPM
· B-28 Replace the Engine Oil and Filter Cummins Models
Genie S-100 & S-105 & S-120 & S-125
4 - 19
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
Perkins models:
· A-3 Inspect for Damage and Loose or
Missing Parts
· A-5 Check the Engine Coolant Level Liquid Cooled Models
· B-3 Check the Engine Belt(s) - Deutz and
Perkins Models
· B-5 Replace the Air Filter
· B-8 Replace the Hydraulic Tank Return
Filters
· B-13 Inspect the Tires and Wheels
(including lug nut torque)
· C-3 Replace the Fuel Filter Element Perkins and Cummins Models
· C-6 Inspect the Boom Extend/Retract
Cables
· D-4 Check the Turnable Rotation Bearing
Bolts
· D-10 Check the Engine Valve Clearances Cummins and Perkins Models
· B-15 Check and Adjust the Engine RPM
· C-4 Replace the Engine Oil and Filter Deutz and Perkins Models
A-19
Check the Engine Fasteners Deutz Models
Engine specifications require that
this procedure be performed after
40 hours of use.
Properly torqued engine fasteners are essential to
good engine performance and operational safety.
Loose or improperly torqued fasteners can result in
engine component damage and hazardous
conditions.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
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.
4 - 20
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE A PROCEDURES
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 Tighten all valve cover retaining fasteners.
Torque to 108 in-lbs (12 Nm).
5 Tighten all air intake pipe clamps. Torque to 108
in-lbs (12 Nm).
6 Tighten all intake manifold retaining fasteners.
Torque to 17 ft-lbs (23 Nm).
7 Tighten all exhaust manifold retaining fasteners.
Torque to 30 ft-lbs (40 Nm).
8 Tighten all engine mounting fasteners. Torque
engine to bracket mounting fasteners to 54 ftlbs (73 Nm) and bracket to engine pivot plate
mounting fasteners to 175 ft-lbs (237 Nm).
9 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
10 Swing the engine pivot plate in towards the
machine.
11 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. 62401
A-20
Check the Batteries
Genie specifications require that
this procedure be performed every
125 hours.
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 is used for starting
the engine and the other is used to power the
control system. The two batteries are charged by
the alternator through a battery separator.
Electrocution 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 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
3 Be sure that the battery hold downs and cable
connections are tight.
Genie S-100 & S-105 & S-120 & S-125
4 - 21
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
A PROCEDURES
4 Be sure that the battery separator wire
connections are tight.
5 Remove the battery vent caps from both
batteries and check the specific gravity of each
battery with a hydrometer.
Result: If any battery cell displays a specific
gravity of less than 1.026, the battery must be
replaced.
6 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
7 Install the vent caps.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
4 - 22
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
Table B Procedures
2 Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
B-1
Check the Radiator Liquid Cooled Models
3 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Maintaining the radiator in good condition is
essential for good engine performance. Operating
a machine with a damaged or leaking radiator may
result in engine damage. Also, restricting air flow
through the radiator (i.e., dirt or debris) will affect
the performance of the cooling system. A frequent
check allows the inspector to identify changes in
the condition of the radiator that might indicate
cooling system problems.
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 parts and coolant.
Contact with hot engine parts and/
or coolant may cause severe
burns.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
a
4 Inspect the radiator for leaks and physical
damage.
5 Clean the radiator fins of debris and foreign
materials.
6 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
7 Swing the engine pivot plate in towards the
machine.
8 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.
b
a
b
Part No. 62401
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
engine pivot plate anchor hole
engine pivot plate retaining fastener
Genie S-100 & S-105 & S-120 & S-125
4 - 23
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-2
Check the Oil Cooler and
Cooling Fins - Deutz 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.
5 Clean the fan blower fins of debris and foreign
material.
6 Inspect the cylinder head cooling passages and
fins for physical damage or foreign material,
using a flashlight.
7 Clean the cylinder head cooling passages of
debris and foreign material.
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.
Oil Cooler
1 Open the latches from the engine side cover.
Remove the cover.
2 Inspect the oil cooler for leaks and physical
damage.
3 Clean the oil cooler of debris and foreign
material.
Cooling and Fan Blower Fins
4 Inspect the fan blower fins for physical damage.
4 - 24
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-3
Check the Engine Belt(s) Deutz and Perkins Models
Maintaining the engine belt(s) is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
belt and continued use may cause component
damage.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.
Burn injury hazard. Beware of hot
engine components. Contact with
hot engine components may
cause severe burns.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
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.
Deutz models:
4 Remove the front engine access cover
mounting fasteners and remove the front
engine access cover.
All models:
5 Inspect the engine belt for:
· Cracking
· Glazing
· Separation
· Breaks
6 Replace the belt if any damage is found.
7 Inspect the generator belt (if equipped) for:
· Cracking
· Glazing
· Separation
· Breaks
a
b
a
b
engine pivot plate anchor hole
engine pivot plate retaining fastener
a
2 Locate the engine pivot plate anchor hole at the
pivot end of the engine pivot plate.
Perkins engine
a
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
Deutz engine
generator belt
4 - 25
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
8 Check the engine belt(s) for proper tension.
Perkins engine
Deutz engine
Deutz models:
9 Install the front engine access cover mounting
fasteners and install the front engine access
cover.
All models:
10 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
11 Swing the engine pivot plate in towards the
machine.
12 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.
B-4
Replace the Inline Fuel Filter/
Water Separator Element
Replacing the inline fuel filter/water separator
element is essential for good engine performance
and service life. A dirty or clogged filter may cause
the engine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
1 Tag, disconnect and plug the fuel line from the
fuel tank at the inline fuel filter/water separator
head.
Belts - Genie part numbers
Deutz Engine Belt
Deutz Generator Belt
Perkins Engine Belt
Perkins Generator Belt
Belt deflection
4 - 26
62431
75053
62428
75053
3 /8
inch to 1/2 inch
9 mm to 12 mm
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
2 Loosen the vent plug located on the inline fuel
filter/water separator head.
10 Tighten the head bolt to 65 in-lbs (7.3 Nm).
11 Tighten the vent plug.
12 Clean up any diesel fuel that may have spilled
during the procedure.
13 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
14 Install the fuel tank line onto the inline fuel filter/
water separator head. Tighten the hose clamp.
a
b
c
d
e
f
head bolt
vent plug
drain plug
filter bowl
filter element
fuel filter/water separator head
Inline fuel filter/water separator element Genie part number
Bleed the fuel system:
Before bleeding the fuel system,
be sure the fuel tank is full.
3 Place a suitable container under the filter bowl.
4 Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel from the
bowl.
62433
Deutz models:
1 Loosen the overflow valve at the injector pump.
5 Loosen the head bolt. Rotate the filter bowl
counterclockwise and remove it from the
element.
6 Install the bowl onto the new inline filter element
(Genie part number 62433). Tighten the drain
plug.
7 Fill the element and bowl with clean diesel fuel.
8 Apply a thin layer of oil onto the element gasket.
9 Install the filter/bowl assembly onto the filter
head and tighten it securely by hand.
The filter/bowl assembly must be
full of fuel when it is installed onto
the filter head or the fuel system
will have to be bled.
Part No. 62401
a
b
c
d
e
Genie S-100 & S-105 & S-120 & S-125
overflow valve
fuel lift pump priming lever
oil filter
filter head
fuel filter
4 - 27
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
2 Operate the priming lever of the fuel lift pump
until fuel, free from air, comes from the vent.
Cummins models:
Controlled venting is provided at
the injection pump. Small amounts
of air introduced by changing the
filters or injection pump supply line
will be vented automatically. If the
fuel filter is changed in accordance
with instructions, no manual
bleeding of the fuel system is
needed.
3 While continuing to operate the priming lever,
tighten the overflow valve.
4 Clean up any diesel fuel that might have spilled
during the procedure.
5 Start the engine and inspect for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Component damage hazard.
Damage to the fuel injection pump,
battery and starter motor can
occur if the stater motor is used
excessively to eliminate air from
the fuel system. Do not engage
the starter motor for more than 30
seconds at a time. Wait 120
seconds between starter motor
engagements.
Component damage hazard.
Operate the engine at low idle
speed for a minimum of two
minutes immediately after air has
been removed from the fuel
system. This will ensure that the
pump is free of air and prevent
any damage to the pumps by
metal to metal contact.
If the engine does not start or runs
erratically, refer to the Deutz
Operation Manual, Deutz part
number 0297 7341 (Genie part
number 62446) for additional
information on the fuel system.
4 - 28
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
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.
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
4 Loosen the fuel filter/water separator filter vent
screw, located on top of the fuel filter/water
separator head.
a
b
c
d
filter head vent screw
fuel filter
lift pump
priming lever
5 Operate the priming lever on the fuel lift pump
until fuel, free from air, comes out from the vent
screw.
6 While continuing to operate the priming lever,
tighten the vent screw. Torque the vent screw
to 80 in-lbs (9 Nm).
10 Clean up any diesel fuel that may have spilled
during the procedure.
Part No. 62401
11 Start the engine and inspect for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Component damage hazard.
Damage to the fuel injection pump,
battery and starter motor can
occur if the stater motor is used
excessively to eliminate air from
the fuel system. Do not engage
the starter motor for more than 30
seconds at a time. Wait 120
seconds between starter motor
engagements.
Component damage hazard.
Operate the engine at low idle
speed for a minimum of two
minutes immediately after air has
been removed from the fuel
system. This will ensure that the
pump is free of air and prevent
any damage to the pumps by
metal to metal contact.
If the engine does not start or runs
erratically, refer to the Cummins
Operation and Maintenance
Manual, Cummins part number
3810205 (Genie part number
62448) for additional information
on the fuel system.
Genie S-100 & S-105 & S-120 & S-125
4 - 29
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
12 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
13 Swing the engine pivot plate in towards the
machine.
14 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.
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 Loosen the fuel filter/water separator filter vent
screw, located on top of the fuel filter/water
separator head.
Perkins models:
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
a
b
a
b
a
b
c
vent screw
fuel filter head
fuel filter
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.
4 - 30
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
5 Operate the priming lever of the fuel lift pump
until fuel, free from air, comes from the vent.
If the drive cam of the fuel lift
pump is at the point of maximum
lift, it will not be possible to
operate the priming lever. In this
situation, rotate the crankshaft one
revolution.
a
fuel lift pump
6 While continuing to operate the priming lever,
tighten the vent screw.
7 Loosen the union nut on the fuel inlet pipe at the
injection pump.
8 Operate the priming lever of the fuel lift pump
until fuel, free from air, comes from the
connection.
9 Tighten the union nut.
11 Start the engine and check for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Component damage hazard.
Damage to the fuel injection pump,
battery and starter motor can
occur if the stater motor is used
excessively to eliminate air from
the fuel system. Do not engage
the starter motor for more than 30
seconds at a time. Wait 120
seconds between starter motor
engagements.
Component damage hazard.
Operate the engine at low idle
speed for a minimum of two
minutes immediately after air has
been removed from the fuel
system. This will ensure that the
pump is free of air and prevent
any damage to the pumps by
metal to metal contact.
If the engine does not start or runs
erratically, refer to the Perkins
User's Handbook, Perkins part
number TPD 1349 (Genie part
number 62447) for additional
information on the fuel system.
10 Clean up any diesel fuel that may have spilled
during the procedure.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 31
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
12 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
B-5
Replace the Air Filter
13 Swing the engine pivot plate in towards the
machine.
14 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.
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.
Perform this procedure with the
engine off.
1 Open the evacuator valve located on the air
cleaner cap by squeezing the sides together
with your fingers.
2 Open the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
3 Remove the filter element.
4 Clean the inside of the air cleaner canister and
end cap with a damp cloth.
5 Install the new filter element.
6 Replace the end cap on the canister.
Be sure the evacuator valve is
pointing in the down direction.
Air filter - Genie part number
4 - 32
Genie S-100 & S-105 & S-120 & S-125
62425
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-6
Inspect the Air Intake System
B-7
Check the Exhaust System
Maintaining the air intake system 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.
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.
Perform this procedure with the
engine off.
1 Inspect the intake piping for cracked hoses,
loose clamps or punctures which can allow dirt
and debris to enter the engine.
2 Tighten or replace parts as necessary to make
sure the air intake system does not leak.
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.
Cummins and Perkins models:
1 Be sure that all fasteners are tight.
2 Inspect all welds for cracks.
3 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 33
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
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.
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.
5 Inspect all welds for cracks.
6 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
4 - 34
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-8
Replace the Hydraulic Tank
Return Filters
2 Place a suitable container under the hydraulic
tank return filters.
3 Remove each filter with an oil filter wrench.
4 Apply a thin layer of clean oil to the new oil filter
gaskets.
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.
5 Install the new system return filter (Genie part
number 61326) and tighten it securely by hand.
6 Install the drive motor case drain return filter
(Genie part number 44207) and tighten it
securely by hand.
7 Clean up any oil that may have spilled during
the procedure.
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filters.
Perform this procedure with the
engine off.
9 Start the engine from the ground controls.
There are two return filters on the
machine. One is the system return
filter and the other one is the
return filter for the drive motor
case drains.
1 Open the ground controls side turntable side
cover and locate the tank return filters.
10 Inspect the filters and related components to
be sure that there are no leaks.
Hydraulic tank return filters Genie part numbers
System return filter
Drive motor case drain return filter
61326
44207
The system return filter is located
near the top of the hydraulic tank
and the drive motor case drain
return filter is located below the
system return filter.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 35
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-9
Replace the Hydraulic Tank
Breather Filter
5 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
Hydraulic tank breather filter
Genie part number
60559
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
Replacement of the hydraulic tank breather 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.
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
Perform this procedure with the
engine off.
1 Open the ground controls side cover and locate
the tank breather filter.
The tank breather filter is located
on top of the hydraulic tank.
2 Remove the filter with an oil filter wrench.
3 Apply teflon tape to the threads of the hydraulic
tank filter mount.
4 Install a new tank breather filter (Genie part
number 60559) onto the filter mount and tighten
it securely by hand.
4 - 36
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
2 Place a suitable container under the filters.
B-10
Replace the Medium and
High Pressure Hydraulic Filters
3 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housing.
4 Remove the filter element from the housing.
5 Inspect the housing seal and replace it if
necessary.
Replacement of the medium and high pressure
filters 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 filters be replaced
more often.
6 Install the new medium pressure filter element
into the housing (Genie part number 60858)
and tighten it securely.
7 Install the new high pressure filter elements into
the housings (Genie part number 60857) and
tighten them securely.
8 Clean up any oil that may have spilled during
the installation procedure.
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
9 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housings.
The medium pressure filter is for
the charge pump and the high
pressure filters are for the drive
circuit.
10 Start the engine from the ground controls.
11 Inspect the filter housings and related
components to be sure that there are no leaks.
Perform this procedure with the
engine off.
1 Open the engine side turntable cover and locate
the three filters mounted to the bulkhead.
Medium and high pressure filters Genie part numbers
Medium pressure filter
High pressure filter
60858
60857
a
b
a
b
Part No. 62401
high pressure filters
medium pressure filter
Genie S-100 & S-105 & S-120 & S-125
4 - 37
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-11
Inspect the Electrical Wiring
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 hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
· Engine wiring harness
· Ground control box harness connectors
5 Turn the engine off.
6 Remove the boom storage area cover retaining
fasteners and remove the boom storage area
cover.
7 Inspect the turntable area for burnt, chafed and
pinched cables.
8 Install the boom storage area cover and install
the boom storage area cover retaining
fasteners.
9 Raise the boom to a horizontal position.
10 Remove the safety chock and lower the boom
to the stowed position.
10 Turn the engine off.
11 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Cable track on the boom
· Turntable manifold wiring
2 Start the engine from the platform controls and
extend the axles.
3 Turn the key switch to ground control and raise
the boom above the turntable covers.
· Boom to platform cable harness
· Platform control box harness connectors
· Platform manifold wiring
4 Install a safety chock (Genie part number
75097) 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.
The lift cylinder safety chock is
available through Genie (Genie
part number 75097).
4 - 38
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-12
Confirm the Proper
Brake Configuration
B-13
Inspect the Tires and Wheels
(including lug nut torque)
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.
Maintaining the tires and wheels in good
condition 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.
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
The tires on these machines are
foam filled and do not need air
added to them.
disengage position
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
engage position
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque.
Tires and wheels
Tire size
Tire ply rating
Wheel lugs
Part No. 62401
18-22.5
18
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
569.5 Nm
Lug nut torque, lubricated
320 ft-lbs
433.9 Nm
Genie S-100 & S-105 & S-120 & S-125
4 - 39
First Edition • First Printing
TABLE B
Section 4 • Scheduled Maintenance Procedures
PROCEDURES
4 Install the plug into the drive hub.
B-14
Check the Oil Level in the
Drive Hubs
When removing the drive hub plug
on machines before serial number
158, replace the drive hub plug
with the new O-ring style drive hub
plug (Genie part number 75107).
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage.
5 Repeat this procedure for each drive hub.
Drive hub oil
Drive Hubs
Capacity
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at
90°.
Type:
83 fl oz
2.5 liters
SAE 80W-90 EP multipurpose gear oil
Turntable Rotate Drive Hub
a
The turntable rotate drive hub is
located under a fixed turntable
cover at the ground controls side
of the machine. The cover has to
be removed before the following
procedure can be completed.
2 Remove the plug located at 90° and check the
oil level.
1 Remove the power to platform plug panel upper
retaining fasteners and loosen the lower
retaining fasteners. Do not disconnect the
wiring.
Result: The oil level should be even with the
bottom of the plug hole.
2 Support the cover with a suitable lifting device.
Protect the cover from damage.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
3 Remove the cover retaining fasteners. Remove
the cover from the machine.
a
Part No. 62401
drive hub plugs
Crushing hazard. The turntable
cover may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported.
Genie S-100 & S-105 & S-120 & S-125
4-1
Section 4 • Scheduled Maintenance Procedures
First Edition • First Printing
TABLE B PROCEDURES
4 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.
a
c
B-15
Check and Adjust the
Engine RPM
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.
Deutz models:
b
1 Start the engine from the ground controls.
2 Push one of the LCD
screen buttons shown until
engine rpm is displayed.
Result: Low idle should be 1300 rpm.
Skip to step 11 if the low idle rpm is correct.
a
b
c
plug
turntable rotate drive hub
drive brake
5 If necessary, add oil until the oil level is even
with the bottom of the plug hole.
3 Remove the secondary idle adjustment screw
cap from the secondary idle adjustment screw
on the injection pump. Loosen the locknut.
6 Install the plug into the drive hub.
Turntable rotate drive hub oil
Capacity (approximately)
Type
92 fl oz
2.7 liters
SAE 80W-90 EP multipurpose gear oil
Deutz engine
a
primary idle adjustment screw
b
secondary idle adjustment screw
4-2
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
4 Turn the secondary adjustment screw
counterclockwise until the adjustment screw is
loose. Tighten the locknut.
Be sure the adjustment screw is
loosened until there is no spring
tension felt.
5 Remove the primary idle adjustment screw cap
from the primary idle adjustment screw on the
injection pump. Loosen the locknut.
6 Adjust the primary idle adjustment screw until
low idle is 1250 rpm. Tighten the locknut.
7 Install the primary idle adjustment screw cap
and tighten. Do not over tighten.
8 Loosen the secondary idle adjustment screw
locknut.
9 Adjust the secondary adjustment screw until the
low idle is 1300 rpm. Tighten the locknut.
12 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.
Be sure the solenoid fully retracts
when activating high idle.
Deutz models
Low idle
1300 rpm
High idle
2350 rpm
Cummins and Perkins models:
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
10 Install the secondary idle adjustment screw cap
and tighten. Do not over tighten.
11 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Result: High idle should be 2350 rpm.
If the high idle is correct, disregard adjustment
step 12.
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.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
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.
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.
4 Start the engine from the ground controls.
5 Push one of the LCD screen buttons shown
until engine rpm is
displayed.
Result: Low idle should be
1300 rpm.
Skip to step 7 if the low idle rpm is correct.
Perkins models
a
low idle adjustment screw
b
yoke lock nut
c
solenoid boot
d
high idle adjustment nut
e
yoke
f
low idle lock nut
Cummins models
a
yoke
b
yoke lock nut
c
solenoid boot
d
high idle adjustment nut
e
low idle adjustment screw
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 43
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
7 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
B-16
Test the Key Switches
Result: High idle should be 2350 rpm.
Skip to step 9 if the high idle rpm is correct.
8 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.
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.
10 Swing the engine pivot plate in towards the
machine.
11 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.
Cummins and Perkins models
Low idle
1300 rpm
High idle
2350 rpm
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.
The Main key switch controls machine operation
from the ground or platform controls.
When the Service Bypass/Recovery key switch is
turned to the service bypass position, the 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. 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 unit will turn on and fully retract the
boom, and then lower the boom to a stowed
position. 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.
Perform this procedure with the
axles retracted.
1 Open the ground controls side turntable side
cover.
4 - 44
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
2 Pull out the Emergency Stop button to the ON
position at both the ground and platform
controls.
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.
12 Remove the key from the main key switch and
insert the key into the service bypass/recovery
key switch.
The key switch should remain in
the GROUND CONTROL position.
13 Turn the service bypass/recovery key switch to
the SERVICE BYPASS position.
14 Raise the boom.
Result: The boom should raise.
15 Remove the key from the service
bypass/recovery key switch and insert the key
into the main key switch.
16 Turn the main key switch to the OFF position.
17 Remove the key from the main key switch and
insert the key into the service bypass/recovery
key switch.
18 Turn and hold the service bypass/recovery key
switch to the RECOVERY position.
Result: The boom should return to the stowed
position.
9 Open the ground controls side turntable side
cover.
19 Turn the service bypass/recovery key switch to
the run position.
10 Turn the main key switch to ground control and
start the engine.
20 Remove the key from the service
bypass/recovery key switch and insert the key
into the main key switch.
11 Raise the boom.
Result: The boom should raise to 10° above
horizontal and then stop. The boom should not
raise above the limit switch unless both axles
are extended.
Part No. 62401
21 Turn the main key switch to the OFF position.
22 Close the turntable side cover.
Genie S-100 & S-105 & S-120 & S-125
4 - 45
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-17
Test the Emergency
Stop Buttons
B-18
Test the Ground Control Override
Properly functioning Emergency Stop buttons
are essential for safe machine operation. An
improperly operating Emergency Stop button
will fail to shut off power and stop all machine
functions, resulting in a hazardous situation for
ground and platform personnel.
As a safety feature, selecting
and operating the ground controls
will override the platform controls,
including the Emergency Stop
button.
1 Start the engine from the ground controls.
2 Push in the Emergency Stop button to the OFF
position.
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 Emergency
Stop button on 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 platform Emergency Stop button
to the OFF position.
2 Start the engine from the ground controls.
3 Operate each boom function through a
partial cycle.
Result: All boom functions should operate.
Result: The engine should shut off and no
machine functions should operate.
3 Start the engine from the platform controls.
4 Push down the Emergency Stop button to the
OFF position.
Result: The engine should shut off and no
machine functions should operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch
is switched to platform control.
4 - 46
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-19
Test the Safety Envelope and
Circuits
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.
1 Raise the boom to approximately 60°.
For S-100 or S-105 models,
proceed to step 15.
101 feet (30.8 m) Length Safety Switch,
LSB2RS
2 Extend the boom to more than 80 feet (24.4 m).
3 Disconnect the 68° proximity switch LSB14AO
and install a wire jumper between pin 3 and pin
4 of the deutsch connector.
Result: ">65 DEG" should be present on the
display screen at the ground controls.
4 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.
5 Using auxiliary power, retract the boom until the
boom is extended to approximately 95 feet
(29 m).
6 Remove the wire jumper installed in step 3 and
connect the deutsch connector to LSB14AO.
65° Angle Safety Switch,
LSB9AS
7 Raise the boom to the maximum angle.
8 Fully extend the boom.
9 Disconnect the 68° proximity switch LSB14AO
and install a wire jumper between pin 3 and pin
4 of the deutsch connector.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 47
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
10 Start the engine and activate the function
enable/high RPM button and lower the boom to
65°.
16 Disconnect the 53° proximity switch LSB13AO
and install a wire jumper between pin 3 and pin
4 of the deutsch connector.
Result: The engine should stop and the boom
down function should be disabled.
17 Activate the function enable/high RPM button
and lower the boom to 50°.
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.
Result: The engine should stop and the boom
down function should be disabled.
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.
11 Measure the angle of the boom.
Result: The angle of the boom should be
greater than 65°.
12 Using auxiliary power, raise the boom until the
boom angle is greater than 68°.
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 to
greater than 53°. Failure to raise
the boom could result in death or
serious injury.
18 Measure the angle of the boom.
Result: the angle of the boom should be greater
than 50°.
13 Remove the wire jumper installed in step 9 and
connect the deutsch connector to LSB14AO.
19 Using auxiliary power, raise the boom until the
boom angle is greater than 53°.
50° Angle Safety Switch,
LSB8AS
20 Remove the wire jumper installed in step 16 and
connect the deutsch connector to LSB13AO.
14 Raise the boom to approximately 60°.
15 Extend the boom to approximately
95 feet (24.4 m).
4 - 48
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
76 feet (30.8 m) Length Safety Switch,
LSB4ES
Cable Break Safety Switch,
LSB6S
21 Disconnect the 75 feet (22.9 m) proximity switch
LSB3EO and install a wire jumper between pin
3 and pin 4 of the deutsch connector.
25 Start 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).
LSB3EO is located on top of boom
tube number 2 at the platform end
of the machine.
22 Start 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.
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.
23 Using auxiliary power, retract the boom until the
boom is extended to less than 75 feet (22.9 m).
26 Remove the boom end cover from the pivot end
of the boom.
27 Remove the arm from the cable break limit
switch LSB6S.
LSB6S is located at the end of the
boom tubes at the pivot end of the
boom.
28 Using the arm just removed from LSB6S, rotate
the head of the switch 45 degrees 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.
24 Remove the wire jumper installed in step 21 and
connect the harness plug to LSB3EO.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 49
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
29 Activate 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.
30 Using the arm just removed from LSB6S, rotate
the head of the switch 90 degrees 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.
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.
31 Activate the function enable/high RPM button
and attempt to retract the boom.
Axle Extend Safety Switch,
LSAX1ES and LSAX2ES
and
3 feet (0.9 m) Safety Switch,
LSB3RS
and
11° Angle Safety Switch,
LSB7DS
33 Fully retract and lower the boom to the stowed
position.
34 Retract both axles approximately 1 foot (0.3 m).
35 Remove the access cover from each axle.
36 Disconnect the square-end axle extend safety
switch LSAX1ES and install a wire jumper
between pin 3 and pin 4 of the deutsch
connector.
37 Place 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
Result: The boom retract function should be
disabled.
Result: If the boom retracts, the LSB6S switch
or wiring circuit is faulty and will need to be
replaced or repaired. See Repair Section.
32 Rotate the head of the switch 45 degrees
clockwise and install the arm onto LSB6S.
4 - 50
Proximity switch
a
target area
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
38 Activate 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.
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.
39 Activate 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.
40 Remove the wire jumper installed in step 36 and
connect the deutsch connector to LSAX1ES.
41 Disconnect the circle-end axle extend safety
switch LSAX2ES and install a wire jumper
between pin 3 and pin 4 of the deutsch
connector.
42 Activate 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.
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.
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.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 51
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
43 Activate 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.
44 Remove the wire jumper installed in step 41 and
connect the deutsch connector to LSAX2ES.
Reverse Load Moment Switch,
LSB20LO
47 Activate the function enable/high RPM button
and extend the boom until ">0" is present on
the display screen at the ground controls.
Result: The alarm should sound and "REVERSE
LOAD MOMENT FAULT" should be present on the
display screen at the ground controls.
Result: If the alarm does not sound or if
"REVERSE LOAD MOMENT FAULT" is not present on
the display screen at the ground controls, the
LSB20LO 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 alarm
does not sound or if "REVERSE LOAD
MOMENT FAULT" is not present on the
display screen at the ground
controls, stop immediately and
fully retract the boom. Failure to
retract the boom could result in
death or serious injury.
45 Activate the function enable/high RPM button
and fully retract the boom.
48 Activate the function enable/high RPM button
and raise the boom to clear the alarm.
46 Activate the function enable/high RPM button
and lower the boom onto the boom rest pad
and continue to hold the boom lower function
button for 5 seconds.
49 Activate the function enable/high RPM button
and lower the boom to the stowed position.
4 - 52
50 Turn the key switch to the OFF position.
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-20
Test the Platform Self-leveling
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.
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.
Part No. 62401
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.
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.
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.
Genie S-100 & S-105 & S-120 & S-125
4 - 53
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-21
Test the Horn
B-22
Test the Foot Switch
A functional horn is essential to safe machine
operation. The horn is activated at the platform
controls and sounds at the ground as a warning to
ground personnel. An improperly functioning horn
will prevent the operator from alerting ground
personnel of hazards or unsafe conditions.
A properly functioning foot switch is essential to
safe machine operation. Machine functions should
activate and operate smoothly as long as the foot
switch is pressed down, and promptly stop when
the foot switch is released. Pressing down the foot
switch will also shift the engine into high idle if the
engine idle select (rpm) indicates that the rabbit
and foot switch symbol is selected. An improperly
functioning foot switch can cause an unsafe
working condition and endanger platform and
ground personnel.
1 Turn the key switch to platform control and
pull out the Emergency Stop button to the
ON position at both the ground and
platform controls.
2 Push down the horn button at the platform
controls.
Result: The horn should sound.
If necessary, the horn can be
adjusted to obtain the loudest
volume by turning the adjustment
screw near the wire terminals on
the horn.
The engine should not start if the
foot switch is pressed down.
1 Turn the key switch to platform controls and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Press down the foot switch and attempt to start
the engine by pushing the engine start button.
Result: The engine should not start.
3 Do not press down the foot switch and start the
engine.
4 Do not press down the foot switch and test each
machine function control handle, toggle switch
or button.
Result: The machine functions should not
operate.
5 Press down the foot switch.
6 Activate each machine function control handle,
toggle switch or button.
Result: All functions should operate through a
full cycle. Descent alarm (if equipped) should
sound while boom is lowering.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-23
Test the Engine Idle Select
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.
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
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 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 hold the high speed function enable/
speed select button (rabbit symbol).
Result: The engine should change to high idle.
5 Release the high speed function enable/speed
select button.
Result: The engine should return to low idle.
Part No. 62401
d
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.
10 Press down the foot switch.
Result: The engine should change to high idle.
Genie S-100 & S-105 & S-120 & S-125
4 - 55
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-24
Test the Drive Enable System
5 Push the drive enable button and slowly move
the drive/steer control handle off center.
Result: The drive function should operate.
Proper drive enable system operation is
essential to safe machine operation. An improperly
functioning drive enable system may allow the
machine to be moved into an unsafe position.
When the boom is rotated past one of the circleend wheels while the machine is moving, the
indicator light will illuminate and the drive function
will continue to operate until the drive control
joystick is returned to neutral.
The drive enable button must be pressed to
reactivate the drive function and should inform the
operator that the machine will move in the opposite
direction that the drive and steer controls are
moved.
When the boom is rotated past one of the circleend wheels and the machine is not moving, the
indicator light will illuminate and the drive function
is turned off.
1 Start the engine from the platform controls.
2 Press down the foot switch and lower the boom
to the stowed position.
3 Rotate the turntable until
the boom moves past
one of the circle-end
tires.
Collision hazard. Always use the
color-coded direction arrows on
the platform control panel and the
drive chassis to identify which
direction the machine will travel.
Blue
Yellow
When the drive enable system is
in use, the machine may drive in
the opposite direction that the
drive and steer control handle is
moved.
If the drive/steer control handle is
not moved within two seconds of
pushing the drive enable button,
the drive function will not operate.
Result: The drive enable indicator light should
come on while the boom is anywhere in the
range shown.
4 Move the drive/steer control handle off center.
Result: No drive function should operate.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
B-25
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased 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 B-12 in this section,
Confirm the Proper Brake
Configuration.
6 Measure the distance between the test line and
your machine reference point.
Braking, High range
paved surface
4 to 6 ft
1.2 to 1.8 m
The brakes must be able to hold
the machine on any slope it is able
to climb.
Select a test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
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.
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.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-26
Test the Drive Speed Stowed Position
B-27
Test the Drive Speed Raised or Extended Position
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.
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.
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 40 feet (12.2 m) apart.
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.
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.
Drive speed:
stowed position
4 - 58
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 40 feet (12.2 m) apart and
two lines on the ground 10 feet (3 m) apart.
2 Start the engine from the platform controls.
3 Press the engine idle select button until the foot
switch activated high idle (rabbit and foot switch
symbol) is selected.
4 Raise the boom until the engine rpm switches to
low speed.
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.
40 ft/9.1 sec
12.2 m/9.1 sec
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
7 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
16 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.
Drive speed:
raised position
17 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
40 ft/40 sec
12.2 m/40 sec
8 Lower the boom below horizontal.
9 Extend the boom approximately 4 feet (1.2 m).
Drive speed:
fully extended position
10 ft/18 sec
3 m/18 sec
10 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.
11 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.
12 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
Drive speed:
extended position
40 ft/40 sec
12.2 m/40 sec
13 Raise the boom to a horizontal position.
14 Extend the boom until the raise boom LED and
envelope alarm are activated.
15 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.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
B-28
Test the Alarm Package
(if equipped)
3 Turn the key switch to platform control.
Result: The flashing beacon should be on
and flashing.
4 Press down the foot switch. Move the boom
control handle to the DOWN position, hold for a
moment and then release it.
The alarm package includes:
· Travel alarm
Result: The descent alarm should sound when
the control handle is held down.
· Descent alarm
· Travel and descent alarm
· Motion alarm
· Flashing beacon
Alarms and a beacon are installed to alert
operators and ground personnel of machine
proximity and motion. The alarm package is
installed on the turntable covers.
The alarms and beacon will
operate with the engine
running or not running.
5 Press down the foot switch. Move the drive
control handle off center, hold for a moment
and then release it. Move the drive control
handle off center in the opposite direction, hold
for a moment and then release it.
Result: The travel alarm should sound when the
drive control handle is moved off center in
either direction.
1 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
position at both the ground and platform
controls.
Result: The flashing beacon should be on and
flashing.
2 Push and hold a function enable/speed select
button and the boom down button. Hold for a
moment and then release them.
Result: The descent alarm should sound when
the boom down button is pressed.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-29
Replace the Engine Oil and
Filter Cummins Models
Periodic replacement of the engine oil and
filter is essential to good engine performance.
Operating the machine with an improper oil level or
neglecting periodic oil and filter changes can
damage engine components. A daily check
of elapsed machine hours against the hours
noted on the oil filter will allow the inspector to
anticipate and perform oil and filter changes at
the 250 hour interval.
Bodily injury hazard. Beware of
hot engine parts and oil. Contact
with hot engine oil and/or engine
parts may cause severe burns.
Perform this procedure after
warming the engine to normal
operating temperature.
1 Remove the oil filler cap from the valve cover.
2 Place a suitable container under the engine
tray. See capacity specifications.
3 Remove the drain plug from the oil pan and
allow all of the oil from the engine to drain into a
suitable container.
Cummins Model
a
filter head
b
oil filter
c
oil filler cap
4 Install the drain plug into the engine and tighten.
5 Use an oil filter wrench and remove the oil filter.
6 Clean inside the filter head.
7 Fill the filter with clean engine oil.
8 Apply a thin layer of clean oil to the new filter
gasket (Genie part number 62436). Install the
filter and tighten it securely by hand.
9 Clean up any oil that may have spilled during
the procedure.
10 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
B PROCEDURES
11 Fill the engine with new oil per specifications
and install the oil filler cap.
12 Start the engine from the ground controls and
allow the engine to run for 30 seconds. Stop the
engine.
B-30
Inspect the Fuel Tank Cap Venting
System
13 Check the oil filter and oil drain plug for leaks.
14 Wait 15 minutes after stopping the engine and
check the engine oil level on the dipstick. Add
oil if needed.
15 Dispose of the used oil and filter properly.
Cummins B3.9L Engine
Oil capacity (including filter)
11.5 quarts
10.9 liters
Oil filter - Genie part number
62436
Cummins B3.9L Engine
Engine oil viscosity requirements
below 68°F / 20°C
5W-30
-13° to 68°F / -25° to 20°C
10W-30
above 15°F / -9°C
15W-40
Use oils meeting API classification CE (labeled CE/SG).
A free-breathing fuel tank cap is essential for good
engine performance and service life. A dirty or
clogged fuel tank cap may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the cap be inspected more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air should pass through the fuel tank
cap.
When checking for positive fuel
tank cap venting, air should pass
freely through the cap.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE B PROCEDURES
If the fuel tank cap vent is working properly,
proceed to step 5.
B-31
Perform Hydraulic Oil Analysis
3 Using a mild solvent, carefully wash the fuel
tank cap. Dry the cap using low pressure
compressed air.
See E-1, Test or Replace the Hydraulic Oil.
4 Repeat step 2.
5 Install the fuel tank cap onto the fuel tank.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 63
Section 4 • Scheduled Maintenance Procedures
First Edition • First Printing
Table C Procedures
C-1
Check the Engine Valve
Clearances Deutz Models
Complete information to perform this procedure is
available in the Deutz 913 Operation Manual,
Deutz part number 0297 9690 (Genie part number
62446).
C-2
Clean the Fuel Pump Strainer Perkins Models
Cleaning the fuel pump strainer is essential to
good engine performance and service life. A dirty
or clogged strainer may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the strainer be cleaned more
often.
Explosion and fire hazard. Engine
fuels are combustible. Replace the
fuel filter in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
1 Tag, disconnect and plug the fuel line from the
fuel tank at the inline fuel filter/water separator
head.
4 - 64
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE C PROCEDURES
2 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
a
5 Locate the fuel lift pump.
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.
a
fuel lift pump
6 Remove the fuel lift pump cover retaining
fastener. Remove the cover and seal from the
top of the fuel lift pump.
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.
a
b
c
d
e
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
cover with retainer
strainer
seal
pump body
priming lever
4 - 65
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
C PROCEDURES
7 Remove the strainer from the fuel lift pump.
8 Using a mild solvent, carefully wash the inside
of the fuel lift pump body.
C-3
Replace the Fuel Filter Element Perkins and Cummins Models
9 Using a mild solvent, clean the strainer, the seal
and the lift pump cover.
10 Install the strainer and seal onto the fuel lift
pump body.
11 Install the cover onto the fuel lift pump. Tighten
the fuel lift pump cover retaining fastener.
Be sure that the lift pump body
and cover are installed correctly.
An incorrect fit will let air into the
fuel system.
12 Clean up any fuel that might have spilled during
the procedure.
13 Bleed the fuel system. See Maintenance
Procedure B-4, Replace the Inline Fuel Filter/
Water Separator Element.
Before bleeding the system, fill the
fuel tank.
Replacing the diesel fuel filter element is essential
for good engine performance and service life. A
dirty or clogged filter may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may required that the filter be replaced more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
Immediately clean up any fuel that
may have spilled during this
procedure.
1 Tag, disconnect and plug the fuel line from the
fuel tank at the inline fuel filter/water separator
head.
4 - 66
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE C PROCEDURES
2 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
6 Remove the fuel filter element and dispose of
properly.
7 Clean the inside surfaces of the filter head.
8 Fill the new fuel filter element with clean diesel
fuel. Lightly lubricate the O-ring with clean
diesel fuel and install the element into the filter
head.
a
Failure to fill the fuel filter element
with clean diesel fuel before
installation will require bleeding
the fuel system.
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.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
9 Clean up any fuel that may have spilled during
this procedure.
10 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
11 Install the fuel tank line onto the inline fuel filter/
water separator head. Tighten the hose clamp.
12 Bleed the fuel system. See Maintenance
Procedure B-4, Replace the Inline Fuel Filter/
Water Separator Element.
Before bleeding the system, fill the
fuel tank.
5 Locate the fuel filter. Thoroughly clean the
outside surfaces of the fuel filter assembly.
Fuel filter elements Genie part numbers
Perkins models
Cummins models
62426
62435
Cummins model
a
fuel filter
b
lift pump
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 67
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
C PROCEDURES
C-4
Replace the Engine Oil and
Filter Deutz and Perkins Models
Periodic replacement of the engine oil and
filter is essential to good engine performance.
Operating the machine with an improper oil level or
neglecting periodic oil and filter changes can
damage engine components. A frequent check
of elapsed machine hours against the hours
noted on the oil filter will allow the inspector to
anticipate and perform oil and filter changes at
the 500 hour interval.
Bodily injury hazard. Beware of
hot engine parts and oil. Contact
with hot engine oil and/or engine
parts may cause severe burns.
4 Use an oil filter wrench to remove the oil filter.
Deutz model
a
oil filler cap
b
oil filter
c
filter head
d
fuel filter
Perform this procedure after
warming the engine to normal
operating temperature.
1 Remove the oil filler cap.
2 Remove the drain plug and sealing washer from
the oil pan and allow all of the oil from the
engine to drain into a suitable container. See
capacity specifications.
Be sure that the sealing washer is
not damaged.
3 Install the sealing washer onto the drain plug
and tighten the drain plug.
4 - 68
Perkins model
a
oil filler cap
b
oil filter
c
filter head
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE C PROCEDURES
5 Clean inside the filter head.
14 Dispose of the used oil and filter properly.
6 Fill the filter with clean engine oil.
7 Apply a thin layer of clean engine oil to the new
filter gasket. Install the filter and tighten it
securely by hand.
8 Clean up any oil that may have spilled during
this procedure.
9 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
10 Fill the engine with new oil per specifications
and install the oil filler cap.
11 Start the engine from the ground controls and
allow the engine to run for 30 seconds. Stop the
engine.
Deutz F4L 913 Engine
Oil capacity (including filter)
14.3 quarts
13.5 liters
Deutz F4L 913 Engine
Engine oil viscosity requirements
below 60°F / 15.5°C (synthetic)
5W-30
-10°F to 90°F / -23°C to 32°C
10W-40
above -4°F / -20°C
15W-40
Engine oil should have properties of API classification
CC/SE or CC/SF grades OR ACEA classification E1-96.
Oil filter - Genie part number
62430
Perkins 1004-42 Engine
Oil capacity (including filter)
8.9 quarts
8.4 liters
12 Check the oil filter and oil drain plug for leaks.
13 Wait 15 minutes after stopping the engine and
check the engine oil level on the dipstick. Add
oil if needed.
Perkins 1004-42 Engine
Engine oil viscosity requirements
below 32°F / 0°C
0W
-13°F to 68°F / -25°C to 20°C
5W-20
10°F to 104°F / -12°C to 40°C
10W-30
14°F to 122°F / -10°C to 50°C
15W-40
above 23°F / -5°C
20W-50
Engine oil should have properties of API classification
CF4 grade OR ACEA classification E3.
Oil filter - Genie part number
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
62427
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
C PROCEDURES
C-5
Check the Specific Gravity of the
Coolant Liquid Cooled Models
5 Remove the radiator filler cap. Inspect the cap
for wear. Replace as necessary.
Burn hazard. Allow any pressure
to dissipate gradually before
removing the radiator cap.
6 Drain some coolant from the cooling system
into a suitable container.
The quality of the coolant which is used can have a
great effect on the efficiency and life of the cooling
system. Old or dirty coolant may cause the engine
to perform poorly and continued use may cause
engine damage.
Burn injury hazard. Beware of hot
engine parts and coolant. Contact
with hot engine parts and/or
coolant may cause severe burns.
7 Use a special coolant hydrometer to check the
temperature and the specific gravity of the
coolant.
8 Adjust the mixture of the coolant as necessary
to protect the engine to -34°F (-37°C).
9 Install the radiator filler cap.
Perform this procedure with the
machine on level ground.
Perform this procedure with the
engine off.
1 Put on protective clothing and eyewear.
2 Operate the engine until it is warm enough to
open the thermostat. Continue to run the engine
until the coolant has circulated the cooling
system.
3 Stop the engine.
4 Allow the engine to cool until the temperature of
the coolant is below 140° F (60° C).
Burn hazard. Beware of hot
coolant. Contact with hot coolant
may cause severe burns.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE C PROCEDURES
C-6
Inspect the Boom Extend/Retract
Cables
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.
3 Visually inspect the cables and components
through both inspection holes for the following:
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. 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.
Perform this procedure with the
boom in the stowed position and
the engine off.
1 Remove the boom end cover from the pivot end
of the boom.
· 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
A flashlight and inspection mirror
may be necessary to thoroughly
inspect the above items.
A pulley groove gauge should be
used to check the condition of the
pulleys.
4 Replace the cables if any damage is found.
a
b
c
boom end cover
side access covers
cable ends (located
underneath the boom)
5 At the pivot end of the boom, visually inspect for
the following:
· 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.
7 Start the engine from the platform controls.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
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TABLE
First Edition • First Printing
C PROCEDURES
8 Extend the boom approximately 2 feet (0.6 m).
9 Retract the boom. While retracting the boom,
visually inspect the number 2 and number 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.
If the number 2 boom tube moves
more than 1/2 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.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
Table D Procedures
D-1
Check the Boom 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.
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.
8 Repeat step 7 until all boom inspection covers
at the pivot end of the boom are removed.
9 Measure each wear pad at the pivot end of the
boom.
Boom wear pad specifications
Minimum thickness
1/2 inch
12.7 mm
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
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 zero
clearance.
10 Replace any wear pad if it is less than
specification. If a wear pad is not less than
specification, shim as necessary to obtain zero
clearance.
11 Extend and retract the boom through the entire
range of motion to check for tight spots that
may cause binding of the boom tubes.
Always maintain squareness
between the outer and inner
boom tubes.
If the wear pads are still within
specification, refer to Repair
Section 4-2, How to Shim the
Boom.
6 Remove the boom end cover retaining
fasteners at the pivot end of the boom. Remove
the boom end cover from the machine.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
D PROCEDURES
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.
D-2
Check the Extendable Axle
Wear Pads
Always maintain squareness
between the outer and inner
axle tubes.
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.
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
7/16 inch
11.1 mm
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 zero
clearance and zero drag.
If the wear pads are still within
specification, refer to Repair
Section 15-1, How to Shim the
Extendable Axles.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE D PROCEDURES
5 Manually rotate each wheel at the square-end
of the machine.
D-3
Check the Free-wheel
Configuration
Result: Each wheel at the square-end of the
machine should rotate with minimum effort.
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.
1 Chock both of the wheels at the circle-end of
the machine to prevent the machine from
rolling.
2 Center a lifting jack of ample capacity
(30,000 lbs/15000 kg) under the drive chassis
between the wheels at the square-end of the
machine.
3 Lift the wheels off the ground and place blocks
under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each wheel hub
at the square-end of the machine.
disengage position
engage position
6 Re-engage the drive hubs by turning over
the 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 Center a lifting jack of ample capacity
(30,000 lbs/15000 kg) under the drive chassis
between the wheels at the circle-end of the
machine.
9 Lift the wheels off the ground and place jack
stands under the drive chassis for support.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each wheel hub
at the circle-end of the machine.
11 Manually 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.
12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands. Lower the machine.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury
and property damage.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
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TABLE
First Edition • First Printing
D PROCEDURES
D-4
Check the Turntable Rotation
Bearing Bolts
3 Be sure that each turntable rotation bearing
mounting bolt above the turntable is torqued in
sequence to 190 ft-lbs (258 Nm).
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 (Genie part number
75097) 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.
The lift cylinder safety chock is
available through Genie (Genie
part number 75097).
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 to 190 ft-lbs (258 Nm).
The turntable rotation bearing bolt
torque sequence is the same from
above the turntable and below the
drive chassis.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE D PROCEDURES
D-5
Check the Turntable Rotation
Gear Backlash
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.
Be sure to check the backlash
with the machine fully stowed and
the counterweight at the square
end of the machine.
Select a test area that is firm, level
and free of obstructions.
This procedure may require two
people.
1 Rotate the turntable in a clockwise direction
until the turntable rotation motor pinion gear is
directly over the 3 red-painted gear teeth on the
turntable rotation bearing.
The 3 red-painted gear teeth on
the turntable rotation bearing are
the teeth closest to the blue arrow
side of the drive chassis.
a
a
b
Part No. 62401
2 Mark a test line approximately two feet long
(0.6 m), perpendicular to the length to the
boom, on the ground under the platform and
near the platform reference point selected.
Choose a point on the machine
platform; i.e., outside edge of the
platform, as a visual reference for
use while performing this
procedure.
3 Apply approximately 20 lbs (89 N) of side force
to the platform, moving the platform to one side
as far as it will go. Mark a reference point on
the test line where the platform stops moving.
4 Apply approximately 20 lbs (89 N) of side force
to the platform, moving the platform in the
opposite direction as far as it will go. Mark a
reference point on the test line where the
platform stops moving.
5 Measure the distance on the test line between
the two reference marks.
Result: The platform movement should not
exceed 2 inches (51 mm). If the platform
movement exceeds 2 inches (51 mm), proceed
to step 6.
Turntable rotation gear backlash
Maximum side to side movement
at platform
2 inches
51 mm
yellow arrow
blue arrow
red painted teeth
Genie S-100 & S-105 & S-120 & S-125
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
D PROCEDURES
Adjusting the backlash:
6 Remove the ground control side fixed turntable
cover from the machine. Refer to Repair
Section 5-1, How to Remove a Fixed Turntable
Cover.
7 Loosen the turntable drive hub mounting bolts.
Do not remove them.
It may be necessary to raise the
boom slightly to access all the
turntable drive hub mounting bolts.
10 Tighten the turntable drive hub adjustment bolt
until the turntable drive hub gear is fully
engaged and tight into the turntable rotate gear.
11 Turn the adjustment bolt 1/4 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
12 Rotate the drive hub away from the turntable
until it contacts the adjustment bolt. Torque the
drive hub mounting bolts to 210 ft-lbs (283 Nm).
13 Torque the turntable rotate pivot bolt to
210 ft-lbs (283 Nm).
14 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
15 Install the ground control side fixed turntable
cover onto the machine and tighten the
retaining fasteners.
a
b
c
d
e
f
motor
brake
drive hub
pivot bolt
mounting bolt
adjustment bolt with lock nut
8 Loosen the turntable drive hub pivot bolt. Do not
remove it.
9 Loosen the lock nut on the turntable drive hub
adjustment bolt.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE D PROCEDURES
D-6
Grease the Turntable Rotation
Bearing and Rotate Gear
Yearly 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.
D-7
Replace the Drive Hub Oil
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.
Drive Hubs:
1 Remove the turntable rotation gear cover
retaining fasteners and remove the gear cover
from the machine.
1 Select the drive hub to be serviced. Drive the
machine until one of the two drain plugs is at
the lowest point.
2 Open the ground controls side turntable side
cover.
2 Remove both plugs and drain the oil into a
suitable container.
3 Locate the grease fitting below the ground
control box.
3 Drive the machine until one plug hole is at the
top and the other is at 90°.
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.
a
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.
Grease type
Part No. 62401
a
drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Multi-purpose grease
Genie S-100 & S-105 & S-120 & S-125
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Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
D PROCEDURES
5 Install the plug into the drive hub.
When removing the drive hub plug
on machines before serial number
158, replace the drive hub plug
with the new O-ring style drive hub
plug (Genie part number 75107).
6 Repeat steps 1 through 5 for all the other drive
hubs.
Drive hub oil
Capacity
83 fl oz
2.5 liters
Type:
SAE 80W-90 EP multipurpose gear oil
2 Remove the ground control side fixed turntable
cover. Refer to Repair Section 5-1, 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.
Turntable Rotate Drive Hub:
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 Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
unlocked
4 - 80
locked
a
b
c
d
e
f
g
h
Genie S-100 & S-105 & S-120 & S-125
drive motor
drive brake
brake drain plug
drive hub
pivot bolt
mounting bolt
adjustment bolt with lock nut
drive hub drain plug
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE D PROCEDURES
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 drive brake drain plug from the
side of the drive brake and drain the oil from the
drive brake into a suitable container. See
capacity specifications.
6 Remove the drive hub drain plug from the side
of the drive hub and drain the oil from the drive
hub into a suitable container. See capacity
specifications.
7 Fill the drive hub with oil until the oil is level
with the bottom of the threads. Install the drain
plug and tighten.
When removing the drive brake
plug on machines before serial
number 158, replace the drive hub
plug with the new O-ring style
drive hub plug (Genie part number
75107).
9 Install the drive hub onto the machine. Install
the pivot bolt and the mounting bolts and
tighten the bolts until they are finger tight.
10 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.
11 Adjust the turntable rotation gear backlash. See
D-5, Check the Turntable Rotation Gear
Backlash.
12 Install the ground control side fixed turntable
cover onto the machine and tighten the
retaining fasteners.
Turntable rotate drive hub oil
Capacity
Type:
92 fl oz
2.7 liters
SAE 80W-90 EP multipurpose gear oil
8 Fill the drive brake with oil until the oil is level with
the bottom of the threads. Install the drain plug
and tighten.
When removing the drive hub plug
on machines before serial number
158, replace the drive hub plug
with the new O-ring style drive hub
plug (Genie part number 75107).
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 81
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
D PROCEDURES
D-8
Inspect the Engine Belt(s) Cummins Models
Maintaining the engine belt is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
belt and continued use may cause component
damage.
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.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
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
anchor hole to secure it from
moving could result in death or
serious injury.
If the machine is not equipped with the
generator option, proceed to step 7.
4 Loosen the generator and remove the generator
belt.
5 Inspect the generator belt for:
· Cracking
· Glazing
· Separation
· Breaks
a
b
a
b
a
b
4 - 82
a
b
generator (option)
generator belt
engine pivot plate anchor hole
engine pivot plate retaining fastener
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE D PROCEDURES
6 Replace the belt if any damage is found.
7 Lift the belt tensioner and remove the engine
belt.
8 Inspect the engine belt for:
· Cracking
15 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.
· Glazing
Belts - Genie part numbers
· Separation
· Breaks
9 Replace the belt if any damage is found.
10 Check the torque of the belt tensioner retaining
fastener. Torque to 32 ft-lbs (43 Nm).
Cummins Engine Belt
Cummins Generator Belt
Generator belt deflection
62437
60725
3 /8
inch to 1/2 inch
9 mm to 12 mm
11 Lift the belt tensioner and install the engine belt.
Cummins engines are equipped
with a serpentine belt and
incorporate a self adjusting pulley
tensioner. No adjustment is
required.
If the machine is not equipped with the
generator option, proceed to step 13.
12 Install the generator belt.
13 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
14 Swing the engine pivot plate in towards the
machine.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 83
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
D PROCEDURES
D-9
Replace the Fuel Filter Deutz Models
2 Place a suitable container beneath the fuel filter.
Replacing the diesel fuel filter is essential to good
engine performance and service life. A dirty or
clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
Explosion and fire hazard. Engine
fuels are combustible. Replace the
fuel filter in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
Immediately clean up any fuel that
may have spilled during this
procedure.
1 Tag, disconnect and plug the fuel hose from the
fuel tank at the inline fuel filter/water separator
head.
a
b
c
d
e
overflow valve
fuel lift pump priming lever
oil filter
filter head
fuel filter
3 Loosen the fuel filter with a filter wrench and
drain the fuel into a suitable container. Remove
the fuel filter from the machine when the fuel
flow has slowed or stopped.
4 Apply a thin layer of clean diesel fuel to the new
fuel filter gasket (Genie part number 29560).
5 Install the new filter and tighten it securely by
hand.
6 Clean up any diesel fuel that might have spilled
during the procedure.
7 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
4 - 84
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE D PROCEDURES
8 Install the fuel tank hose onto the inline fuel
filter/water separator head. Tighten the hose
clamp.
9 Bleed the fuel system. See Maintenance
Procedure B-4, Replace the Inline Fuel Filter/
Water Separator Element.
D-10
Check the Engine Valve
Clearances Perkins and Cummins Models
Before bleeding the system, fill the
fuel tank.
Perkins models:
Complete information to perform this procedure is
available in the Perkins User's Handbook,
Perkins part number TPD 1349
(Genie part number 62447).
Cummins models:
Complete information to perform this procedure is
available in the Cummins Operation and
Maintenance Manual, Cummins part number
3810205 (Genie part number 62448).
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 85
Section 4 • Scheduled Maintenance Procedures
First Edition • First Printing
Table E Procedures
E-1
Test or Replace the Hydraulic Oil
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.
2 Close the three hydraulic shutoff valves located
at the hydraulic tank.
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.
The machine uses Dexron
equivalent hydraulic oil. 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.
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.
Perform this procedure with the
boom in the stowed position and
the axles extended.
4 Remove the ground controls support bracket
retaining fasteners and remove the ground
control box assembly from the machine.
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 Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
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.
1 Remove the ground controls side turntable side
cover. Refer to Repair Section 5-1, How to
Remove a Hinged Turntable Cover.
4 - 86
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE E PROCEDURES
6 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank shutoff
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.
10 Remove the hydraulic tank breather filter from
the tank.
15 Remove the case drain filter from the case drain
filter head.
16 Remove the suction strainers from the tank and
clean them using a mild solvent.
17 Rinse out the inside of the tank using a mild
solvent.
18 Install the suction strainers using Loctite® 567
on the pipe threads.
Always use Loctite® 567 on all
pipe threads.
19 Install the drain plug using Loctite® 567 on the
pipe threads.
Always use Loctite® 567 on all
pipe threads.
11 Remove the hydraulic tank strap retaining
fasteners and remove the hydraulic tank straps
from the machine.
20 Install the hydraulic tank onto the machine.
12 Support 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.
22 Install the horn and horn retaining fasteners
onto the machine. Connect the wiring.
13 Remove 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.
14 Remove the hydraulic tank return filter from the
hydraulic tank return filter head.
Part No. 62401
21 Install the hydraulic tank retaining straps and
install the hydraulic tank retaining fasteners.
23 Install the ground control box assembly and
assembly retaining fasteners onto the machine.
24 Install the two suction hoses and the supply
hose for the auxiliary power unit onto the
machine.
25 Install the case drain hose onto the return filter
head.
26 Install the T-fitting and 2 hoses connected to it
to the hydraulic tank return filter head.
Genie S-100 & S-105 & S-120 & S-125
4 - 87
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
E PROCEDURES
27 Fill the tank with hydraulic oil until the level is 3/4
inch (19 mm) from the top of the sight gauge.
Do not overfill.
36 Open the hydraulic tank shutoff 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 Section 10-2, How
to Prime the Pump.
28 Apply teflon tape to the threads of the hydraulic
tank filter mount.
29 Install a new tank breather filter (Genie part
number 60559) onto the filter mount and tighten
it securely by hand.
30 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
31 Install a new tank case drain return filter (Genie
part number 44207) onto the filter mount and
tighten it securely by hand.
32 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
33 Install a new tank return filter (Genie part
number 61326) onto the filter mount and tighten
it securely by hand.
34 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
35 Clean up any oil that may have spilled during
the procedure.
4 - 88
Use only Dexron equivalent
hydraulic fluid.
37 Install the turntable side cover.
Hydraulic system
Hydraulic tank capacity
55 gallons
208 liters
Hydraulic system
capacity (including tank)
80 gallons
303 liters
Hydraulic fluid
Dexron equivalent
Hydraulic tank return filters Genie part numbers
Hydraulic tank breather filter
System return filter
Drive motor case drain return filter
Genie S-100 & S-105 & S-120 & S-125
60559
61326
44207
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE E PROCEDURES
E-2
Change or Recondition the
Engine Coolant Liquid Cooled Models
Replacing or reconditioning the engine coolant is
essential to good engine performance and service
life. Old or dirty coolant may cause the engine to
perform poorly and continued use may cause
engine damage. Extremely dirty conditions may
require coolant to be changed more frequently.
Bodily injury hazard. Beware of
hot engine parts and coolant.
Contact with hot engine parts
and/or coolant will cause severe
burns.
Perform this procedure with the
engine off and cooled.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
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 Put on protective clothing and eye wear.
5 Disconnect the coolant return hose at the
radiator and drain the coolant return tank into a
suitable container. See capacity specifications.
6 Slowly remove the radiator cap from the
radiator.
Bodily injury hazard. Allow any
pressure to dissipate gradually
before removing the radiator cap.
7 Open the drain valve on the radiator and allow
the coolant to drain into a suitable container.
8 After all the coolant has drained, close the drain
valve.
9 Open the drain valve on the engine block and
allow the coolant to drain into a suitable
container.
10 After all the coolant has drained, close the drain
valve.
11 Replace all coolant hoses and clamps.
a
b
a
b
Part No. 62401
12 Fill the radiator with the proper coolant mixture
(coolant and water) for your climate until it is
full.
engine pivot plate anchor hole
engine pivot plate retaining fastener
Genie S-100 & S-105 & S-120 & S-125
4 - 89
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
E PROCEDURES
13 Fill the coolant recovery tank to the COLD FULL
line on the tank.
E-3
Change the Fuel Hoses
14 Clean up any coolant that may have spilled
during this procedure.
15 Start the engine from the ground controls and
let it run until the engine is up to operating
temperature. Continue to run the engine until
the coolant has circulated the cooling system.
16 Stop the engine.
Maintaining the fuel hoses in good condition is
essential to safe operation and good engine
performance. Failure to detect a worn, cracked or
leaking fuel hose may cause an unsafe operating
condition.
17 Allow the engine to cool.
Explosion and fire hazard. Engine
fuels are combustible. Replace the
fuel lines in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
18 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
19 Swing the engine pivot plate in towards the
machine.
20 Install the bolt that was just removed into the
original hole to secure the engine pivot plate.
Bodily injury hazard. Fuel may be
expelled under pressure. Wrap a
cloth around fuel hoses to absorb
leaking fuel before disconnecting
them.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
21 Check the coolant level in the coolant recovery
tank. Add coolant if needed.
Immediately clean up any fuel that
may have spilled during this
procedure.
Coolant capacity
Perform this procedure with the
engine off.
20 quarts
18.9 liters
Deutz models:
1 Remove the engine side turntable fixed side
cover. Refer to Repair Section 5-1, How to
Remove a Fixed Turntable Cover.
4 - 90
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
TABLE E PROCEDURES
2 Tag, disconnect and plug the fuel line from the
fuel tank at the inline fuel filter/water separator
head.
2 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.
3 Remove and replace the following fuel line
hoses and clamps:
· Hose from the fuel tank to the inline fuel
filter/water separator
· Hose from the inline fuel filter/water
separator to the fuel lift pump
· Hose from the fuel lift pump to the fuel filter
· Hose from the fuel filter to the fuel injector
pump
· Hose from the fuel injectors to the fuel tank
3 Clean up any fuel that may have spilled during
this procedure.
4 Install the fuel tank line onto the inline fuel filter/
water separator head. Tighten the hose clamp.
5 Install the ground control side fixed turntable
cover onto the machine and tighten the
retaining fasteners.
6 Bleed the fuel system. See B-4, Replace the
Inline Fuel Filter/ Water Separator Element.
Before bleeding the system, fill the
fuel tank.
Perkins and Cummins models:
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.
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 Tag, disconnect and plug the fuel line from the
fuel tank at the inline fuel filter/water separator
head.
1 Remove the engine side turntable fixed side
cover. Refer to Repair Section 5-1, How to
Remove a Fixed Turntable Cover.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 91
Section 4 • Scheduled Maintenance Procedures
TABLE
First Edition • First Printing
E PROCEDURES
6 Remove and replace the following fuel line
hoses and clamps:
Perkins models:
· Hose from the fuel tank to the inline fuel
filter/water separator
· Hose from the inline fuel filter/water separator
to the fuel lift pump
· Hose from the fuel lift pump to the fuel filter
Cummins models:
· Hose from the fuel tank to the inline fuel
filter/water separator
· Hose from the inline fuel filter/water separator
to the fuel lift pump
· Hose from the fuel injectors to the fuel tank
7 Clean up any fuel that may have spilled during
this procedure.
E-4
Check the Engine Valve
Clearances Cummins Models
Complete information to perform this procedure is
available in the Cummins Operation and
Maintenance Manual, Cummins part number
3810205 (Genie part number 62448).
E-5
Check the Fuel Injectors Deutz Models
8 Install the fuel tank line onto the inline fuel filter/
water separator head. Tighten the hose clamp.
9 Install the ground control side fixed turntable
cover onto the machine and tighten the
retaining fasteners.
10 Bleed the fuel system. See Maintenance
Procedure B-4, Replace the Inline Fuel Filter/
Water Separator Element.
Engine specifications require
that this procedure be performed
at 3000 hours.
Complete information to perform this procedure is
available in the Deutz Workshop Manual, Deutz
part number 297-7293 (Genie part number 62434).
Before bleeding the system, fill the
fuel tank.
4 - 92
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 4 • Scheduled Maintenance Procedures
E-6
Remove and Inspect the
Boom Extend/Retract Cables
Genie specifications require that
this procedure be performed at
5 years or 5000 hours, whichever
comes first and every 2 years
thereafter until the cables are
replaced.
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. Removal and inspection of the boom extend/
retract cables at specified intervals is essential to
good machine performance and safe machine
operation. The boom extend/retract functions
should operate smoothlyand be free of hesitation,
jerking and unusual noise.
1 Remove the boom extend cylinder from the
machine. See Repair Procedure 4-4, How to
Remove the Primary Boom Extension Cylinder.
5 Attach a rope to the boom retract cables at the
pivot end of the boom.
6 At the platform end of the boom, pull the boom
retract cables out of the boom assembly and
lay them on the ground.
7 Using a flashlight, visually inspect the boom
retract cables and components inside the boom
assembly for the following:
· Frayed or broken wire strands
· Kinks in the cables
· Corrosion
· Paint or foreign materials on the cable
· Split or cracked cable ends
· Cables at end of adjustment range
8 Replace the cables if there is any damage to
the cables.
The retract cables must be
replaced in pairs.
If the cables are replaced, the
cable sheaves or pulleys should
also be replaced.
2 Remove the extend cables from the boom
extension cylinder assembly and lay them flat
on the ground.
9 At the pivot end of the boom, pull the boom
retract cables into the boom assembly using the
rope.
3 Visually inspect the boom extend cables and
components for the following:
10 Install the boom extension cylinder assembly
into the boom.
· Frayed or broken wire strands
· Kinks in the cables
· Corrosion
11 Adjust the boom extend/retract cables. See
Repair Procedure 4-5, How to Adjust the Boom
Extend/Retract Cables.
· Paint or foreign materials on the cable
· Split or cracked cable ends
· Cables at end of adjustment range
4 Replace the boom extend cables if there is any
damage to the cables.
The extend cables must be
replaced in pairs.
If the cables are replaced, the
cable sheaves or pulleys should
also be replaced.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
4 - 93
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Troubleshooting Flow Charts
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Genie S-100
and Genie S-105 Operator's Manual or the Genie
S-120 and Genie 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 flow chart 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 flat, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the circle-end wheels
· Turntable secured with the turntable
rotation lock pin
· Key switch in the OFF position with the
key removed
· Welder disconnected from the machine
(if equipped with the weld cable to
platform option)
· Wheels chocked
Electrocution 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.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5-1
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
TROUBLESHOOTING FLOW CHARTS
General Repair Process
About This Section
When a malfunction is discovered, the flow charts
in this section will help a service professional
pinpoint the cause of the problem. To use this
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges.
The location of terminals mentioned in this section
can be found on the appropriate electrical or
hydraulic schematics provided in Section 6,
Schematics.
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
Since various degrees of a particular function
loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will not
operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.
5-2
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Fault Code Chart
Diagnostic code displayed
Condition
Possible Causes
Solution
Consult Genie Industries Service
Department. The platform membrane
panel may need to be replaced.
AXLE EXT/RET BUTTONS FAULT
Axles will not extend or retract.
Shorted axle extend or retract
membrane on platform membrane
panel.
AXLE VALVE FAULT
Axle extend or axle retract
inoperative.
UP/DOWN JOYSTICK NOT
CALIBRATED
UP/DOWN JOYSTICK SHORTED
TO 0V
UP/DOWN JOYSTICK SHORTED
TO 5V
UP/DOWN JOYSTICK VALUE TOO
HIGH
Up/down functions inoperative from
platform.
Up/down functions inoperative from
platform.
Up/down functions inoperative from
platform.
Up/down functions inoperative from
platform.
Axle extend or axle retract valve coils Refer to charts 33 and 34 to
circuits open or shorted to ground or troubleshoot.
the coils are bad.
Up/down joystick not calibrated.
Calibrate up/down joystick refer to
repair section.
Open circuit between platform control Refer to charts 13 and 14 to
card and up/down joystick.
troubleshoot.
Shorted circuit between platform
Refer to charts 13 and 14 to
control card and up/down joystick.
troubleshoot.
Refer to charts 13 and 14 to
Damaged circuit between platform
control card and up/down joystick or troubleshoot.
Joystick may need to be replaced.
UP/DOWN JOYSTICK VALUE TOO Up/down functions inoperative from
platform.
LOW
Damaged circuit between platform
control card and up/down joystick or
Joystick may need to be replaced.
Refer to charts 13 and 14 to
troubleshoot.
Up/down functions inoperative from
turntable.
Shorted boom up/down membrane
on turntable membrane panel.
EXTEND/RETRACT JOYSTICK
NOT CALIBRATED
EXTEND/RETRACT JOYSTICK
SHORTED TO 0V
Consult Genie Industries Service
Department. The turntable
membrane panel may need to be
replaced.
Up/down function speeds to fast or to Up/down speed calibration set from Calibrate Boom up/down speed refer
slow.
display or Reset Boom up/down flow to repair section.
valve defaults set from display. Refer
to Display module section.
No movement on up/down functions Reset Boom up/down flow valve
Calibrate Boom up/down Thresholds
until joystick is moved past half
defaults set from display. Refer to
refer to repair section.
stroke.
Display module section.
Up/down functions inoperative.
Boom up/down flow valve coil circuit Refer to charts 13 and 14 to
open or shorted to ground or the coil troubleshoot.
itself is bad.
Up function inoperative.
Boom up valve coil circuit open or
Refer to chart 13 to troubleshoot.
shorted to ground or the coil itself is
bad.
Down function inoperative.
Boom down valve coil circuit open or Refer to chart 14 to troubleshoot.
shorted to ground or the coil itself is
bad.
Extend and up functions inoperative Boom angle operational switches out Refer to chart 12 to troubleshoot.
and boom down function operative
of sequence.
only when boom is fully retracted.
Extend/retract functions inoperative Extend/retract joystick not calibrated. Calibrate extend/retract joystick refer
from platform.
to repair section.
Extend/retract functions inoperative Open circuit between platform control Refer to charts 16 and 17 to
from platform.
card and extend/retract joystick.
troubleshoot.
EXTEND/RETRACT JOYSTICK
SHORTED TO 5V
Extend/retract functions inoperative
from platform.
EXTEND/RETRACT JOYSTICK
VALUE TOO HIGH
Extend/retract functions inoperative
from platform.
Shorted circuit between platform
control card and extend/retract
joystick.
Damaged circuit between platform
control card and extend/retract
joystick or Joystick may need to be
replaced.
UP/DOWN BUTTONS FAULT
BOOM UP/DOWN SPEED NOT
CALIBRATED
BOOM UP/DOWN FLOW VALVE
NOT CALIBRATED
BOOM UP/DOWN FLOW VALVE
FAULT
BOOM UP VALVE FAULT
BOOM DOWN VALVE FAULT
BOOM ANGLE SWITCHES FAULT
Refer to charts 16 and 17 to
troubleshoot.
Refer to charts 16 and 17 to
troubleshoot.
Continued on next page
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5-3
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
FAULT CODE CHART
Diagnostic code displayed
Condition
EXTEND/RETRACT JOYSTICK
VALUE TOO LOW
Extend/retract functions inoperative
from platform.
EXTEND/RETRACT BUTTONS
FAULT
Extend/retract functions inoperative
from turntable.
Possible Causes
Damaged circuit between platform
control card and extend/retract
joystick or Joystick may need to be
replaced.
Shorted boom extend/retract
membrane on turntable membrane
panel.
Extend/retract function speeds to fast Extend/retract speed calibration set
or to slow.
from display or Reset Boom ext/ret
flow valve defaults set from display.
Refer to Display module section.
No movement on extend/retract
Reset Boom extend/retract flow valve
BOOM EXT/RET FLOW VALVE
functions until joystick is moved past defaults set from display. Refer to
NOT CALIBRATED
half stroke.
Display module section.
Extend/retract functions inoperative. Boom extend/retract flow valve coil
BOOM EXT/RET FLOW VALVE
circuit open or shorted to ground or
FAULT
the coil itself is bad.
Extend function inoperative.
Boom extend valve coil circuit open
BOOM EXT VALVE FAULT
or shorted to ground or the coil itself
is bad.
Retract function inoperative.
Boom retract valve coil circuit open or
BOOM RET VALVE FAULT
shorted to ground or the coil itself is
bad.
Retract function inoperative when
Boom retract lockout valve coil circuit
LOCK OUT VALVE P1 FAULT
boom length is <100’.
open or shorted to ground or the coil
itself is bad.
Extend function inoperative when
Boom extend lockout valve coil circuit
LOCK OUT VALVE P2 FAULT
boom length = or >100’
open or shorted to ground or the coil
itself is bad.
Boom length operational switches out
BOOM LENGTH SWITCHES FAULT Extend, up, and down functions
inoperative.
of sequence.
TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Turntable rotate joystick not
from platform.
calibrated.
NOT CALIBRATED
TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Open circuit between platform control
from platform.
card and turntable rotate joystick.
SHORTED TO 0V
BOOM EXT/RET SPEED NOT
CALIBRATED
TURNTABLE ROTATE JOYSTICK
SHORTED TO 5V
TURNTABLE ROTATE JOYSTICK
VALUE TOO HIGH
TURNTABLE ROTATE JOYSTICK
VALUE TOO LOW
TURNTABLE ROTATE BUTTONS
FAULT
Turntable rotate functions inoperative Shorted circuit between platform
from platform.
control card and turntable rotate
joystick.
Turntable rotate functions inoperative Damaged circuit between platform
from platform.
control card and turntable rotate
joystick or Joystick may need to be
replaced.
Turntable rotate functions inoperative Damaged circuit between platform
from platform.
control card and turntable rotate
joystick or Joystick may need to be
replaced.
Turntable rotate functions inoperative Shorted turntable rotate membrane
from turntable.
on turntable membrane panel.
Solution
Refer to charts 16 and 17 to
troubleshoot
Consult Genie Industries Service
Department. The turntable
membrane panel may need to be
replaced.
Calibrate Boom extend/retract speed
refer to repair section.
Calibrate Boom extend/retract
Thresholds refer to repair section.
Refer to charts 16 and 17 to
troubleshoot.
Refer to chart 16 to troubleshoot.
Refer to chart 17 to troubleshoot.
Refer to chart 16 to troubleshoot
Refer to chart 17 to troubleshoot.
Refer to chart 15 to troubleshoot.
Calibrate turntable rotate joystick
refer to repair section.
Refer to charts 22 and 23 to
troubleshoot.
Refer to charts 22 and 23 to
troubleshoot.
Refer to charts 22 and 23 to
troubleshoot.
Refer to charts 22 and 23 to
troubleshoot.
Consult Genie Industries Service
Department. The turntable
membrane panel may need to be
replaced.
Continued on next page
5-4
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
FAULT CODE CHART
Diagnostic code displayed
Condition
TURNTABLE ROTATE SPEED NOT Turntable rotate function speeds to
fast or to slow.
CALIBRATED
TURNTABLE ROTATE FLOW
VALVE NOT CALIBRATED
TURNTABLE ROTATE FLOW
VALVE FAULT
No movement on Turntable rotate
functions until joystick is moved past
half stroke.
Turntable rotate functions
inoperative.
TURNTABLE ROTATE CW VALVE Turntable rotate CW function
inoperative.
FAULT
TURNTABLE ROTATE CCW
VALVE FAULT
Turntable rotate CCW function
inoperative.
MULTI FUNCTION VALVE FAULT
Multiple functions inoperative. Boom
up/dwn,ext/ret, and turntable rotate
auxiliary functions inoperative.
Steering functions inoperative.
Possible Causes
Solution
Turntable rotate speed calibration set Calibrate Turntable rotate speed refer
from display or Reset turntable rotate to repair section.
flow valve defaults set from display.
Refer to Display module section.
Reset turntable rotate flow valve
defaults set from display. Refer to
Display module section.
Turntable rotate flow valve coil circuit
open or shorted to ground or the coil
itself is bad.
Turntable rotate CW valve coil circuit
open or shorted to ground or the coil
itself is bad.
Turntable rotate CCW valve coil
circuit open or shorted to ground or
the coil itself is bad.
Multi function valve coil circuit open
or shorted to ground or coil may be
bad
Steering joystick not calibrated.
Calibrate turntable rotate Thresholds
refer to repair section.
Refer to charts 22 and 23 to
troubleshoot.
Refer to chart 22 to troubleshoot.
Refer to chart 23 to troubleshoot.
Refer to chart 32 to troubleshoot.
Calibrate steering joystick refer to
repair section.
Open circuit between platform control Refer to charts 35,36,37, and 38 to
Steering functions inoperative from
platform.
card and steering joystick.
troubleshoot.
Steering functions inoperative from
Shorted circuit between platform
Refer to charts 35,36,37, and 38 to
platform.
control card and steering joystick.
troubleshoot.
steering functions inoperative from
Damaged circuit between platform
Refer to charts 35,36,37, and 38 to
platform.
control card and steering joystick or troubleshoot.
Joystick may need to be replaced.
Damaged circuit between platform
Refer to charts 35,36,37, and 38 to
STEERING JOYSTICK VALUE TOO Steering functions inoperative from
platform.
control card and steering joystick or troubleshoot.
LOW
Joystick may need to be replaced.
Blue end blue side steering functions Open circuit between blue end blue Refer to chart 35 to troubleshoot.
BLUE END BLUE SIDE STEER
inoperative.
side steering sensor and DCON box.
SENSOR SHORTED TO 0V
STEERING JOYSTICK NOT
CALIBRATED
STEERING JOYSTICK SHORTED
TO 0V
STEERING JOYSTICK SHORTED
TO 5V
STEERING JOYSTICK VALUE TOO
HIGH
BLUE END BLUE SIDE STEER
SENSOR SHORTED TO 5V
Blue end blue side steering functions Shorted circuit between blue end blue Refer to chart 35 to troubleshoot.
inoperative.
side steering sensor and DCON box.
BLUE END BLUE SIDE STEER
SENSOR VALUE TOO HIGH
BLUE END YELLOW SIDE STEER
SENSOR SHORTED TO 0V
Blue end blue side steering functions Damaged circuit between blue end
Refer to chart 35 to troubleshoot.
inoperative.
blue side steering sensor and DCON
box or steering sensor may need to
be replaced.
Refer to chart 35 to troubleshoot.
Blue end blue side steering functions Damaged circuit between blue end
inoperative.
blue side steering sensor and DCON
box or steering sensor may need to
be replaced.
Blue end yellow side steering
Open circuit between blue end yellow Refer to chart 36 to troubleshoot.
functions inoperative.
side steering sensor and DCON box.
BLUE END YELLOW SIDE STEER
SENSOR SHORTED TO 5V
Blue end yellow side steering
functions inoperative.
BLUE END BLUE SIDE STEER
SENSOR VALUE TOO LOW
Shorted circuit between blue end
yellow side steering sensor and
DCON box.
Refer to chart 36 to troubleshoot.
Continued on next page
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5-5
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
FAULT CODE CHART
Diagnostic code displayed
Condition
BLUE END YELLOW SIDE STEER
SENSOR VALUE TOO HIGH
Blue end yellow side steering
functions inoperative.
BLUE END YELLOW SIDE STEER
SENSOR VALUE TOO LOW
Blue end yellow side steering
functions inoperative.
YELLOW END BLUE SIDE STEER
SENSOR SHORTED TO 0V
Yellow end blue side steering
functions inoperative.
YELLOW END BLUE SIDE STEER
SENSOR SHORTED TO 5V
Yellow end blue side steering
functions inoperative.
YELLOW END BLUE SIDE STEER
SENSOR VALUE TOO HIGH
YELLOW END BLUE SIDE STEER
SENSOR VALUE TOO LOW
YELLOW END YELLOW SIDE
STEER SENSOR SHORTED TO 0V
YELLOW END YELLOW SIDE
STEER SENSOR SHORTED TO 5V
YELLOW END YELLOW SIDE
STEER SENSOR VALUE TOO HIGH
YELLOW END YELLOW SIDE
STEER SENSOR VALUE TOO LOW
BLUE END BLUE SIDE STEER
VALVE FAULT
BLUE END YELLOW SIDE STEER
VALVE FAULT
YELLOW END BLUE SIDE STEER
VALVE FAULT
YELLOW END YELLOW SIDE
STEER VALVE FAULT
Possible Causes
Shorted circuit between yellow end
blue side steering sensor and DCON
box.
Yellow end blue side steering
Damaged circuit between yellow end
functions inoperative.
blue side steering sensor and DCON
box or steering sensor may need to
be replaced.
Yellow end blue side steering
Damaged circuit between yellow end
functions inoperative.
blue side steering sensor and DCON
box or steering sensor may need to
be replaced.
Yellow end yellow side steering
Open circuit between yellow end
functions inoperative.
yellow side steering sensor and
DCON box.
Yellow end yellow side steering
Shorted circuit between yellow end
functions inoperative.
yellow side steering sensor and
DCON box.
Yellow end yellow side steering
Damaged circuit between yellow end
functions inoperative.
yellow side steering sensor and
DCON box or steering sensor may
need to be replaced.
Yellow end yellow side steering
Damaged circuit between yellow end
functions inoperative.
yellow side steering sensor and
DCON box or steering sensor may
need to be replaced.
Blue end blue side CW or blue end
Blue end blue side CW or CCW valve
blue side CCW functions inoperative. coils circuits open or shorted to
ground or the coils are bad.
Blue end yellow side CW or blue end Blue end yellow side CW or CCW
yellow side CCW functions
valve coils circuits open or shorted to
inoperative.
ground or the coils are bad.
Yellow end blue side CW or CCW
Yellow end blue side CW or yellow
valve coils circuits open or shorted to
end blue side CCW functions
inoperative.
ground or the coils are bad.
Yellow end yellow side CW or yellow Yellow end yellow side CW or CCW
valve coils circuits open or shorted to
end yellow side CCW functions
inoperative
ground or the coils are bad.
Drive functions inoperative.
Drive joystick not calibrated.
DRIVE JOYSTICK NOT
CALIBRATED
DRIVE JOYSTICK SHORTED TO 0V Drive functions inoperative.
DRIVE JOYSTICK SHORTED TO 5V Drive functions inoperative.
Solution
Refer to chart 36 to troubleshoot.
Damaged circuit between blue end
yellow side steering sensor and
DCON box or steering sensor may
need to be replaced.
Refer to chart 36 to troubleshoot.
Damaged circuit between blue end
yellow side steering sensor and
DCON box or steering sensor may
need to be replaced.
Open circuit between yellow end blue Refer to chart 37 to troubleshoot.
side steering sensor and DCON box.
Refer to chart 37 to troubleshoot.
Refer to chart 37 to troubleshoot.
Refer to chart 37 to troubleshoot.
Refer to chart 38 to troubleshoot.
Refer to chart 38 to troubleshoot.
Refer to chart 38 to troubleshoot.
Refer to chart 38 to troubleshoot.
Refer to charts 35 to troubleshoot.
Refer to charts 36 to troubleshoot.
Refer to charts 37 to troubleshoot.
Refer to charts 38 to troubleshoot.
Calibrate drive joystick refer to repair
section.
Open circuit between platform control Refer to charts 39 and 40 to
card and drive joystick.
troubleshoot.
Refer to charts 39 and 40 to
Shorted circuit between platform
control card and drive joystick.
troubleshoot.
Continued on next page
5-6
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
FAULT CODE CHART
Diagnostic code displayed
Condition
Possible Causes
Refer to charts 39 and 40 to
troubleshoot.
PLATFORM LEVEL SENSOR
DEGREES SHORTED TO 0V
PLATFORM LEVEL SENSOR
DEGREES SHORTED TO 5V
PLATFORM LEVEL SENSOR
DEGREES VALUE TOO HIGH
Platform level and boom up/down
functions inoperative.
Refer to chart 24 to troubleshoot.
PLATFORM LEVEL SENSOR
DEGREES VALUE TOO LOW
Platform level and boom up/down
functions inoperative.
DRIVE JOYSTICK VALUE TOO
LOW
DRIVE VALVE NOT CALIBRATED
DRIVE VALVE FAULT
BRAKE VALVE FAULT
MOTOR COIL FAULT
AUX PROPEL VALVE FAULT
PLATFORM LEVEL TOGGLE
SWITCHES FAULT
Drive functions inoperative.
Solution
Damaged circuit between platform
control card and drive joystick or
Joystick may need to be replaced.
Drive functions inoperative.
Damaged circuit between platform
control card and drive joystick or
Joystick may need to be replaced.
Reset propel valve defaults set from
No movement on Drive forward or
display. Refer to Display module
reverse functions until joystick is
moved past half stroke.
section.
Drive forward and drive reverse
Drive forward or drive reverse valve
functions inoperative.
coils circuits open or shorted to
ground or the coils are bad.
Brake valve circuit open or shorted to
Drive forward or drive reverse
functions inoperative.
ground or coil is bad.
High drive inoperative.
Motor coil circuit open or shorted to
ground or the coil is bad.
Auxiliary drive forward or reverse
Auxiliary propel valve coils circuits
inoperative (Only seen if Aux. Drive open or shorted to ground or the coils
option is enabled from display. Refer are bad.
to display module section.).
Manual platform level inoperative
Shorted platform level toggle switch
on the platform control box or shorted
from platform or turntable controls.
platform level up or down membrane
switch on the turntable membrane
panel.
Open circuit between platform level
Platform level and boom up/down
functions inoperative.
sensor and platform control box.
Platform level and boom up/down
Shorted circuit between platform level
functions inoperative.
sensor and platform control box.
DRIVE JOYSTICK VALUE TOO
HIGH
PLATFORM LEVEL VALVE FAULT Platform level up or platform level
down function inoperative.
PLATFORM ROTATE TOGGLE
SWITCHES FAULT
Platform rotate functions inoperative
from platform or turntable controls.
PLATFORM ROTATE VALVE
FAULT
Platform rotate CW or CCW
inoperative.
JIB UP/DOWN TOGGLE
SWITCHES FAULT
Jib functions inoperative.
Damaged circuit between platform
level sensor and platform control box
or platform level sensor may need to
be replaced.
Damaged circuit between platform
level sensor and platform control box
or platform level sensor may need to
be replaced.
Platform level up or platform level
down coils circuits open or shorted to
ground or the coils are bad.
Shorted platform rotate toggle switch
on the platform control box or shorted
platform rotate CW or CCW
membrane switch on the turntable
membrane panel.
Platform rotate cw or ccw coils
circuits open or shorted to ground or
the coils are bad.
Shorted jib toggle switch on the
platform control box or shorted jib up
or down membrane switch on the
turntable membrane panel.
Refer to charts 39 and 40 to
troubleshoot.
Calibrate propel thresholds refer to
repair section.
Refer to charts 39 and 40 to
troubleshoot.
Refer to charts 39 and 40 to
troubleshoot.
Refer to chart 42 to troubleshoot.
Refer to chart 44 To troubleshoot.
Refer to charts 25 and 26 to
troubleshoot.
Refer to chart 24 to troubleshoot.
Refer to chart 24 to troubleshoot.
Refer to chart 24 to troubleshoot.
Refer to charts 25 and 26 to
troubleshoot.
Refer to charts 28 and 29 to
troubleshoot.
Refer to charts 28 and 29 to
troubleshoot.
Refer to charts 30 and 31 to
troubleshoot.
Continued on next page
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5-7
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
FAULT CODE CHART
Diagnostic code displayed
Condition
Possible Causes
Solution
JIB VALVE FAULT
Jib up or jib down inoperative.
Jib up or jib down coils circuits open Refer to charts 30 and 31 to
or shorted to ground or coils are bad. troubleshoot.
ENGINE SPEED NO RESPONSE
Engine runs then dies.
Engine RPM signal from alternator
below 100RPM.
Engine RPM signal from alternator
above 3500RPM.
Engine oil pressure below 12psi.
ENGINE SPEED VALUE TOO HIGH Engine runs then dies.
ENGINE OIL PRESSURE VALUE
TOO LOW
ENGINE OIL PRESSURE SENSOR
SHORTED TO 0V
ENGINE OIL PRESSURE SENSOR
SHORTED TO 5V
ENGINE OIL PRESSURE SENSOR
VALUE TOO HIGH
Engine runs then dies.
Engine runs then dies.
Engine runs then dies.
Engine runs then dies.
ENGINE OIL PRESSURE SENSOR Engine runs then dies.
VALUE TOO LOW
ENGINE TEMPERATURE VALUE
TOO HIGH
Engine runs then dies.
Engine oil pressure sensor circuit
shorted to ground.
Engine oil pressure sensor circuit
open.
Engine oil pressure sensor circuit
damaged or sensor may need to be
replaced.
Engine oil pressure sensor circuit
damaged or sensor may need to be
replaced.
Engine temperature above maximum
allowable temp for engine.
ENGINE TEMPERATURE SENSOR Engine runs then dies.
SHORTED TO 0V
ENGINE TEMPERATURE SENSOR Engine runs then dies.
SHORTED TO 5V
ENGINE TEMPERATURE SENSOR Engine runs then dies.
VALUE TOO HIGH
Engine temperature sensor circuit
shorted to ground.
Engine temperature sensor circuit
open.
Engine temperature sensor circuit
damaged or sensor may need to be
replaced.
Engine temperature sensor circuit
ENGINE TEMPERATURE SENSOR Engine runs then dies.
damaged or sensor may need to be
VALUE TOO LOW
replaced.
Unit out of level LED, icon and alarm Open circuit in turntable level sensor
TURNTABLE LEVEL SENSOR Xactive.
X-direction wiring.
DIRECTION SHORTED TO 0V
TURNTABLE LEVEL SENSOR XDIRECTION SHORTED TO 5V
Unit out of level LED, icon and alarm Short in turntable level sensor Xactive.
direction circuit wiring.
TURNTABLE LEVEL SENSOR XDIRECTION VALUE TOO HIGH
Unit out of level LED, icon and alarm Damaged circuit in turntable level
active.
sensor X-direction wiring or turntable
level sensor may need to be
replaced.
TURNTABLE LEVEL SENSOR XDIRECTION VALUE TOO LOW
TURNTABLE LEVEL SENSOR YDIRECTION SHORTED TO 0V
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Refer to chart 4 to troubleshoot.
Repair open in circuit. Refer to
electrical schematic to troubleshoot.
Repair short in circuit. Refer to
electrical schematic to troubleshoot.
Repair damage in circuit wiring. Refer
to electrical schematic to
troubleshoot or consult Genie
Industries Service Department to
determine if turntable level sensor
needs to be replaced.
Unit out of level LED, icon and alarm Damaged circuit in turntable level
Repair damage in circuit wiring. Refer
active.
sensor X-direction wiring or turntable to electrical schematic to
level sensor may need to be
troubleshoot or consult Genie
replaced.
Industries Service Department to
determine if turntable level sensor
needs to be replaced.
Unit out of level LED, icon and alarm Open circuit in turntable level sensor Repair open in circuit. Refer to
active.
Y-direction wiring.
electrical schematic to troubleshoot.
Continued on next page
5-8
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
FAULT CODE CHART
Diagnostic code displayed
Condition
Possible Causes
TURNTABLE LEVEL SENSOR YDIRECTION SHORTED TO 5V
Unit out of level LED, icon and alarm Short in turntable level sensor Yactive.
direction circuit wiring.
TURNTABLE LEVEL SENSOR YDIRECTION VALUE TOO HIGH
Unit out of level LED, icon and alarm Damaged circuit in turntable level
active.
sensor Y-direction wiring or turntable
level sensor may need to be
replaced.
TURNTABLE LEVEL SENSOR YDIRECTION VALUE TOO LOW
DCON CAN NO RESPONSE
CAN BUS NO RESPONSE
SAFETY SWITCH P3 FAULT
SAFETY SWITCH P6R1 FAULT
SAFETY SWITCH P6R2 FAULT
SAFETY SWITCH P7 FAULT
SAFETY SWITCH P7R FAULT
SAFETY SWITCH P9A FAULT
SAFETY SWITCH P9B FAULT
SAFETY SWITCH P10 FAULT
SAFETY SWITCH P11 FAULT
Solution
Repair short in circuit. Refer to
electrical schematic to troubleshoot.
Repair damage in circuit wiring. Refer
to electrical schematic to
troubleshoot or consult Genie
Industries Service Department to
determine if turntable level sensor
needs to be replaced.
Repair damage in circuit wiring. Refer
Unit out of level LED, icon and alarm Damaged circuit in turntable level
active.
sensor Y-direction wiring or turntable to electrical schematic to
troubleshoot or consult Genie
level sensor may need to be
Industries Service Department to
replaced.
determine if turntable level sensor
needs to be replaced.
Repair damage in circuit wiring. Refer
All drive chassis functions
Open or shorted wires in CAN bus
to electrical schematic to
inoperative.
circuits between DCON and TCON
troubleshoot or consult Genie
control box’s.
Industries Service Department.
Repair damage in circuit wiring. Refer
No functions from platform control
Open or shorted wires in CAN bus
to electrical schematic to
box and all platform functions
circuits between PCON and TCON
troubleshoot or consult Genie
inoperative when using turntable
control box’s.
controls.
Industries Service Department.
Open circuit in tether Emergency stop Repair damage in circuit wiring. Refer
All functions inoperative.
wiring.
to electrical schematic to
troubleshoot or consult Genie
Industries Service Department.
Boom extend and boom down
Bad K4 relay inside turntable control Replace K4 relay or consult Genie
functions inoperative. This fault
box.
Industries Service Department.
creates Safety switch P9A,P10,P11,
and P18 fault.
Engine cranks but won’t start.
Bad K3 relay inside turntable control Replace K3 relay or consult Genie
box.
Industries Service Department.
Bad K5 relay inside turntable control Replace K5 or K1 relays or consult
No boom functions. Fault creates
Genie Industries Service Department.
safety switch P7R,P22,P14,P12 and box or bad K1 relay inside platform
P22R faults.
control box.
Bad K2 relay inside turntable control Replace relays or consult Genie
No boom functions. Fault creates
box or bad K2 relay inside platform
Industries Service Department.
safety switch P22,P22R,P14, and
P12 faults.
control box.
Boom extend and boom down
Open in Boom envelope safety
Refer to chart 18 or 19 to
functions inoperative. This fault
circuits or operational limit switches troubleshoot.
creates Safety switch P10 and P18
LSB3EO,LSB13AO,LSB4EO, or
faults.
LSB14AO have failed.
Engine cranks but won’t start.
Open in Boom envelope safety
Refer to chart 18 or 19 to
circuits or operational limit switches troubleshoot.
LSB3EO,LSB13AO,LSB4EO, or
LSB14AO have failed.
Boom extend inoperative.
Boom extension cables out of
Refer to chart 20 or 21 to
adjustment or LSB6S limit switch is troubleshoot.
bad or there is an open in the safety
circuit wiring.
Boom up inoperative.
Open in axle safety switch circuit or Refer to chart 18 or 19 and chart 20
limit switch LSB7DS,LSAX1ES, or
or 21 to troubleshoot.
LSAX2ES have failed or operational
limit switch LSB1DO has failed.
Continued on next page
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5-9
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
FAULT CODE CHART
Diagnostic code displayed
Condition
Possible Causes
Solution
SAFETY SWITCH P12 FAULT
Axle retract inoperative.
Open in stowed safety circuit or limit
switch LSB7DS or LSB3RS have
failed or operational limit switches
LSB1DO or LSB3RO have failed.
Refer to chart 18 or 19 and chart 20
or 21 to troubleshoot.
SAFETY SWITCH P14 FAULT
Axle retract inoperative.
Refer to chart 18 or 19 and chart 20
or 21 to troubleshoot.
SAFETY SWITCH P18 FAULT
Boom extend inoperative.
SAFETY SWITCH P22 FAULT
Platform level inoperative. Fault
creates a safety switch P22R fault.
SAFETY SWITCH P22R FAULT
Platform level and Boom up/down
inoperative.
DCON SAFETY SWITCH P7R
FAULT
Steering and axle functions
inoperative.
Open in stowed safety circuit or limit
switch LSB7DS has failed or limit
switch LSB1DO has failed.
Open in axle safety switch circuit or
limit switch LSB3RS,LSAX1ES, or
LSAX2ES have failed or operational
limit switch LSB3RO has failed.
Platform out of level >10degrees out
of stowed position or platform level
sensor is bad or there is an open in
the platform level sensor circuit or
limit switches LSB1DO or LSB3RO
are bad.
Platform out of level >10degrees out
of stowed position or platform level
sensor is bad or there is an open in
the platform level sensor circuit or
limit switches LSB1DO or LSB3RO
are bad.
Open in Red S56PRV wire circuit that
runs from the turntable control box to
the DCON control box.
PROX. KILL SW. FAULT
BOOM DOWN OVERLOAD FAULT All functions except Boom up and
retract inoperative.
5 - 10
Refer to chart 27 to troubleshoot.
Refer to chart 27 to troubleshoot.
Repair damage in circuit wiring. Refer
to electrical schematic to
troubleshoot or consult Genie
Industries Service Department.
All functions inoperative unless spare Proximity Kill Bumper under platform Activate spare membrane and
membrane on platform control box is has run into an obstruction or is out of carefully move away from obstruction
or readjust proximity kill limit switch.
activated.
adjustment.
PLTFRM OVERLOAD SEN. FAULT All functions inoperative red LED
above spare membrane flashing.
All functions except Boom retract
BOOM UP OVERLOAD FAULT
inoperative.
PRESS PLATFORM ESTOP
Refer to chart 18 or 19 and chart 20
or 21 to troubleshoot.
Code displayed whenever engine is
running and controller is waiting for
engine to be shut off to save
calibrations or any parameter
changes made with the display to
memory.
Load in platform is above rated load
or load sensor is out of adjustment.
Load in platform is above rated load
or boom has run into an obstruction
or boom up overload switch is out of
adjustment.
Boom has been lowered into an
obstruction with boom extended or
boom down overload switch is out of
adjustment or there is an open in
boom down overload circuit.
Just finished a speed calibration for
boom up/dwn, ext.ret, or turntable
rotate or Joysticks were calibrated
with engine running or a function
parameter was changed with the
display while the engine was running.
Genie S-100 & S-105 & S-120 & S-125
Unload excessive weight out of
platform or readjust load sensor.
Unload excessive weight out of
platform or readjust limit switch or
move away from obstruction.
Refer to chart 14 to troubleshoot.
Turn key switch to platform control
position and depress platform
Emergency stop.
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 1
Display Not
Active
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 11
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 1
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5 - 12
)UTZOT[KJUT
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ZNKTK^ZVGMK
VGMK
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 1
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 13
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 1
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5 - 14
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 1
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 15
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 2
Engine Will Not
Crank Over
=OZNZNKQK_Y]OZIN
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Be sure to check fuel
level.
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Be sure the key switch
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position.
Be sure that both
Emergency Stop
buttons are pulled out to
the ON position.
Be sure the circuit
breakers are not
tripped.
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5 - 16
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 2
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 17
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 2
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5 - 18
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 2
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 19
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 2
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5 - 20
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 2
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 21
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 3
Engine Cranks
Over But Will
Not Start
Be sure to check the
fuel level and fill as
needed.
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Be sure the fuel system
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Be sure the batteries
are fully charged and
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OTYKXZKJ
2UUYKTH[ZJUTUZ
XKSU\KZNKXKJ
MXU[TJIUTZXURHU^GTJ
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ZNKTK^ZVGMK
5 - 22
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 3
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
*OYGHRKZNKYZGXZKXH_
XKSU\OTMZNKYZGXZKX
XKRG_6[YNZNKKTMOTK
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IUTZXURHU^SG_HK
LG[RZ_
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 23
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 3
)UTZOT[KJLXUS
VGMK
*OYGHRKZNKYZGXZKXH_
=OZNZNKQK_Y]OZIN
XKSU\OTMZNKYZGXZKX
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XKRG_*OYIUTTKIZZNK
JK[ZYINIUTTKIZUXMUOTM
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8KVRGIKZNKL[KR
YURKTUOJ
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GTJINKIQZNK\URZGMKGZ
6XKYYZNKKTMOTKYZGXZ
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INKIQZNKGJP[YZSKTZUL
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Y]OZINZUZNK0
MXU[TJIUTZXURHU^
IUTTKIZUXGZZNKMXU[TJ
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TUJGSGMK
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58IUTY[RZZNK-KTOK
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VUOTZYGTJINGLKJ
YNUXZKJ]OXOTMGTJ
XKVGOXZNK8*(':
)(2']OXK
<
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+96*]OXKIOXI[OZ
INKIQOTMLUXGHXKGQOT
8KVGOXJGSGMKZU
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]OXOTM/LKTMOTKYZORR
]UTZYZGXZIUTY[RZZNK
ZNK]OXKUXGYNUXZZU
-KTOK/TJ[YZXOKY9KX\OIK
MXU[TJ)NKIQLUX
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VXUVKXVOTOTYKXZOUTUT
ZNKIUTTKIZUXYUXLUX
HXUQKTUXYNUXZKJ]OXKY
MUUJ
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LXUSZNKHKMOTTOTMUL
ZNKINGXZ58IUTY[RZZNK
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 24
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 4
Engine Starts
and Runs for 3
Seconds and
Dies
Be sure to check the
engine oil level and fill
as needed.
=OZNZNKQK_Y]OZIN
Z[XTKJZUMXU[TJ
TU
IUTZXURYGTJHUZN
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*KVGXZSKTZ
+SKXMKTI_9ZUVH[ZZUTY
54
V[RRKJU[ZZUZNK
VUYOZOUTINKIQLUX
JOGMTUYZOIIUJKYUTZNK
JOYVRG_YIXKKTGZZNK
MXU[TJIUTZXURY
'XKIUJKYVXKYKTZ%
_KY
Be sure to check fuel
level and fill as needed.
Be sure to check
coolant level and fill as
needed.
Be sure fuel system is
properly bled.
Be sure the batteries
are fully charged and
properly connected.
/Y+4-/4+5/2
68+99;8+<'2;+
8KVRGIKUORVXKYY[XK
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+4-/4+5/2
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68+99;8+9+4958
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=:(1)698]OXK
9.58::5<VXKYKTZ
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UTZNKJOYVRG_YIXKKT%
IUTTKIZUXGZZNKMXU[TJ
8KVGOXUXXKVRGIKZNK
=:(1)698]OXK
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MUUJ
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68+99;8+9+4958
)NKIQLUXGYNUXZOTZNK
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=.(1)698]OXK
9.58::5<VXKYKTZ
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UTZNKJOYVRG_YIXKKT%
IUTTKIZUXGZZNKMXU[TJ
HGJ
8KVGOXUXXKVRGIKZNK
=.(1)698]OXK
IUTZXURYZUZNKKTMOTKUOR
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TU
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MUUJ
)UTZOT[KJUT
ZNKTK^ZVGMK
8KVRGIKUORVXKYY[XK
YKTYUX
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 25
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 4
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
_KY
/Y+4-/4+
:+36+8':;8+
/YZNKKTMOTKHRUIQ
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IRUMMOTM58XKLKXZUZNK
<'2;+:55./-.
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U\KXNKGZOTMKTMOTK
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HGJ
=.8*):98]OXK
8KVGOXUXXKVRGIKZNK
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IUTTKIZUXGZZNKMXU[TJ
IUTZXURHU^ZUZNK
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TU
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MUUJ
8KVRGIKZNK
ZKSVKXGZ[XKYKTYUX
_KY
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:+36+8':;8+
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9+4958<'2;+:55
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9+4958<'2;+:55
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:+36+8':;8+
9+49589.58::5
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=.8*):98]OXK
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:+36+8':;8+
9+49589.58::5
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=.8*):98]OXK
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=.8*):98]OXK
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8KVRGIKZNK
ZKSVKXGZ[XKYKTYUX
5 - 26
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 4
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y+4-/4+96++*45
8+96549+VXKYKTZUT
_KY
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(GZVUYZUTZNK
<
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8*6(':]OXKZNGZ
X[TYLXUSZNKGRZKXTGZUX
ZUZNKHGZZKX_YKVGXGZUX
GTJXKVGOXUXXKVRGIKZNK
8*6(':]OXK58
IUTY[RZZNK-KTOK
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=NORKZNKKTMOTKOY
X[TTOTMINKIQZNK
\URZGMKGZZNK58(1
RKYY
ZNGT<
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LGTHKRZ58IUTY[RZZNK
)863]OXKUTZNK
-KTOK/TJ[YZXOKY9KX\OIK
GRZKXTGZUXLXUSVOTUL
*KVGXZSKTZ
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GTJGJP[YZZNXUZZRK
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*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 27
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 5
Engine
High Idle
Inoperative
Be sure mechanical
linkage is not binding.
)NKIQNOMNOJRK
=OZNZNKQK_Y]OZIN
GJP[YZSKTZYKK
Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
_KY
3GOTZKTGTIK9KIZOUT
+SKXMKTI_9ZUVH[ZZUTY
58XKLKXZUZNKKTMOTK
V[RRKJU[ZZUZNK
SGT[GRLUX
VUYOZOUTYZGXZZNKKTMOTK
ZXU[HRKYNUUZOTMZNKL[KR
GTJYKRKIZZNKNOMN863
OTPKIZOUTY_YZKS
54
SUJK*UKYZNKYVKKJ
YURKTUOJV[RROT%
Be sure the batteries
are fully charged and
properly connected.
TU
)NKIQZNK\URZGMKULZNK
(18*)863]OXKGZ
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8KVGOXUXXKVRGIKZNK
8*(1)863]OXK
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OTYOJKZNKMXU[TJIUTZXUR
8KVRGIKZNKMXU[TJ
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HU^P[YZKTU[MNZU
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GTJINKIQZNK\URZGMKGZ
ZKXSOTGRULZNKXKRG_
<
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VOTUXVOTULZNK0
8KVRGIKZNKMXU[TJ
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(18*)863]OXK
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0IUTTKIZUXUTMXU[TJ
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ZNKTK^ZVGMK
5 - 28
IUTZXURHU^ZUYVKKJ
YURKTUOJ
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 5
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
)NKIQLUXGTUVKTOTZNK
HGJ
(84<2<8+:]OXK
8KVGOXUXXKVRGIKZNK
(84<2<8+:]OXK
IOXI[OZLXUSVOTULZNK
0IUTTKIZUXGZZNK
MXU[TJIUTZXURHU^ZU
ZNKYVKKJYURKTUOJ
MUUJ
*UKYZNKYVKKJ
YURKTUOJSU\KOTGTJ
TU
)NKIQZNKROTQGMKLUX
HOTJOTM
HGJ
8KVGOXUXXKVRGIKZNK
ROTQGMK
U[Z]OZNU[ZHOTJOTM%
MUUJ
_KY
8KVRGIKZNKYURKTUOJ
8KVRGIKYVKKJ
YURKTUOJ58IUTY[RZZNK
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 29
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 6
Engine Low Idle
Inoperative
Be sure that mechanical
linkage from 2-speed
solenoid to fuel injection
system is not binding or
is defective.
Be sure the batteries
are fully charged and
properly connected.
=OZNZNKQK_Y]OZIN
)NKIQLUXGYNUXZZU
Z[XTKJZUMXU[TJ
HGZZKX_VUYOZO\KOTZNK
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+SKXMKTI_9ZUVH[ZZUTY
54
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MXU[TJIUTZXURHU^
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OTPKIZOUTY_YZKS58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 30
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 7
All Functions
Inoperative,
Engine Starts
and Runs
)NKIQZNKV[SVY[IZOUT
Be sure the batteries are
fully charged and
properly connected.
*UZNKV[SVYLKKR
K^IKYYO\KR_NUZ%
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SG_NG\KJGSGMKJUTK
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UXGRRULZNKV[SVY
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/TJ[YZXOKY9KX\OIK
5VKT\GR\KYGTJYZGXZ
*KVGXZSKTZ
ZNKKTMOTK)NKIQGRR
Be sure the hydraulic
suction line shutoff
valves for the pumps
are in the OPEN position.
Be sure the hydraulic
tank is filled to the
correct level.
IRUYKJ
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SGINOTKL[TIZOUTYLUX
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SGOTV[SVH[ZRKG\KGRR
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GTJIXGTQZNKKTMOTK
U\KX]NORKUHYKX\OTM
YVROTKJXO\KZNGZZNKMKGX
V[SVYVR[MOTZU
YVROTKJUKY
TUZZ[XT
:NKKTMOTKZUV[SVLRK^
VRGZKIU[VROTMOYLG[RZ_
58ZNKSGOTV[SVOY
LG[RZ_)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 31
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 8
Boom Up/Down,
Extend/Retract,
Turntable Rotate
and Platform
Functions
Inoperative,
Drive, Steer and
Axle Extend/
Retract
Functions
Operational
Be sure the hydraulic
suction line shutoff valve
for the lift/steer pump is in
the OPEN position.
Be sure the hydraulic tank
is filled to the correct
level.
/TYZGRRGZU69/
HGXVXKYY[XK
SUXK
:XU[HRKYNUUZKGIN
L[TIZOUTOTJO\OJ[GRR_58
MG[MKZUZNKZKYZVUXZUT
IUTY[RZZNK-KTOK
ZNKL[TIZOUTSGTOLURJ
/TJ[YZXOKY9KX\OIK
9ZGXZZNKKTMOTKLXUS
*KVGXZSKTZ
ZNKMXU[TJIUTZXURY
'IZO\GZKZNKL[TIZOUT
KTGHRKNOMN863H[ZZUT
GTJZNKHUUSXKZXGIZ
H[ZZUTGTJINKIQZNK
N_JXG[ROIVXKYY[XK
RKYYZNGT
VYO
'JP[YZZNKL[TIZOUT
.URJZNKL[TIZOUT
SGTOLURJY_YZKSXKROKL
VYOUX
KTGHRKNOMN863H[ZZUT
\GR\KOZKS(/UX,/GRR
SUXK
GTJVXKYYZNKHUUS
ZNK]G_OTIRUIQ]OYK
XKZXGIZH[ZZUTGTJGJP[YZ
IU[TZOTMZNKT[SHKXUL
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Z[XTY'IZO\GZKZNK
ZUVYOHGX
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863H[ZZUTGTJZNK
HUUSXKZXGIZH[ZZUTGTJ
INKIQZNKN_JXG[ROI
VXKYY[XK
RKYYZNGT
VYO
)NKIQZNKL[TIZOUT
V[SV9KK8KVGOX
Be sure the batteries are
fully charged and properly
connected.
VYOUX
9KIZOUT
HGJ
8KVRGIKZNKMVS
2SOTL[TIZOUT
V[SV
MUUJ
8KVRGIKZNKXKROKL\GR\K
OZKS(/UX,/58XKVGOX
UXXKVRGIKZNK
JOLLKXKTZOGRYKTYOTM\GR\K
OZKS(6UX,658
XKVGOXUXXKVRGIKZNK
RUGJYKTYKVXOUXOZ_LRU]
XKM[RGZUX\GR\K
OZKS(+UX,+58ZNK
SGTOLURJNGYGTOTZKXTGR
LG[RZ)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 32
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 9
All Platform,
Steering and
Axle Functions
Inoperative,
All Other
Functions
Operational
/TYZGRRGZU69/
HGXVXKYY[XK
VYOUX
SUXK
:XU[HRKYNUUZVRGZLUXS
L[TIZOUTYOTJO\OJ[GRR_58
MG[MKZUZNKZKYZVUXZUT
IUTY[RZZNK-KTOK
ZNKVRGZLUXSSGTOLURJ
/TJ[YZXOKY9KX\OIK
9ZGXZZNKKTMOTKGTJ
*KVGXZSKTZ
GIZO\GZKZNKL[TIZOUT
KTGHRKNOMN863H[ZZUT
GTJZNKPOHHUUSJU]T
H[ZZUTGTJINKIQZNK
N_JXG[ROIVXKYY[XK
RKYYZNGT
VYO
Be sure the hydraulic
suction line shutoff
valve for the lift/steer
pump is in the OPEN
position.
Be sure the hydraulic
tank is filled to the
correct level.
Be sure the batteries are
fully charged and
properly connected.
'JP[YZZNKVRGZLUXS
'IZO\GZKZNKL[TIZOUT
SGTOLURJY_YZKSXKROKL
KTGHRKNOMN863H[ZZUT
\GR\KGZZNKJOYZXOH[ZOUT
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SGTOLURJOZKS')GRR
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Z[XTY'IZO\GZKZNK
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L[TIZOUTY
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588*)3,<]OXK
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Part No. 62401
)UTZOT[KJUT
)UTZOT[KJUT
ZNKTK^ZVGMK
VGMK
Genie S-100 & S-105 & S-120 & S-125
5 - 33
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 9
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
:KYZZNKMVS
2SOTV[SV9KK
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MUUJ
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2SOTV[SV
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SUJKRY58ZNK
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SGTOLURJYNG\KGT
OTZKXTGRLG[RZ)UTY[RZ
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 34
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 9
)UTZOT[KJLXUS
VGMK
'XKZNKXKGT_JOGMTUYZOI
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68,';2:VXKYKTZUT
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ZNKRU]KX6IUTTKIZUX
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TU
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TU
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*)54
Part No. 62401
)UTZOT[KJUT
)UTZOT[KJUT
ZNKTK^ZVGMK
VGMK
Genie S-100 & S-105 & S-120 & S-125
5 - 35
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 9
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/TYZGRRGZUVYO
HGXVXKYY[XK
MG[MKZUZNKZKYZVUXZUT
VYOUX
SUXK
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G^RKL[TIZOUTY
OTJO\OJ[GRR_UXIUTY[RZ
ZNKYZKKXG^RKSGTOLURJ
ZNK-KTOK/TJ[YZXOKY
GTJJOYIUTTKIZ
9KX\OIK*KVGXZSKTZ
29'>85UX29'>85
=OZNZNKQK_Y]OZIN
Z[XTKJZUVRGZLUXS
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*KVGXZSKTZ
5 - 36
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 9
)UTZOT[KJLXUS
VGMK
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*)54
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*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 37
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 10
Ground
Controls
Inoperative,
Platform
Controls
Operate
Normally
Be sure all other
functions operate
normally, including
the platform
controls.
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+SKXMKTI_9ZUVH[ZZUT
54
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+SKXMKTI_9ZUVH[ZZUT
IUTZGIZ'(
54
V[RRKJU[ZZUZNK
VUYOZOUTINKIQZNK
Be sure the
batteries are fully
charged and
properly connected.
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5 - 38
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 10
=OZNZNKQK_Y]OZIN
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Part No. 62401
(
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Genie S-100 & S-105 & S-120 & S-125
5 - 39
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 11
Platform
Controls
Inoperative,
Ground
Controls
Operate
Normally
*UKYKTMOTKYZGXZLXUS
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Be sure all
cables from chassis
through the cable
track are in good
condition with no
kinks or abrasions.
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54
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Be sure the
batteries are fully
charged and
properly connected.
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5 - 40
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 11
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+9:56]OXKLXUSZNK
+SKXMKTI_9ZUVH[ZZUT
IUTZGIZZUVOTULZNK
0IUTTKIZUX
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 41
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 12
Boom Angle
Switch Fault
=OZNZNKHUUSL[RR_
XKZXGIZKJGTJZNKHUUS
GTMRKGZRKYYZNGT
Be sure the machine
is on level ground.
_KY
*OYIUTTKIZGTJZKYZ
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8KVRGIK29('5
29('59KK8KVGOX
9KIZOUT
(553
'4-2+9=/:).+9 ,';2:
JKMXKKYOY
UQ
VXKYKTZUTZNKJOYVRG_
YIXKKTGZZNKMXU[TJ
Be sure the boom
angle limit switches
are properly
connected to the
correct wiring
harness leads.
IUTZXURY%
=OZN29('5
8KVGOXUXXKVRGIKZNK
JOYIUTTKIZKJINKIQLUX
\URZGMK
=.)'9]OXKLXUS
\URZGMKUTZNK=.
VXKYKTZ
VOTULZNKJK[ZYIN
)'9]OXKGZVOTUL
IUTTKIZUXZUVOTUL
ZNKJK[ZYINIUTTKIZUX
ZNK0IUTTKIZUXGZ
ZNGZ]GYIUTTKIZKJZU
MXU[TJIUTZXURHU^
29('5
TU\URZGMK
Be sure the
batteries are fully
charged and
properly connected.
VXKYKTZ
*OYIUTTKIZGTJZKYZ
HGJ
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29('59KK8KVGOX
9KIZOUT
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=OZN29('5
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\URZGMKUTZNK=.(1
)'9]OXKGZVOTUL
8KVGOXUXXKVRGIKZNK
\URZGMK
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=.(1)'9]OXK
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ULZNK0IUTTKIZUX
ZNGZ]GYIUTTKIZKJZU
GZZNKMXU[TJIUTZXUR
29('5
HU^
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)NKIQLUXVXUVKX
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58IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
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5 - 42
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 12
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
=OZNZNKSGINOTKUT
RK\KRMXU[TJGZZGING
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9KIZOUT
=NORKSUTOZUXOTMZNK
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VXKYKTZUTZNKJOYVRG_%
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 43
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 12
)UTZOT[KJLXUSZNK
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5 - 44
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 13
Boom Up
Function
Inoperative
=OZNZNKQK_Y]OZIN
Z[XTKJZUMXU[TJ
'IZO\GZKZNKHUUS[V
TU
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)UTZOT[KJUTVGMK
H[ZZUT/YZNKXKGT
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G[JOHRKHKKV]NKT
+SKXMKTI_9ZUVH[ZZUTY
H[ZZUTOYVXKYYKJ%
54
V[RRKJU[ZZUZNK
Be sure all other
functions operate
normally.
Be sure the axles are
fully extended.
VUYOZOUTGIZO\GZKZNK
863H[ZZUTGTJZNK
HUUS[VH[ZZUT
)UTY[RZZNK-KTOK
'XKZNKXKGT_JOGMTUYZOI
/TJ[YZXOKY9KX\OIK
IUJKYVXKYKTZUTZNK
*KVGXZSKTZ:NKMXU[TJ
JOYVRG_YIXKKTGZZNK
IUTZXURSKSHXGTKJKIGR
MXU[TJIUTZXURY%
SG_TKKJZUHK
XKVRGIKJ
Be sure the platform is
level to gravity within
7 degrees.
Be sure the batteries are
fully charged and
properly connected.
TU
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 45
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 13
)UTZOT[KJLXUSZNK
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9',+:?9=/:).6
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5 - 46
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 13
)UTZOT[KJLXUSZNK
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OTLUXSGZOUT
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 47
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 13
)UTZOT[KJLXUS
VGMK
'XKZNKXKSKINGTOIGR
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5 - 48
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 14
Boom Down
Function
Inoperative
=OZNZNKQK_Y]OZIN
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'IZO\GZKZNKHUUSJU]T
TU
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+SKXMKTI_9ZUVH[ZZUTY
H[ZZUTOYVXKYYKJ%
54
V[RRKJU[ZZUZNK
Be sure all other
functions operate
normally.
Be sure the axles are
fully extended.
Be sure the platform is
level to gravity within
7 degrees.
Be sure the batteries are
fully charged and
properly connected.
VUYOZOUTGIZO\GZK
TU
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 49
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 14
)UTZOT[KJLXUSZNK
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5 - 50
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 14
)UTZOT[KJLXUSZNK
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)UTZOT[KJUT
ZNKTK^ZVGMK
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 51
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 14
)UTZOT[KJLXUSZNK
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LUXSUXKOTLUXSGZOUT
5 - 52
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 14
)UTZOT[KJLXUS
VGMK
'XKZNKXKSKINGTOIGR
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*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 53
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 15
Boom Length
Switch Fault
=OZNZNKHUUSL[RR_
TU
)UTZOT[KJUTVGMK
XKZXGIZKJGTJHUUS
GTMRKRKYYZNGT
Be sure all other
functions operate
normally.
Be sure the boom length
limit switches are
properly connected to
the correct wiring
harness leads.
(553
2+4-:.9=/:).+9 ,';2:
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9KIZOUT
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Be sure the batteries are
fully charged and
properly connected.
=OZN29(+5
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5 - 54
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 15
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
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8KVGOXUXXKVRGIKZNK(2
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 55
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 15
)UTZOT[KJLXUS
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9=/:).+9,';2:
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5 - 56
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 15
)UTZOT[KJLXUSZNK
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*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 57
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 16
Boom Extend
Function
Inoperative
=OZNZNKQK_Y]OZIN
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H[ZZUTOYVXKYYKJ%
54
V[RRKJU[ZZUZNK
Be sure all other
functions operate
normally.
Be sure the axles are
fully extended.
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XKVRGIKJ
Be sure the boom is
within the operation
envelope zone.
Be sure the batteries
are fully charged and
properly connected.
TU
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VGMK
5 - 58
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 16
)UTZOT[KJLXUSZNK
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 59
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 16
)UTZOT[KJLXUSZNK
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5 - 60
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 61
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 16
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5 - 62
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 16
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 63
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 16
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5 - 64
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 16
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 65
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 16
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5 - 66
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 17
Boom Retract
Function
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 67
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 17
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5 - 68
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 17
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 69
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 17
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5 - 70
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 17
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 71
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 18
Boom Envelope
Operational
Switch Failure,
S-100 and
S-105 Models
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A boom envelope safety
fault is the result of the
boom exceeding the
operational limits and
activating the safety
switches OR when the
safety switches are
tripped within the
operational range.
Press the (+) and (-)
keys together to access
the status screen. The
status screen can
display the following
information:
- Hydraulic pressure
- Boom Length
- Boom Angle
- Axle status
Boom lengths are given
in feet. The first number
is the length for a S-100,
the second number is
for a S-105. For
example, 75.5/80.5 feet.
Greater than or equal to
is indicated by >= on the
display.
A digital protractor
will be needed to
properly troubleshoot
the machine.
Be sure the batteries
are fully charged and
properly connected.
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5 - 72
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 18
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Part No. 62401
)UTZOT[KJUT
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Genie S-100 & S-105 & S-120 & S-125
5 - 73
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 18
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5 - 74
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 18
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 75
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 18
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5 - 76
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 19
Boom Envelope
Operational
Switch Failure,
S-120 and
S-125 Models
A boom envelope safety
fault is the result of the
boom exceeding the
operational limits and
activating the safety
switches OR when the
safety switches are
tripped within the
operational range.
:NKMXU[TJIUTZXURHU^
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9=/:).6',';2:GTJ
9',+:?9=/:). 6(
,';2:UX9',+:?
9=/:).6(,';2:
JOYVRG_XKGJY
Boom lengths are given
in feet. The first number
is the length for a S-120,
the second number is
for a S-125. For
example, 75.5/80.5 feet.
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Press the (+) and (-)
keys together to access
the status screen. The
status screen can
display the following
information:
- Hydraulic pressure
- Boom Length
- Boom Angle
- Axle status
/YZNKHUUSRKTMZNKW[GR
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Greater than or equal to
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display.
HUUS
A digital protractor
will be needed to
properly troubleshoot
the machine.
Be sure the batteries
are fully charged and
properly connected.
Part No. 62401
)UTZOT[KJUT
ZNKTK^ZVGMK
Genie S-100 & S-105 & S-120 & S-125
5 - 77
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 19
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5 - 78
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 19
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Genie S-100 & S-105 & S-120 & S-125
5 - 79
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 19
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5 - 80
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 19
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 81
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 19
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5 - 82
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 19
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 83
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 19
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5 - 84
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 19
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 85
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 20
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Safety Switch
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S-100 and S-105
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5 - 86
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 87
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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5 - 88
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 89
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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5 - 90
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 91
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 93
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 95
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 97
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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5 - 98
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 99
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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5 - 100
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 101
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 20
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5 - 102
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 20
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 103
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 21
Boom
Envelope
Safety Switch
Failure,
S-120 and
S-125 Models
Be sure all other
functions operate
normally.
Be sure the batteries
are fully charged and
properly connected.
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5 - 104
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 105
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 107
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
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5 - 108
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 109
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
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5 - 110
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 111
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
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Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 113
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 115
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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5 - 116
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 117
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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5 - 118
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 119
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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5 - 120
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 121
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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5 - 122
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 123
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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5 - 124
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 125
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 21
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5 - 126
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 21
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 127
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 22
Turntable
Rotate
Clockwise
Function
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Be sure all other
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5 - 128
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 22
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 129
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 22
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)NKIQLUXGTUVKTUX
HGJ
YNUXZOTZNK(8
8KVGOXUXXKVRGIKZNK
(8<2<8+:]OXK
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
ZNKMXU[TJIUTZXURYZU
VOTULZNK*OT
IUTTKIZUXGZZNK
Z[XTZGHRKXUZGZKLRU]
\GR\KIUOROZKS(-UX
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MUUJ
)NKIQZNKXKYOYZGTIKUL
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VXUVUXZOUTGRIUTZXUR
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
\GR\KIUOROZKS(-UX
OZKS,-
UXOTLOTOZKUNSY
8KVRGIKZNKVXUVUXZOUTGR
\GR\KIUOR
)UTZOT[KJUT
ZNKTK^ZVGMK
5 - 130
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 22
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y(553*5=4
5<+825'*,';2:
'XKZNKXKSKINGTOIGR
_KY
_KY
XKYZXOIZOUTYQKKVOTMZNK
VXKYKTZUTZNKJOYVRG_
HUUSJU]TL[TIZOUT
YIXKKT%
LXUSUVKXGZOTM%
8KSU\KUXXKVGOXZNK
SKINGTOIGRXKYZXOIZOUT
TU
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8KSU\KUXXKVGOXZNK
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:KYZ29(25LUX
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9KIZOUT
MUUJ
)NKIQLUXVXUVKX
HGJ
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'JP[YZ29(259KK
8KVGOX9KIZOUT
MUUJ
)NKIQLUXGTUVKTUX
TU
HGJ
YNUXZOTZNK8*(1
8KVGOXUXXKVRGIKZNK
8*(1)29]OXK
)29]OXKLXUSVOT
ULZNK0IUTTKIZUX
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29(25
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)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
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)UTZOT[KJUT
ZNKTK^ZVGMK
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 131
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 22
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y:;84:'(2+ 85:':+
)=<'2<+,';2:
)NKIQLUXGTUVKTUX
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=.):82]OXK
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ULZNK*OTIUTTKIZUXGZ
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IRUIQ]OYK\GR\KIUOR
OZKS()UXOZKS,)
MUUJ
)NKIQLUXGTUVKTUX
HGJ
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8KVGOXUXXKVRGIKZNK
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TU
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/LGT_UZNKXIUJKYGXK
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XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
5 - 132
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 23
Turntable
Rotate
Counter
Clockwise
Function
Inoperative
Be sure all other
functions operate
normally.
=OZNZNKQK_Y]OZIN
6XKYYJU]TZNKLUUZ
Z[XTKJZUMXU[TJ
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IUTZXURYGTJHUZN
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8KVRGIKZNKMXU[TJ
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IUTZXURSKSHXGTKJKIGR
58IUTY[RZZNK-KTOK
+SKXMKTI_9ZUVH[ZZUTY
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H[ZZUT/YZNKXKGT
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VUYOZOUTVXKYYZNKLUUZ
G[JOHRKHKKV%
54
Y]OZINGTJGIZO\GZKZNK
L[TIZOUTKTGHRKNOMN
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863H[ZZUTGTJZNK
Z[XTZGHRKXUZGZKIU[TZKX
IRUIQ]OYKH[ZZUT'XK
'XKZNKXKSKINGTOIGR
ZNKXKGT_LG[RZIUJKY
XKYZXOIZOUTYQKKVOTMZNK
VXKYKTZUTZNKJOYVRG_GZ
Z[XTZGHRKLXUSXUZGZOTM%
_KY
8KSU\KUXXKVGOXZNK
SKINGTOIGRXKYZXOIZOUTY
ZNKMXU[TJIUTZXURY%
TU
Be sure the axles are
fully extended.
Be sure the batteries
are fully charged and
properly connected.
/TYZGRRGZU69/
8KVGOXUXXKVRGIKZNK
HGXVXKYY[XK
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MG[MKGZZNKW[OIQ
VXUVUXZOUTGR\GR\KOZKS
JOYIUTTKIZIU[VROTMUT
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SGTOLURJGTJYZGXZZNK
(-UXOZKS,-58
RKYYZNGT
VYO
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Z[XTZGHRKXUZGZK
KTMOTK'ZZNKMXU[TJ
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IUTZXURYVXKYYGTJNURJ
()UXOZKS,)58
ZNKL[TIZOUTKTGHRKNOMN
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863H[ZZUTGTJGIZO\GZK
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IU[TZKXIRUIQ]OYKH[ZZUT
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69/
8KVGOXUXXKVRGIKZNK
HXGQK9KK8KVGOX
9KIZOUT
)UTZOT[KJUT
ZNKTK^ZVGMK
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 133
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 23
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y:;84:'(2+ 85:':+
05?9:/)145:
)'2/(8':+* VXKYKTZUT
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ZNKJOYVRG_YIXKKT%
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TU
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)'2/(8':+* VXKYKTZUT
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8KVGOX9KIZOUT
ZNKJOYVRG_YIXKKT%
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
5 - 134
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 23
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y:;84:'(2+ 85:':+
,25=<'2<+,';2:
)NKIQLUXGTUVKTUX
_KY
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YNUXZOTZNK=.8*
VXKYKTZUTZNKJOYVRG_
):8,]OXKLXUSVOT
YIXKKT%
ULZNK0IUTTKIZUXGZ
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ZNKMXU[TJIUTZXURYZU
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OZKS(-UXOZKS,-
MUUJ
)NKIQLUXGTUVKTUX
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8KVGOXUXXKVRGIKZNK
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UXOTLOTOZKUNSY
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\GR\KIUOR
)UTZOT[KJUT
ZNKTK^ZVGMK
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 135
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 23
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y(553*5=4
5<+825'*,';2:
'XKZNKXKSKINGTOIGR
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LXUSUVKXGZOTM%
8KSU\KUXXKVGOXZNK
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TU
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8KSU\KUXXKVGOXZNK
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9KIZOUT
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'JP[YZ29(259KK
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9KK8KVGOX9KIZOUT
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5 - 136
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 23
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
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))=<'2<+ ,';2:
)NKIQLUXGTUVKTUX
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YIXKKT%
ULZNK0IUTTKIZUX
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=.(1):88]OXK
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IRUIQ]OYK\GR\KIUOR
OZKS(-UXOZKS,-
MUUJ
)NKIQLUXGTUVKTUX
HGJ
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8KVGOXUXXKVRGIKZNK
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ULZNK0IUTTKIZUX
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VOTULZNK*OT
IUTTKIZUXGZZNK
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TU
IUOROZKS(-UXOZKS
,-
MUUJ
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INGXZLUXSUXK
OTLUXSGZOUT
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 137
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 24
Platform Level
Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the platform
out of level LED and
ICON are not flashing
at the ground control
box.
=OZNZNKQK_Y]OZIN
:[XTZNKQK_Y]OZINZU
Z[XTKJZUMXU[TJ
VRGZLUXSIUTZXURYGTJ
IUTZXURYGTJHUZN
TU
8KVRGIKZNKZUMMRK
Y]OZIN
ZKYZZNKVRGZLUXSRK\KR
+SKXMKTI_9ZUVH[ZZUTY
ZUMMRKY]OZINLUXVXUVKX
V[RRKJU[ZZUZNK
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9KIZOUT
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/YZNKY]OZINLG[RZ_%
54
_KY
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863H[ZZUTGTJZNK
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TU
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99GTJ9
IUTTKIZUXYGZZNKZUMMRK
Y]OZINGTJVOTYGTJ
ULZNK6IUTTKIZUX
Be sure the batteries
are fully charged and
properly connected.
GZZNKIOXI[OZHUGXJ
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/TYZGRRGZU69/
8KVGOXUXXKVRGIKZNK
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JOYIUTTKIZIU[VROTMUT
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I_ROTJKX58ZNKVRGZLUXS
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L[TIZOUTSGTOLURJIU[RJ
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ZNKTK^ZVGMK
5 - 138
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 24
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y62':,5832+<+2
9+4958*+-8++9
9.58:+*:5<52:9
5862':,5832+<+2
9+4958*+-8++9
9.58:+*:5<52:9
5862':,5832+<+2
9+4958*+-8++9 <'2;+
:55./-.58
62':,5832+<+2
9+4958*+-8++9 <'2;+
:5525=VXKYKTZUTZNK
)NKIQLUXGTUVKTUX
YNUXZOTZNK]OXKIOXI[OZ
_KY
8KVRGIKZNKVRGZLUXSZORZ
MUUJ
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HKZ]KKTVOTYGTJ
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ULZNK0IUTTKIZUX
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9=/:).68,';2:
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IUTZOT[K
YIXKKT%
ZXU[HRKYNUUZOTM
_KY
8KLKXZU)NGXZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 139
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 25
Platform Level
Up Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the platform
out of level LED and
ICON are not flashingat
the ground control box.
=OZNZNKQK_Y]OZIN
Z[XTKJZUMXU[TJ
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'IZO\GZKZNKL[TIZOUT
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KTGHRKNOMN863H[ZZUT
GTJZNKVRGZLUXSRK\KR[V
8KVRGIKZNKMXU[TJ
TU
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JKIGRJKIGR58IUTY[RZ
+SKXMKTI_9ZUVH[ZZUTY
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54
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HGJ
8KVRGIKZNKZUMMRK
Y]OZIN
UVKXGZOUT9KK8KVGOX
9KIZOUT
MUUJ
Be sure the batteries
are fully charged and
properly connected.
)NKIQLUXGTUVKTUX
YNUXZOTZNKOTZKXTGR
HGJ
VRGZLUXSIUTZXURHU^]OXK
8KVGOXUXXKVRGIKZNK
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NGXTKYY
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99GTJ9
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5 - 140
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 25
)UTZOT[KJLXUSZNK
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:5--2+9=/:).9,';2:
:KYZZNKVRGZLUXSRK\KR
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 141
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 25
)UTZOT[KJLXUSZNK
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5 - 142
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 25
)UTZOT[KJLXUSZNK
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OTLUXSGZOUT
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 143
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 26
Platform Level
Down Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the platform out
of level LED and ICON
are not flashing at the
ground control box.
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9KIZOUT
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Be sure the batteries are
fully charged and
properly connected.
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5 - 144
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
8KSU\KUXXKVGOXZNK
SKINGTOIGRXKYZXOIZOUTY
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 26
)UTZOT[KJLXUSZNK
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:5--2+9=/:).+9
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 145
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 26
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5 - 146
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 26
)UTZOT[KJLXUSZNK
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 147
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 27
Platform Level
Safety Fault
"SAFETY SWITCH
P22 FAULT"
"SAFETY SWITCH
P22R FAULT"
=OZNZNKQK_Y]OZIN
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Be sure all other
functions operate
normally.
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9=/:).6,';2:
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Be sure the batteries
are fully charged and
properly connected.
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5 - 148
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 27
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 149
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 27
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5 - 150
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 28
Platform Rotate
Clockwise
Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the axles are
fully extended.
=OZNZNKQK_Y]OZIN
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 151
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 28
)UTZOT[KJLXUSZNK
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5 - 152
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 28
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OTLUXSGZOUT
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 153
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 29
Platform Rotate
Counter
Clockwise
Function
Inoperative
Be sure all other
functions operate
normally.
=OZNZNKQK_Y]OZIN
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5 - 154
*KVGXZSKTZ
8KSU\KUXXKVGOXZNK
SKINGTOIGRXKYZXOIZOUTY
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 29
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 155
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 29
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5 - 156
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 30
Jib Up
Function
Inoperative
Be sure all other functions
operate normally.
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 157
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 30
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5 - 158
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 30
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 159
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 31
Jib Down
Function
Inoperative
Be sure all other functions
operate normally.
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Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 31
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 161
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 31
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5 - 162
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 32
Auxiliariy
Functions
Inoperative
Be sure all other
functions operate
normally.
Be sure the batteries
are fully charged and
properly connected.
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 163
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 32
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5 - 164
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 32
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 165
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 32
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5 - 166
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 32
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 167
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 33
Axle Extend
Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the batteries
are fully charged and
properly connected.
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5 - 168
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 33
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 169
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 33
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5 - 170
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 33
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 171
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 33
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5 - 172
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 33
)UTZOT[KJLXUSZNK
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 173
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 34
Axle Retract
Function
Inoperative
Be sure the boom is in
the stowed position.
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Be sure all other
functions operate
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5 - 174
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 34
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 175
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 34
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5 - 176
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 34
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 177
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 35
Blue End
Blue Side
Steering
Function
Inoperative
Be sure all other
functions operate
normally.
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Be sure the batteries
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5 - 178
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 35
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 179
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 35
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5 - 180
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 36
Blue End
Yellow Side
Steering
Function
Inoperative
Be sure all other
functions operate
normally.
=OZNZNKQK_Y]OZIN
9ZUVZNKKTMOTK/TYZGRR
)NKIQLUXSKINGTOIGR
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54
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Be sure the batteries
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 181
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 36
)UTZOT[KJLXUSZNK
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5 - 182
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 36
)UTZOT[KJLXUSZNK
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9/*+9:++8<'2<+
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 183
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 37
Yellow End
Blue Side
Steering
Function
Inoperative
Be sure all other
functions operate
normally.
=OZNZNKQK_Y]OZIN
9ZUVZNKKTMOTK/TYZGRR
)NKIQLUXSKINGTOIGR
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54
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5 - 184
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 37
)UTZOT[KJLXUSZNK
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 185
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 37
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y?+225=+4*(2;+
9/*+9:++8<'2<+,';2:
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5 - 186
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 38
Yellow End
Yellow Side
Steering
Function
Inoperative
Be sure all other
functions operate
normally.
=OZNZNKQK_Y]OZIN
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54
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Be sure the batteries
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 187
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 38
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/Y9:++8/4-05?9:/)1
9.58:+*:5<52:9UX
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9.58:+*:5<52:9UX
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IUTZXURY6)54]OXK
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5 - 188
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 38
)UTZOT[KJLXUSZNK
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 189
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 39
Drive Forward
Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the engine is
running.
Be sure the drive hubs
are not in the free wheel
configuration.
Be sure the batteries
are fully charged and
properly connected.
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5 - 190
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 39
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 191
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 39
)UTZOT[KJLXUSZNK
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5 - 192
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 39
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 193
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 39
)UTZOT[KJLXUSZNK
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5 - 194
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 39
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 195
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 40
Drive Reverse
Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the engine is
running.
=OZNZNKQK_Y]OZIN
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configuration.
Be sure the batteries
are fully charged and
properly connected.
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5 - 196
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 40
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 197
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 40
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5 - 198
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 40
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 199
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 40
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5 - 200
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 40
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 201
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 41
Drive Enable
Fault
Be sure all other
functions operate
normally.
Be sure the batteries
are fully charged and
properly connected.
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5 - 202
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 41
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 203
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 42
Drive Mode
Select
Inoperative
Be sure the boom is
in the stowed
position.
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Be sure all other
functions operate
normally.
Be sure the batteries
are fully charged and
properly connected.
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5 - 204
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 42
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 205
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 42
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5 - 206
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 42
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 207
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 42
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5 - 208
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 42
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Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 209
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
Chart 43
Engine Start
Assist
Inoperative
Be sure the boom is
in the stowed
position.
Be sure all other
functions operate
normally.
Be sure the batteries
are fully charged and
properly connected.
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5 - 210
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
CHART 43
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*KVGXZSKTZ
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 211
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 43
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5 - 212
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 5 • Troubleshooting Flow Charts
Chart 44
Auxiliary
Drive
Function
Inoperative
Be sure the auxiliary
drive option has been
activated.
Be sure all other
functions operate
normally.
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Be sure the batteries
are fully charged and
properly connected.
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)UTZOT[KJUT
ZNKTK^ZVGMK
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
5 - 213
Section 5 • Troubleshooting Flow Charts
First Edition • First Printing
CHART 44
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5 - 214
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
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
Observe and Obey:
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
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
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.
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 Genie
S-100 and Genie S-105 Operator's Manual or
Genie S-120 and Genie S-125 Operator's
Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 62445
problem
solved
Genie S-100 & S-105 & S-120 & S-125
Inspect
and test
Perform
repair
6-1
Section 6 • Schematics
First Edition • First Printing
Electrical Components
Item
Description
Genie
Part Number
Manufacturer
Manufacturer
Part Number
Qty
B1 ........................... Battery,
12V DC, 105AH ................. 57159 ............ Allied ...................................... Group 27TM ............. 1
B2 ........................... Battery,
12V DC, 190AH ................. 57160 ............ Allied ...................................... Group 4D .................. 1
B3 ........................... Battery separator ............... 61343 ............ Surepower Industries ............. 1314 .......................... 1
CB1 ........................ Circuit breaker, 40A ........... 61188 ............ Klixon ..................................... 7851-37-40-I ............. 1
CB2 ........................ Circuit breaker, 20A ........... 61187 ............ Klixon ..................................... 7851-37-20-I ............. 1
CR6, CR7,
CR10 through
CR17 ...................... Relay, SPDT, 12V DC ....... 34052 ............ Potter-Brumfield ..................... VF4-15F11-CO5 ..... 10
F1 ........................... Fuse, 20A, Maxi
(Deutz models) .................. 75433 ............ Bussman ................................ MAX 20 ..................... 1
F2 ........................... Fuse, 70A, Maxi ................. 61116 ............ Bussman ................................ MAX 70 ..................... 1
FB .......................... Flashing beacon ................ 20189 ............ ECCO Electronic Controls ..... 6400A-GEN .............. 2
FS1 ........................ Foot switch ........................ 13482 ............ Linemaster Switch Corp. ........ 632-S ........................ 1
H1, H2 .................... Alarm - Audio ..................... 62379 ............ Sauer Danfoss ....................... K27631 ..................... 2
H3 .......................... Horn,
12V DC, 112 dB ................. 54506 ............ Wolo Industries ...................... 300LJ-12 ................... 1
JC1, JC3 ................ Joystick controller,
Dual axis ............................ 62390 ............ Sauer Danfoss ....................... K26519(1090332) ..... 2
JC2 ......................... Joystick controller,
Single axis ......................... 62391 ............ Sauer Danfoss ....................... K26520(1090333) ..... 1
KS1, KS2 ............... Contact, N.O. ..................... 45081 ............ Telemecanique ...................... ZB2-BE101 ............... 5
Contact, N.C. ..................... 29732 ............ Telemecanique ...................... ZB2-BE102 ............... 6
6-2
Genie S-100 & S-105 & S-120 & S-125
Part No. 62401
First Edition • First Printing
Section 6 • Schematics
ELECTRICAL COMPONENTS
Item
Description
Genie
Part Number
Manufacturer
Manufacturer
Part Number
Qty
Proximity switch ..... Proximity switch ................. 60987 ............ Power Components ................ FP-2000 .................. 10
Relay ...................... Relay, SPDT, 12V DC
(Deutz models) .................. 60521 ............ Potter-Brumfield ..................... VF4-65F11-S01 ........ 4
(Cummins and
Perkins models) ................. 60521 ............ Potter-Brumfield ..................... VF4-65F11-S01 ........ 3
Relay ...................... Relay, SPDT, 12V DC
(Deutz models) .................. 61225 ............ Potter-Brumfield ..................... VF7-41F11-C05 ........ 2
(Cummins and
Perkins models) ................. 61225 ............ Potter-Brumfield ..................... VF7-41F11-C05 ........ 1
SS1 through
SS4 ........................ Steer sensor ...................... 50159 ............ Power Components ................ HP-NRPS ................. 4
TS1, TS2,
TS3 ........................ Toggle switch, DPDT,
3 position momentary ........ 16397 ............ Microswitch Control Inc. ......... 2NT1-7 ...................... 3
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
6-3
Section 6 • Schematics
First Edition • First Printing
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
AC Generator
Angle
Auxiliary Boom Valve
Auxiliary Forward Valve
Auxiliary Platform Valve
Auxiliary Reverse Valve
Auxiliary Reverse Valve
Auxiliary Steer/Drive Valve
Axle Extend Valve
Axle Oscillate
Axle Retract Valve
Battery
Boom Extended
Boom Stowed
Brake
Bypass Valves
CAN High Signal
CAN Low Signal
CAN Shield
Chain Break
Data High
Data Low
Drive Chassis Controller
Drive Enable
Electrical Displacement Control
Engine Speed Select
Engine Status Lamp
Filter Restricted
Filter Switch
Float Switch
Foot switch Signal
Forward
Fuel Select (gas/LP)
2
The circuit number may be used more than
once in a circuit.
For Example:
C 74 PRLO – 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. PRLO
stands for Primary Lockout.
S 62 BSTO – 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 BSTO
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.
V 61 AXRT – V stands for valve power. 61 stands
for axle retracted circuit and AXRT is the
mnemonic for Axle Retracted.
6-4
Genie S-100 & S-105 & S-120 & S-125
suffix
GEN
ANG
ABV
AFV
APV
AREV
AREV
ASV
AXEX
AXOS
AXRT
BAT
BEX
BST
BRK
BV
CAN+
CANSHLD
CNBK
DTA+
DTADCON
DRE
EDC
ESPD
ESL
FLR
FLTR
FS
FTS
FWD
FUEL
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
WIRE CIRCUIT LEGEND
Fuel Solenoid
FSOL
Ground Control
TCON
Horn
HRN
Ignition
IGN
Jib Down
JD
Jib Flow Control
JFC
Jib Select Valve
JSV
Jib Up
JU
Lamps
LPS
Left Front
LF
Left Front Steer Sensor
LFS
Left Rear
LR
Left Rear Steer Sensor
LRS
Limit Switch
LS
Load Sensor
LDS
Low fuel
LOF
Motor Shift (Speed)
MS
Multi Function Valve
MFV
Platform Control
PCON
Platform Level Down
PLD
Platform Level Flow Control
PLF
Platform Level Up
PLU
Platform Rotate Flow Control
PRF
Platform Rotate Left (CCW)
PRL
Platform Rotate Right (CW)
PRR
Platform Tilt Alarm
PTA
Platform Tilt Sensor
PTS
Pressure Sender
PSR
Pressure Switches
PS
Pri Boom down
PBD
Primary Boom Down
PBD
Primary Boom Extend/Retract Lockout Valve PBL
Primary Boom Extend
PBE
Primary Boom Extend/Retract Flow Control PERF
Primary Boom Retract
PBR
Primary Boom Up
PBU
Part No. 62445
Primary Boom Up/Down Flow Control
Primary Lockout #1
Primary Lockout #2
Proportional Valve
Proximity Sensor
Receptacle
Reverse
Right Front
Right Front Steer Sensor
Right Rear
Right Rear Steer Sensor
RPM
Sec Boom Down
Sec Boom Extend
Sec Boom Extend/Retract Flow Control
Sec Boom Retract
Sec Boom Up
Sec Boom Up/Down Flow Control
Secondary Boom
Secondary Boom Lockout Valve
Spare
Start Aid (Glow Plug or choke)
Starter
Steering Valve (CW)
Steering Valve (CCW)
Temp Sender
Temp Switches
Tether
Tilt Alarm X axis
Tilt Alarm Y axis
Ground Control Panel
Turntable Rotate Flow Control
Turntable Rotate Right (CW)
Turntable Tilt Alarm
Turntable Tilt Sensor
Test Switch
Genie S-100 & S-105 & S-120 & S-125
PBF
P1L
P2L
PRV
PXS
REC
REV
RF
RFS
RR
RRS
RPM
SBD
SBE
SERF
SBR
SBU
SBFC
SB
SBLO
SP
SA
STR
STC
STCC
TSR
TS
TET
TAX
TAY
TCON
TRF
TRR
TTA
TTSR
TSW
6-5
Section 6 • Schematics
First Edition • First Printing
WIRE CIRCUIT LEGEND
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
BL
BL/BK
BL/RD
BL/WH
BK
BK/RD
BK/WH
BR
GRN
GR/BK
GR/WH
RD
RD/BK
RD/WH
OR
OR/BL
OR/BK
OR/RD
WHT
WH/BK
WH/RD
YL
6-6
Blue
Blue/Black
Blue/Red
Blue/White
Black
Black/Red
Black/White
Brown
Green
Green/Black
Green/White
Red
Red/Black
Red/White
Orange
Orange/Blue
Orange/Black
Orange/Red
White
White/Black
White/Red
Yellow
Color, Circuit #, and Primary function
RD
1
Primary boom up drive
RD/BK 2
Primary boom down drive
RD/WH 3
Primary boom up/down 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/down 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/down FC
proportional valve drive
GR/RD 17
Platform rotate left valve driver
GR/BK 18
Platform rotate right valve driver
GR/WH 19
Jib select valve driver circuit
RD
20
12 battery supply
WH
21
12 ignition supply
BK
22
Key switch power to platform
Emergency Stop
WH
23
Power to platform
WH
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
WH/BK 31
Reverse
WH/RD 32
Brake
BK
33
Start
BK/WH 34
Start Aid (glow plug or choke)
BK/RD 35
Engine speed select
BL
36
Steer clockwise
Genie S-100 & S-105 & S-120 & S-125
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
WIRE CIRCUIT LEGEND
BL/BK
BL/WH
BL/RD
OR
OR/BK
OR/RD
GR
GR/BK
GR/WH
WH
WH/BK
WH/RD
WH/BK
BL
BL/WH
BL/RD
WH/BK
BK/WH
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
GR/BK 55
RD
56
RD/WH
RD/BK
GR/WH
GR/WH
GR
OR
OR/RD
57
58
59
60
61
62
63
OR/BL
BL/WH
BL
BL
RD
BL
BL/WH
BL/BK
BL/WH
BL/RD
RD
RD/WH
BL
64
65
66
67
68
69
70
71
72
73
74
75
76
Part No. 62445
Steer counterclockwise
Gas
LP
Limit switch signal stowed
RPM signal
Boom retracted signal
Jib Up
Jib Down
AC Generator
Drive Horn
Output Power Enable
Work Lamp
Motion Lamp
Auxiliary Boom
Auxiliary Steer
Auxiliary Platform
Boom envelope safety valve cutoff
Power to safety interlock
switches (engine)
Axle oscillation
Foot switch/TCON
Emergency Stop power
Boom down safety interlock
Safety interlock to engine
Chain break circuit
Axle extend
Axle retract
Boom stowed (safety)
Power to boom envelope
safety switch
Power for operational switches
Low fuel indication
Drive Enable
Secondary boom not stowed
Pri Boom lowered (operational)
Pri boom #1 extended
Pri boom #2 retracted
Pri boom #2 extended
Secondary boom extended
Secondary boom retracted
Pri #1 Lockout
Pri #2 Lockout
Pri boom #3 extended
WH
77
WH/BK 78
BK
79
GR
YL
GR/WH
GR/BK
GR
OR
RD
RD/BK
BR
RD/BK
RD/WH
WH/BK
WH/RD
WH
OR
RD
BK
WH
BK
WH/RD
WH/BK
OR
OR/RD
BK/WH
BK/RD
GR
RD
BK/RD
GR/WH
BK
OR
RD
OR/RD
BK/RD
RD/BK
GRN
WHT
BK
BL
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
Lower Angle #1 operational
Upper Angle #2 operational
power from TCON ESTOP
80Can 2.0/J1939 Shield
Can 2.0/J1939 Low
Can 2.0/J1939 High
Tilt signal x axis
Tilt signal y axis
Tilt sensor power
Hydraulic Filter restricted
Platform Level Safety Power
Platform Level Safety Output
Platform Level Safety Ground
Proximity Kill
Gate Interlock
Motor Speed (LO/HI)
Motor Bypass
Load Sensor
Tether ESTOP return
Tether Power
Tether ESTOP Power
J1708 + (high)
J1708- (low)
Outrigger lowered
Outrigger raised
Pothole protector up
Pothole protector down
Proprietary Data buss Proprietary Data buss +
Spare
Alternator Field
Engine Status
Sensor Pwr
Sensor Return
Steer Signal
Steer Signal to Solenoid Valve
Multi Function Valve
Load Moment Overweight
Load Moment Underweight
AC Power Ground
AC Power Neutral Wire (-)
AC Power Hot Wire (+)
Hydraulic Pressure Sensor Output
Genie S-100 & S-105 & S-120 & S-125
6-7
Section 6 • Schematics
First Edition • First Printing
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 ••
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.
6-8
LSB9AS ••
LSB8AS
LSB4ES
LST1O
LSB1DO
LSB2RO ••
LSB3RO
LSB3EO
LSB4EO ••
LSB13AO
LSB14AO ••
LSB19LO
LSB20LO
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
Boom >3 feet (0.9 m) stowed
mechanical
Boom 75 feet (22.9 m)
extend proximity
Boom 100 feet (30.5 m)
extend proximity
Boom 53° angle proximity
Boom 68° angle proximity
Load moment mechanical
Reverse load moment proximity
(•• S-120 and S-125 models only)
Genie S-100 & S-105 & S-120 & S-125
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
LIMIT SWITCHES
S-100 & S-105 Models
(S-100 shown)
Part No. 62445
S-120 & S-125 Models
(S-120 shown)
Genie S-100 & S-105 & S-120 & S-125
6-9
Section 6 • Schematics
First Edition • First Printing
Relay Layout
a
b
c
d
e
f
g
h
i
j
k
l
m
n
6 - 10
Fuel solenoid relay (Deutz models only).
Oil cooler relay (Deutz models only).
Engine cold start relay.
Starter relay.
Horn relay.
Flashing beacon relay.
CR17 relay (K7) - powers C35RPM
circuit (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 and
platform 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.
Genie S-100 & S-105 & S-120 & S-125
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
Drive Chassis Controller Pin Legend
Part No. 62445
Genie S-100 & S-105 & S-120 & S-125
6 - 11
Section 6 • Schematics
First Edition • First Printing
Platform Controller Pin Legend
6 - 12
Genie S-100 & S-105 & S-120 & S-125
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
Turntable Controller Pin Legend
Part No. 62445
Genie S-100 & S-105 & S-120 & S-125
6 - 13
Section 6 • Schematics
First Edition • First Printing
Electrical Schematic Legend Drive Chassis (DCON) and Platform Controls (PCON)
6 - 14
Genie S-100 & S-105 & S-120 & S-125
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
Electrical Schematic Legend Ground Controls (TCON)
Part No. 62445
Genie S-100 & S-105 & S-120 & S-125
6 - 15
Section 6 • Schematics
First Edition • First Printing
Electrical Symbols Legend
6 - 16
Genie S-100 & S-105 & S-120 & S-125
Part No. 62445
First Edition • First Printing
Section 6 • Schematics
Limit Switch Harness Schematic,
S-100 & S-105 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
6 - 17
First Edition • First Printing
Section 6 • Schematics
Limit Switch Harness Schematic,
S-120 & S-125 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
6 - 18
First Edition • First Printing
Section 6 • Schematics
Safety Circuit Schematic
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 62401
Genie S-100 & S-105 & S-120 & S-125
6 - 19