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First Edition, First Printing http://www.genieindustries.com e-mail: techsup@genieind.com "Genie" and "S" are registered trademarks of Genie Industries in the USA and many other countries. Printed on recycled paper Printed in U.S.A. Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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This machine complies with: ANSI A92.5 CAN B.354.4 Genie Industries 18340 NE 76th Street Redmond, WA 98052 Serial label (located under cover) Serial number (stamped on chassis) PN - 77055 Part No. 62401 Genie S-100 & S-105 & S-120 & S-125...
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First Edition • First Printing This page intentionally left blank. Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-100 & Genie S-105 Operator's Manual or the Genie S-120 & Genie S-125 Operator's Manual will result in death or serious injury.
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Be sure to properly dispose of old oil or property damage. other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Manifolds 10-1 Function Manifold Components, S-100 and S-105 Models ......7 - 76 10-2 Valve Adjustments - Function Manifold, S-100 and S-105 Models ....7 - 80 10-3 Proportional Valves - Function Manifold ............7 - 81 10-4 Function Manifold Components, S-120 and S-125 Models ......7 - 82 10-5 Valve Adjustments - Function Manifold, S-120 and S-125 Models ....
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13-6 Extendable Axles ..................7 - 129 Appendix Electrical Schematic , Genie part number 62304 Drive Chassis and Platform Control .............. Sheet 1 of 2 Ground Controls ................... Sheet 2 of 2 xvii Part No. 62401 Genie S-100 & S-105 & S-120 & S-125...
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First Edition • First Printing This page intentionally left blank. Genie S-100 & S-105 & S-120 & S-125 Part No. 62401 xviii...
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366 cm Lug nut torque, lubricated 320 ft-lbs 433.9 Nm Turning radius, outside, 24 ft 4 in 24 ft 4 in axles retracted 7.4 m 7.4 m Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 2 - 1...
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(time between fully raised and the 50° envelope limit) 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...
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24 ft 4 in axles retracted 7.4 m 7.4 m Turning radius, inside, 16 ft 4 in 16 ft 4 in axles retracted 4.9 m 4.9 m Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 2 - 3...
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(time between fully raised and a fully lowered position) Boom extended to >80 ft (>24.4 m) 50 to 55 seconds (time between fully raised and the 50° envelope limit) Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 2 - 5...
12 cc to 45 cc bypass pressure 6 bar Hydraulic tank circuit 10 micron with 25 psi return line filter (1.7 bar) bypass Drive motor case drain filter 10 micron 2 - 6 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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...
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...
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-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...
(Genie part number 49612). 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...
Power Source The boom lift cylinder, boom extend cylinders, platform leveling slave cylinder, platform rotator The Genie S-100, S-105, S-120 and S-125 are and jib boom cylinder (S-105 and S-125 models) powered by one of three diesel engines: incorporate counterbalance valves to prevent the Cummins B3.9L, the Deutz F4L 913 and the...
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For example, steering inputs from PCON are sent Membrane type switches are used to select the to DCON via the high speed data bus using various steering and operating modes. multiplexed signals. 3 - 2 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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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...
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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...
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Indicates that an incorrect result has occurred · Wheels chocked after performing a series of steps. · All external AC power supply disconnected from the machine Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 1...
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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. 4 - 2 S-100 & S-105 & S-120 & S-125 Part No. 62401...
After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 5...
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After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 4 - 6 S-100 & S-105 & S-120 & S-125 Part No. 62401...
Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 7...
Operator's Manual on your machine. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 4 - 8 S-100 & S-105 & S-120 & S-125 Part No. 62401...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 4 - 10 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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, this indicates that a hydraulic filter is being bypassed and the filter needs to be replaced. See D-12, Replace the Hydraulic Filter Elements. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 11...
To conserve battery power, test each function through a partial cycle. Result: All boom functions should operate. 4 - 12 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 13...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 4 - 14 S-100 & S-105 & S-120 & S-125 Part No. 62401...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 15...
Genie part number direct grease to the bottom sliding wear pad. 102771 through our Service Parts department. Top wear pad grease fitting Side wear pad grease fitting 4 - 16 S-100 & S-105 & S-120 & S-125 Part No. 62401...
5 Repeat steps 1 through 4 for all the other drive hubs. 6 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 17...
Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 3 Be sure that the battery hold downs and cable connections are tight. 4 - 18 S-100 & S-105 & S-120 & S-125 Part No. 62401...
3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 19...
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Crushing hazard. Failure to install · Wire harness connectors to DCON module the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 4 - 20 S-100 & S-105 & S-120 & S-125 Part No. 62401...
8 If needed, clean the cylinder head cooling passages and fins of debris and foreign material. 9 Install the engine side cover and tighten the retaining fasteners. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 21...
Result: The travel alarm should sound when the drive control handle is moved off center in either direction. 4 - 22 S-100 & S-105 & S-120 & S-125 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. 4 - 24 S-100 & S-105 & S-120 & S-125 Part No. 62401...
4 Install the plugs in the drive hub. 5 Check the torque of the drive hub mounting fasteners. Refer to Section 2, Specifications. 6 Repeat this procedure for each drive hub. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 25...
6 If necessary, add oil until the oil level is even with the bottom of the plug hole. 7 Install the plug into the drive hub. 4 - 26 S-100 & S-105 & S-120 & S-125 Part No. 62401...
Result: Low idle should be 1500 rpm. Skip to step 5 if the low idle rpm is correct. 3 Loosen the locknut on the low idle adjustment screw. low idle adjustment screw Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 27...
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Tighten the low idle lock nut and confirm the rpm. engine pivot plate anchor hole engine pivot plate retaining fastener 4 - 28 S-100 & S-105 & S-120 & S-125 Part No. 62401...
Result: The engine should stop and no functions should operate. 9 Turn the main key switch to ground control and start the engine. 4 - 30 S-100 & S-105 & S-120 & S-125 Part No. 62401...
4 Push and hold a function enable/speed select platform until the indicator light button and adjust the platform to a level position turns off. using the platform level up/down buttons. 4 - 32 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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 S-100 & S-105 & S-120 & S-125 4 - 33...
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20 Remove the wire jumper installed in step 16 and LSB8AS connect the deutsch connector to LSB13AO. 14 Raise the boom to approximately 60°. 15 Extend the boom to approximately 95 feet / 28.96 m. 4 - 34 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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75 feet / 22.9 m. serious injury. 24 Remove the wire jumper installed in step 21 and connect the harness plug to LSB3EO. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 35...
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See Repair Section. 32 Rotate the head of the switch 45 degrees clockwise and install the arm onto LSB6S. Proximity switch target area 4 - 36 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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11°. See Repair Section. Failure to retract the boom could result in death or serious injury. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 37...
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50 Turn the key switch to the position. for 5 seconds. 4 - 38 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Repeat this procedure 1 Remove the cap from the fuel tank. beginning with step 6. 8 Install the breather cap onto the hydraulic tank. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 39...
Result: The engine should change to high idle. 5 Push and release the rpm select button until low rpm is selected (turtle symbol). Result: The engine should return to low idle. 4 - 40 S-100 & S-105 & S-120 & S-125 Part No. 62401...
6 Measure the distance between the test line and the machine reference point crosses the finish your machine reference point. Refer to line. Refer to Section 2, Specifications . Section 2, Specifications . Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 41...
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. 4 - 42 S-100 & S-105 & S-120 & S-125 Part No. 62401...
See E-1, Test or Replace the Hydraulic Oil. boom end cover side access covers cable ends (located underneath the boom) Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 43...
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· 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. 4 - 44 S-100 & S-105 & S-120 & S-125 Part No. 62401...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 4 - 46 S-100 & S-105 & S-120 & S-125 Part No. 62401...
3 Remove all weight, tools and accessories from the platform. Failure to remove all weight, tools and accessories from the platform will result in an inaccurate test. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 47...
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S-100 and S-120- 75 lbs / 34 kg alarm sounds. S-105 and S-125- 50 lbs / 22.7 kg. 8 Test all machine functions from the platform Result: The alarm should sound.
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Result: All platform control functions should operate. If the platform overload system is not operating properly, refer to Repair Section 4-5, Calibrate the Platform Overload System (if equipped). Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 49...
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. 4 - 50 S-100 & S-105 & S-120 & S-125 Part No. 62401...
1 Start the engine from the platform controls and extend the axles. 2 Measure each wear pad. Extendable axle wear pad specifications inch Minimum thickness 11.1 mm Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 51...
4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the square-end of the machine. disengaged position engaged position 4 - 52 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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.
The turntable rotation bearing bolt as far as it will go. torque sequence is the same from above the turntable and below the drive chassis. 4 - 54 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Fasten a straight edge on the side of the rotator using tape so one end is just above the tape measure. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 55...
Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. drive hub plugs 4 - 56 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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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. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 57...
1 inch / turntable rotation gear cover is not 2.5 cm from the turntable rotation installed. bearing. 4 - 58 S-100 & S-105 & S-120 & S-125 Part No. 62401...
11 Lower the boom to the stowed position and turn death or serious injury. the machine off. 12 Remove the dial indicator from the machine. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 59...
2 Place a suitable container under the hydraulic tank return filters. 3 Remove each filter with an oil filter wrench. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 61...
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7 Install the new high pressure filter elements into the housings and tighten them securely. 8 Clean up any oil that may have spilled during the installation procedure. 4 - 62 S-100 & S-105 & S-120 & S-125 Part No. 62401...
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. Part No. 62401 S-100 & S-105 & S-120 & S-125 4 - 63...
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22 Install the horn and horn retaining fasteners onto the machine. Connect the wiring. 37 Install the turntable side cover. 23 Install the ground control box assembly and assembly retaining fasteners onto the machine. 4 - 64 S-100 & S-105 & S-120 & S-125 Part No. 62401...
3 boom to good engine performance and service life. Failure tube on the S-100 and S-105, and the numbers 2 to perform the maintenance procedures can lead to and 3 boom tubes on the S-120 and S-125.
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Perform all troubleshooting on a · Wheels chocked 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...
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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...
Refer to charts 16 and 17 to VALUE TOO HIGH from platform. control card and extend/retract troubleshoot. joystick or Joystick may need to be replaced. Continued on next page Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 3...
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Shorted turntable rotate membrane Consult Genie Industries Service FAULT from turntable. on turntable membrane panel. 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...
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Shorted circuit between blue end Refer to chart 36 to troubleshoot. SENSOR SHORTED TO 5V functions inoperative. yellow side steering sensor and DCON box. Continued on next page Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 5...
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DRIVE JOYSTICK SHORTED TO 5V Drive functions inoperative. Shorted circuit between platform Refer to charts 39 and 40 to control card and drive joystick. troubleshoot. Continued on next page 5 - 6 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Refer to charts 30 and 31 to platform control box or shorted jib up troubleshoot. SWITCHES FAULT or down membrane switch on the turntable membrane panel. Continued on next page Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 7...
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Open circuit in turntable level sensor Repair open in circuit. Refer to active. Y-direction wiring. electrical schematic to troubleshoot. DIRECTION SHORTED TO 0V Continued on next page 5 - 8 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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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...
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%ÆqtÆ& s yy A usÆPW@#&9S P uÆxuÆPW@09W P uÆxuÆr ÆyÆxu ywÆvquuÆqt r ÆqwuÆyÆ'" qtÆxuÆysxÆ Æxq s yy tuwuu ÆBys us xuÆs qsÆ vÆxu PW@09WÆtusx ysxÆ uÆxuÆxu s us ÆqtÆsxusÆv r ÆqwuÆuqsxu Æs yyÆruuu '"Ætuwuu yÆ#ÆqtÆ$Æqt ruuuÆyÆ%ÆqtÆ& Æs yy A yutÆ xuÆuÆqwu A ÆxuÆEuyu GtyuÆWuysu Buqu Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 75...
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us tqÆ sÆqtÆu s Ær Æ ÆquÆu yuÆxuÆuyq xqÆxuÆuyqÆy GqÆxuÆus tq yuutÆ u sÆyÆ ÆusuÆxu uyqÆyÆqsu w t AxusÆyÆ#%Æ vÆxuÆH$ P uÆxuÆut s us ÆqÆxuÆw t us tqÆ sÆqtÆu s Ær Æ ÆquÆu yuÆxuÆuyq xqÆxuÆuyqÆy GqÆxuÆus tq yuutÆ u sÆyÆ ÆusuÆxu uyqÆyÆqsu w t VuqsuÆxuÆw t s Ær ÆSVÆs xuÆEuyuÆGtyu WuysuÆBuqu 5 - 76 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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>= on the display. r A digital protractor will be needed to properly troubleshoot the machine. Be sure the batteries are fully charged and A yutÆ xuÆuÆqwu properly connected. Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 77...
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H##ÆurquÆtusq s us ÆqÆxuÆsysy r qt w t AxusÆv ÆqÆ uÆ VuqsuÆxuÆw t x ÆyÆxuÆyrÆr s Ær Æurqu t ÆurquÆr tusqÆSVÆs Æxu qÆxuÆw tÆs EuyuÆGtyuÆWuysu ruuuÆyÆ#Æ vÆxuÆH## Buqu urquÆtusq s us ÆqÆxuÆsysy r qtÆqtÆyÆ&Æ vÆxu H##ÆurquÆtusq s us ÆqÆxuÆsysy r qt w t A ÆxuÆEuyu GtyuÆWuysu Buqu A yutÆ xuÆuÆqwu 5 - 158 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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x ÆyÆxuÆ@VÆ`P`VCX @VÆ`P`VCXÆyu yuÆv ÆyÆ#Æ vÆxuÆH$ s us ÆqÆxuÆw t s Æ ÆyÆ$Æ vÆxu ByÆs us ÆqÆxuÆyr r ÆÆquÆs yÆyu w t & &Æ Æ( & AxusÆxuÆuyqsuÆ v A ÆxuÆEuyu x yrÆr ÆÆquÆs y GtyuÆWuysu yuÆAP Buqu "Æ ÆyvyyuÆ x VuqsuÆxuÆquÆs y GvÆqÆ xuÆs tuÆqu ÆxuÆtyqÆsuu uvuÆ ÆxuÆvqÆs tu sxqÆv Æ u yv qy Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 159...
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H##ÆurquÆtusq s us ÆqÆxuÆsysy r qt w t AxusÆv ÆqÆ uÆ VuqsuÆxuÆw t x ÆyÆxuÆyrÆr s Ær Æurqu t ÆurquÆr tusqÆSVÆs Æxu qÆxuÆw tÆs EuyuÆGtyuÆWuysu ruuuÆyÆ#Æ vÆxuÆH## Buqu urquÆtusq s us ÆqÆxuÆsysy r qtÆqtÆyÆ&Æ vÆxu H##ÆurquÆtusq s us ÆqÆxuÆsysy r qt w t A ÆxuÆEuyu GtyuÆWuysu Buqu A yutÆ xuÆuÆqwu Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 161...
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yuÆv ÆyÆ#Æ vÆxuÆH$ s us ÆqÆxu qv Æs Ær Æ yÆ$Æ vÆxuÆBy s us ÆqÆxuÆyr r Æt ÆquÆs y yuÆAP w t & &Æ Æ( & AxusÆxuÆuyqsuÆ v A ÆxuÆEuyu x yrÆr Æt ÆquÆs y GtyuÆWuysu yuÆAP Buqu "Æ ÆyvyyuÆ x VuqsuÆxuÆquÆs y GvÆqÆ xuÆs tuÆqu ÆxuÆtyqÆsuu uvuÆ ÆxuÆvqÆs tu sxqÆv Æ u yv qy 5 - 162 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Be sure all other vsy ÆuqruÆr functions operate qtÆqÆr Ævsy normally. r Æu w Ær uut!uqsÆ Ær !t ÆB uÆxu Be sure the batteries Æ uqu7 are fully charged and properly connected. A yutÆ xuÆuÆqwu Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 5 - 163...
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Be sure that all necessary tools and test discovered symptoms equipment are available and ready for use. problem still exists Return to Inspect Perform service and test repair problem solved Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 6 - 1...
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V 61 AXRT – V stands for valve power. 61 stands Foot switch Signal for axle retracted circuit and AXRT is the Forward mnemonic for Axle Retracted. Fuel Select (gas/LP) FUEL 6 - 4 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
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Primary Boom Extend Turntable Rotate Right (CW) Primary Boom Extend/Retract Flow Control PERF Turntable Tilt Alarm Primary Boom Retract Turntable Tilt Sensor TTSR Primary Boom Up Test Switch Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 6 - 5...
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Pri #1 Lockout AC Power Neutral Wire (-) RD/WH 75 Pri #2 Lockout AC Power Hot Wire (+) Pri boom #3 extended Hydraulic Pressure Sensor Output Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 6 - 7...
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Proximity switches are found (•• S-120 and S-125 models only) at the front and rear axle, the turntable and several locations on the boom. 6 - 8 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401...
Used to indicate the presence of Read, understand and obey the safety rules an imminently hazardous situation and operating instructions in the Genie S-100 & which, if not avoided, will result in Genie S-105 Operator’s Manual and the death or serious injury.
How to Calibrate a Joystick Controller. boom up/down and turntable rotate left/right joystick controller Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 4...
5 Remove the control cable plug retaining controls. fasteners from the bottom of the platform 2 Remove the platform control box lid retaining control box. fasteners. Open the control box lid. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 5...
Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 6...
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There should be no calibration faults shown on the 9 Install a new platform controls decal (Genie part display. If calibration faults exist, number 65182) over the membrane decal. repeat steps 1 through 8 for that 10 Open the control box lid and carefuly connect joystick controlled function.
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Result: If the alarm does not sound, repeat the Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1. calibration procedure, beginning with step 1. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 8...
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Result: If the alarm does not sound, repeat the Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1. calibration procedure, beginning with step 1. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 9...
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Result: If the alarm does not sound, repeat the calibration procedure, beginning with step 1. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 10...
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Do not let go of the joystick. There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 11...
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The Emergency Stop button at the platform controls must be pushed in to the position following calibration of the joystick controllers to save the settings in memory. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 12...
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7 Push one of the LCD screen buttons shown until is displayed. EXIT 8 Press the plus button to select and then press the enter button Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 13...
4 to 6 no continuity Single pole (infinite W) double throw (SPDT) terminal 5 to 6 no continuity (infinite W) Double pole double throw (DPDT) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 15...
2 Raise the boom slightly and place blocks under Crushing hazard. The platform the platform. may become unbalanced and fall when it is removed from the machine if it is not properly supported. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 16...
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7 Support the platform leveling cylinder with a Hoses can be damaged if they are suitable lifting device. Protect the cylinder rod kinked or pinched. from damage. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 17...
Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform . Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 18...
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6 Remove the power to platform electrical outlet pivot pin and the platform rotator pivot pin. Do box from the platform and lay it to the side. not remove the pins. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 19...
4 Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the center of the platform floor. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 21...
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There may be a 2 second delay before the platform overload indicator lights and alarm responds. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 22...
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LCD display at the ground S-105 and S-125- 10 lb / 4.5 kg controls. S-100 and S-120- 12 lb / 5.4 kg. There may be a 2 second delay Result: The alarm should be sounding. before the overload indicator lights The platform overload indicator light should be and alarm turn off.
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4 Support the jib boom with a suitable lifting machine if it is not properly device. supported. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 24...
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Protect the cylinder rod from damage. 18 Remove the pin retaining fastener from the platform leveling cylinder rod-end pivot pin. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 25...
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Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 26...
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First Edition • First Printing Section 7 • Repair Procedures This page intentionally left blank. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 27...
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First Edition • First Printing Section 7 • Repair Procedures Boom Components Number 1 Number 2 Number 3 Number 0 Number 1 Number 2 Number 3 Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 28...
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Component damage hazard. Cables, hoses, boom cable tube and cable track can be damaged if they are kinked or pinched. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 29...
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If not removing the boom from the machine, be disconnected are located next proceed to step 25. to the hose fittings that were removed in step 16. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 30...
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Cable tracks can be damaged if 1 Visually inspect the cable track and determine they are twisted. which 3-link section needs to be replaced. 2 Remove the snap-on cable track spacers. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 31...
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11 Tighten the mounting fasteners. 12 Replace the covers. 13 Extend and retract the boom through an entire cycle. Check for tight spots that may cause binding of the boom. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 32...
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14 Remove the boom end cover retaining the rod end of the boom lift cylinder. fasteners from the pivot end of the boom. Remove the cover. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 33...
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The boom envelope switch(s) can be damaged even if the damage is not visible. side access covers Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 34...
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7 Remove the fasteners from the inner cable towards the platform end of the boom track mounting bracket at the primary boom approximately 18 inches / 46 cm. extension cylinder. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 35...
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18 Remove the two cable adjustment bolts. at the platform end of the machine. 19 Remove the cable-end block mounting plate fasteners. Remove the cable-end block mounting plate from the machine. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 36...
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During removal, the overhead plastic boom tube cover at the platform end of crane strap will need to be the machine. Remove the covers. adjusted for proper balancing. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 37...
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During removal, the overhead crane strap will need to be adjusted for proper balancing. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 38...
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47 Attach a lifting strap from an overhead crane to the number 1 boom tube at the platform end of the boom. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 39...
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12 Remove the cable break actuator mounting 5 Disconnect the wiring connector from the cable plate retaining fasteners. Remove the lower break limit switch. plate from the machine. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 40...
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23 Remove the retaining fasteners from the limit switch cover on top of the number 2 boom tube red cable adjustment at the platform end of the machine. locking bracket Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 41...
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During removal, the overhead plastic boom tube cover at the platform end of crane strap will need to be the machine. Remove the covers. adjusted for proper balancing. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 42...
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4 Remove the boom storage area cover retaining fasteners. Remove the cover from the machine. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 43...
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Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 44...
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Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom to a horizontal position. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 45...
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13 Remove the cotter pin and clevis pin from both cables. When installing a clevis pin, always replace the cotter pin with a new one. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 46...
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During removal, the overhead crane strap will need to be adjusted for proper balancing. red cable adjustment locking bracket 19 Remove the two cable adjustment bolts. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 47...
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Do not remove tension equalizer bolt until the the nuts. distance is less than 6 inches / 17 cm. Loosen the jam nut and repeat step 9. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 49...
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16 Start the engine from the platform controls. the number 3 boom tube and the end of the number 2 boom tube should be to 6 inches / 17 to 17.5 cm (d). Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 50...
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8 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 51...
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19 Install the new boom retract pulleys to the pivot end of the boom extension cylinder. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 52...
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Protect the strut cylinder rod from damage. Crushing hazard. The turntable cover will fall when the gas struts are removed if it is not properly supported. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 53...
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Alignment adjustments may be necessary when a new cover is installed. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 54...
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Deutz models- .245 inch / 6.2 mm gap then remove the flex plate from the flywheel. Cummins or Perkins models- .255 inch / 6.5 mm gap Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 55...
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Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. Deutz Engines Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 56...
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Component damage hazard. display at the ground controls. Do not crank the engine with a low oil pressure fault shown on the display at the ground controls. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 57...
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Industries Service Department. When an ECM circuit board is replaced, the proportional valves will need to be calibrated. See 1-3, How to Calibrate a Joystick Controller. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 58...
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Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 59...
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1 Turn the key switch to the position. 2 Open the ground control box and remove the relay to be tested from the ECM circuit board. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 60...
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87 to 87a no continuity (infinite ) terminal 87a to 30 no continuity (infinite ) terminal 87 to 30 continuity (zero ) Control Relay Schematic Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 61...
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First Edition • First Printing Section 7 • Repair Procedures Limit Switches S-100 and S-105 Models S-120 and S-125 Models Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 62...
2 to 3 and 4 no continuity terminal 1 to 3 and 4 no continuity (infinite ) (infinite ) terminal 2 to 3 and 4 no continuity (infinite ) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 63...
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1 Fully retract the boom. 2 Place a digital protractor or digital level on top of the boom tube. Proximity switch target area Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 64...
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LIMIT SWITCHES S-120 and S-125 models: All models: 3 Raise boom until the protractor reads 67.5 14 S-100 and S-105 models: Raise the boom to degrees. 52.5 degrees. 4 Loosen the mounting fasteners from the 68 15 Loosen the mounting fasteners from the 53 degree proximity switch (LSB14AO).
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Extend. If this switch is tripped, then the axle is not fully extended. In this condition, if unit is out of stowed, power is cut to boom up, boom extend and axle retract. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 67...
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100 feet, boom extend and boom down are disabled. The boom retract LED and icon and alarm will flash as long as boom down is operated. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 68...
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The safety cutout is set at +/- 10 from gravity and will disable the primary and secondary boom up/ down functions and the platform level up/down functions. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 69...
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If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 70...
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1 Remove the function pumps. See How to squirt or spray. Remove the Function Pumps. 5 Support the drive pump with a suitable lifting device and remove the two drive pump mounting fasteners. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 71...
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1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to one of the test ports located under the drive pump. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 72...
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Cummins and Perkins models: Connect the wire to the fuel shutoff solenoid at the injector pump. 8 Start the engine and check for hydraulic leaks. Cummins models fuel shutoff solenoid Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 73...
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1. 3 Turn the key switch to ground control and pull out the Emergency Stop button to the position. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 74...
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12 to 18 small post to relay case 2 large posts no continuity (infinite ) small post to no continuity (infinite ) any large post Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 75...
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(schematic item FF) 4.6 3 position 4 way D03 valve, 12V DC (schematic item FD) 5.4 Proportional solenoid valve, 12V DC (schematic item FG) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 76...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 77...
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Solenoid valve, 2 position 3 way ..FR ..Boom extend control ......52-60 ft-lbs / 71-82 Nm Valve Coil Resistance Specification Description Specification 3.4 to 5.4 Solenoid valve, 2 position 3 way, 12V DC (schematic item FQ and FR) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 78...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 79...
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7 Repeat steps 2 through 6 to confirm the relief Tip-over hazard. Do not adjust valve pressure. the relief valve higher than specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 80...
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See 1-3, How to Calibrate a Joystick Controller. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 81...
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3.3 to 5.3 3 position 4 way D03 valve, 12V DC (schematic item BD) 4.3 to 6.3 Proportional solenoid valve, 12V DC (schematic item BG) (9.8 ohm) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 82...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 83...
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(schematic item BN and BO) (7.2 ohm) 3.4 to 5.4 Solenoid valve, 2 position 3 way, 12V DC (schematic item BQ and BR) (4.6 ohm) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 84...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 85...
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7 Repeat steps 2 through 6 to confirm the relief Tip-over hazard. Do not adjust valve pressure. the relief valve higher than specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 86...
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See 1-3, How to Calibrate a Joystick Controller. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 87...
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1 (port P1) ....... 30-35 ft-lbs / 41-47 Nm Valve Coil Resistance Specification Description Specification Solenoid valve, 7.5 to 9.5 2 position 3 way N.O. Poppet 12V DC (schematic item JA) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 88...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 89...
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Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 through 5 to confirm the relief valve pressure. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 90...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS This page intentionally left blank. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 91...
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Joystick Controller. Valve Coil Resistance Specification Description Specification Proportional solenoid valve, 4.4 to 6.4 3 position 4 way 12V DC (schematic items GD and GH) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 92...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 93...
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3 position 4 way ........ CD ..Platform rotate left/right ..... 18-20 ft-lbs / 24-27 Nm Valve Coil Resistance Specification Description Specification Proportional solenoid valve, 4.4 to 6.4 3 position 4 way 12V DC (schematic items CD, CH and CL) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 94...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 95...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 105...
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Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 6 to confirm relief valve pressure. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 106...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS This page intentionally left blank. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 107...
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This list continues. Please turn the page. Valve Coil Resistance Specification Description Specification 7.4 to 9.4 Solenoid valve, 2 position 3 way 12V (schematic items DA) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 108...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 109...
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Solenoid valve, 2 position 3 way ..DO ..Brake control ........25-30 ft-lbs / 38-41 Nm Valve Coil Resistance Specification Description Specification 7.4 to 9.4 Solenoid valve, 2 position 3 way 12V (schematic items DO) Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 110...
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First Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 111...
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4% for each 18°F / 20°C that your air temperature varies from 68°F / 20°C. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 112...
Page 465
AMMETER COIL RESISTOR BATTERY multimeter 9V DC battery 10 resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 113...
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0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 114...
Page 467
Be sure to only use a hand operated pump suitable for use with diesel fuel. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 115...
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Specifications. a suitable container. See capacity specifications. 1 Remove the ground controls side turntable cover. See 5-1, How to Remove a Hinged Turntable Cover. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 116...
Page 469
11 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. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 117...
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2 Remove the ground controls side fixed turntable cover. See 5-1, How to Remove a Fixed motor Turntable Cover. motor/brake mounting bolts brake drive hub mounting bolts drive hub Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 118...
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Apply pipe thread sealant to the plugs and install the plugs. Refer to Section 2, Specifications. 10 Adjust turntable rotation gear backlash. motor motor/brake mounting bolts brake drive hub mounting bolts drive hub Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 119...
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Refer to Section 2, Specifications. turntable rotate drive hub mounting bolts. 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 120...
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First Edition • First Printing Section 7 • Repair Procedures TURNTABLE ROTATION COMPONENTS This page intentionally left blank. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 121...
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5 Repeat step 4 for the other circle-end tire. 2 Press down the foot switch and push the engine idle select button until the engine switches to high rpm. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 122...
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8 Repeat step 4 for the other square-end tire. chassis. 6 Tighten the steer sensor cover fasteners. 7 Repeat steps 2 through 6 for the other square- end steer sensor. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 123...
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Loosen hydraulic end steer sensor. connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 124...
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15 Remove the pin retaining fasteners from the steering cylinder rod-end pivot pins. Remove the pins. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 125...
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2 Remove the drive motor mounting fasteners. 3 Slide the drive motor shaft out of the brake and drive hub. Remove the drive motor from the machine. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 126...
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5 Block the wheels at the opposite end of the machine. 6 Raise the machine approximately 6 inches (15 cm) and place blocks under the chassis for support. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 127...
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Do not allow oil to squirt or spray. 5 Remove the pin retaining fasteners from the steer cylinder pivot pins. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 128...
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5 Extend and retract the axle through an entire cycle. Check for tight spots that could cause binding or scraping of the axle tubes. Always maintain squareness between the inner and outer axle tubes. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 129...
Page 482
Alwayse use a new cotter pin 5 Remove the upper wear pad retainer plate when installing a clevis pin. retaining fasteners. Remove the plate from the machine. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 130...
Page 483
Adjust the proximity 6 Place blocks under the axle extension cylinder switches as necesary to obtain a for support. inch / 3.1 mm gap. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 131...
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10 Carefully support and slide the axle extension cylinder out of the axle. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. Part No. 62401 Genie S-100 • S-105 • S-120 • S-125 7 - 132...
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Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in 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.
Page 490
Proximity kill switch OR platform overload sensing: none, prox, plat overload Work light: yes, no Flashing beacon: yes, no Drive lights: yes, no Steer mode change while driving: yes, no 8 - 6 Genie S-120 & Genie S-125 Part No. 62401...
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All other numbers remain the same. V 61 AXRT – V stands for valve power. Number 61 stands for axle retracted circuit, AXRT stands for Axle Retracted. Part No. 62401 Genie S-120 & Genie S-125 8 - 7...
Platform rotate right valve Limit switch signal boom GR/WH Jib boom select valve circuit stowed position 12V DC battery supply OR/BK RPM signal 12V DC ignition supply OR/RD Boom retracted signal 8 - 8 Genie S-120 & Genie S-125 Part No. 62401...
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RD/BK Safety interlock to engine GR/WH Cable break circuit GR/WH Axle extend Axle retract Boom stowed (safety) OR/RD Power to boom envelope safety switch OR/BL Power to operational switches Part No. 62401 Genie S-120 & Genie S-125 8 - 9...
Page 494
The laptop can be connected to the ground controls via a tee harness connector (Genie part number 75094). The Web GPI software can access all adjustable parameters for the machine. It can also be used to aid in troubleshooting and viewing fault code history.
Page 495
Platform Controls PC Board to Membrane Decal S56PRV-RD 1 of 2 Genie Part number 62304 GNDDCON-BR Black 23 Pin AMP connector - Drive Chassis Controller to Drive Chassis Harness White 23 Pin AMP connector - Drive Chassis Controller to Drive Chassis Harness...
Page 496
2 of 2 White 23 Pin AMP connector - Ground Controls to Engine Harness Genie Part number 62304 White 35 Pin AMP connector - Ground Controls to Function Manifold Black 4 Way Molex connector - Ground Controls to Engine Harness...
Page 497
Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Holland Genie Australia Pty Ltd. Phone Phone 31 70 51 78836 1 61 7 3375 1660 31 70 51 13993 1 61 7 3375 1002 Genie Denmark...
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