Serviceandrepairmanual: Serial Number Range

ServiceandRepairManual
Serial Number Range
from S-10015D-1001
to S-10016D-1549 This manual includes:
Repair procedures
from S-10515D-983 Fault Codes
to S-10516D-1549
Electrical and Hydraulic
® from S-12015D-1012
Schematics
to S-12016D-1549
® from S-12515D-984
to S-12516D-1549
For detailed maintenance
procedures, Refer to the
from S-100D-1550 appropriate Maintenance
from S-105D-1550 Manual for your machine.
from S-120D-1550
from S-125D-1550
Part No. 1268494

Rev B
January 2019
Introduction January 2019
Introduction
Important Technical Publications
Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the Genie S-100 and degree of accuracy possible. However, continuous
Genie S-105 Operator's Manual or the Genie improvement of our products is a Genie policy.
S-120 and Genie S-125 Operator's Manual before Therefore, product specifications are subject to
attempting any maintenance or repair procedure. change without notice.
This manual provides troubleshooting and repair Readers are encouraged to notify Genie of errors
procedures for qualified service professionals. and send in suggestions for improvement. All
communications will be carefully considered for
Basic mechanical, hydraulic and electrical skills are future printings of this and all other manuals.
required to perform most procedures. However,
several procedures require specialized skills,
tools, lifting equipment and a suitable workshop. Contact Us:
In these instances, we strongly recommend that
maintenance and repair be performed at an Internet: www.genielift.com
authorized Genie dealer service center. E-mail: [email protected]
Compliance Find a Manual for this Model

Machine Classification Go to http://www.genielift.com
Group B/Type 3 as defined by ISO 16368
Use the links to locate Operator's, Parts or Service
Machine Design Life Manuals.
Unrestricted with proper operation, inspection and
Hyper link is:http://www.genielift.com/en/service-
scheduled maintenance.
support/manuals/index.htm
Copyright © 2015 by Terex Corporation
1268494 Rev B January 2019

Second Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc.in

the U.S.A and many other countries.
ii S-100 • S-105 • S-120 • S-125 Part No. 1268494

January 2019 Introduction
Introduction
Revision History
Revision Date Section Procedure / Description
A 9/2015 Initial Release
Add Deutz TD201104i Engine &
A1 1/2016 Electrical schematics
A2 9/2016 Introduction Serial Number Legend
A3 2/2017 Specifications Performance Specifications
A4 3/2017 Repair Procedures Update illustration for cable adjustment

Update Platform Manifold Components,
A5 7/2017 Repair Procedures S-105 and S-125 Models
Engine Options- Perkins
(S-100 from serial number S100D-1674)
Engine Options- Cummins
Perkins 1104D-44T Engine Electrical
Schematic
Perkins 854F-34T Engine Electrical
Schematic
Deutz TD2011L04i Engine Electrical
Schematic
Deutz TD2.9 Engine Electrical
B 1/2019 Schematics Schematic
Reference Examples:
Section - Repair Procedure
Section - Fault Codes
Section - Schematics,Legends and schematics
Part No. 1268494 S-100 • S-105 • S-120 • S-125 iii

Introduction January 2019
Introduction
Serial Number Legend
To August 31, 2016
S120 16 D - 12345
1 2 3 4
Model:
Serial number: S12016D-12345
Manufacture date: 1/2/16 Model year: 2016
Electrical schematic number:
Machine unladen weight:
Rated work load (including occupants):
Maximum number of platform occupants:
Maximum allowable side force:
Maximum allowable inclination of the chassis:
5 6
1 Model 4 Sequence number

2 Model year 5 Serial label (located under cover)
3 Facility code 6 Serial number (stamped on chassis)
From September 1, 2016
S120 D - 12345
1 2 3
Model:
Serial number: S120D-12345
Year of manufacture: 2016
Electrical schematic number:
Machine unladen weight:
Rated work load (including occupants):
Maximum number of platform occupants:
Maximum allowable side force:
Maximum allowable inclination of the chassis:
4 5
1 Model 4 Serial label (located under cover)

2 Facility code 5 Serial number (stamped on chassis)
3 Sequence number

iv S-100 • S-105 • S-120 • S-125 Part No. 1268494
January 2019 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. 1268494 S-100 • S-105 • S-120 • S-125 v

Section 1 - Safety Rules January 2019
Safety Rules
Personal Safety Be sure to wear protective eye wear and
other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
Read each procedure thoroughly. This manual and placing loads. Always wear approved steel-toed
the decals on the machine, use signal words to shoes.
identify the following:
Workplace Safety
Safety alert symbol—used to alert
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable
messages that follow this symbol and combustible materials like battery
to avoid possible injury or death. gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Used to indicate the presence of
an imminently hazardous situation Be sure that all tools and working areas
which, if not avoided, will result in are properly maintained and ready for
death or serious injury. use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
a potentially hazardous situation
which, if not avoided, could result Be sure any forklift, overhead crane or
in death or serious injury. other lifting or supporting device is fully
With safety alert symbol—used capable of supporting and stabilizing the
to indicate the presence of a weight to be lifted. Use only chains or straps that
potentially hazardous situation are in good condition and of ample capacity.
which, if not avoided, may cause Be sure that fasteners intended for one
minor or moderate injury. time use (i.e., cotter pins and self-locking
Used to indicate the presence of nuts) are not reused. These components
a potentially hazardous situation may fail if they are used a second time.
which, if not avoided, may result in
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.

vi S-100 • S-105 • S-120 • S-125 Part No. 1268494
January 2019
Table of Contents
Introduction
Important Information.................................................................................................... ii
Revision History........................................................................................................... iii

Serial Number Legend................................................................................................. iv
Section 1 Safety Rules

General Safety Rules.................................................................................................... v
Section 2 Specifications
Machine Specifications, S120 and S-125 Models....................................................2 - 1
Performance Specifications, S120 and S-125 Models.............................................2 - 2
Machine Specifications, S100 and S-105 Models....................................................2 - 3
Performance Specifications, S100 and S-105 Models.............................................2 - 5
Hydraulic Specifications...........................................................................................2 - 6
Hydraulic Component Specifications.......................................................................2 - 8
Deutz Engine F4L 913 Specifications....................................................................2 - 11
Deutz Engine BF4L 2011 Specifications................................................................2 - 12
Deutz Engine TD2011L04i Specifications..............................................................2 - 13
Deutz Engine TD 2.9 Specifications.......................................................................2 - 14
Perkins Engine 1104D-44T Specifications.............................................................2 - 15
Perkins Engine 854F-34T Specifications...............................................................2 - 16
Perkins Engine 1004-42 Specifications..................................................................2 - 18
Perkins Engine 1104C-44 Specifications...............................................................2 - 19
Perkins Engine 804D-33T Specifications...............................................................2 - 20
Cummins Engine B3.3T Specifications..................................................................2 - 22
Cummins Engine B3.9L Specifications..................................................................2 - 23
Cummins Engine B4.5L Specifications..................................................................2 - 24
Machine Torque Specifications...............................................................................2 - 25
Manifold Plug Torque Specifications......................................................................2 - 25
Hydraulic Hose and Fitting Torque Specifications..................................................2 - 26
SAE and Metric Fasteners Torque Charts..............................................................2 - 26
Part No. 1268494 S-100 • S-105 • S-120 • S-125 vii

January 2019
table of contents
Section 3 Repair Procedures

Introduction..............................................................................................................3 - 1
Display Module.........................................................................................................3 - 2
Platform Controls
1-1 Circuit Boards.................................................................................................3 - 7
1-2 Membrane Decal............................................................................................3 - 8
1-3 Joystick Controllers........................................................................................3 - 9
Platform Components
2-1 Platform........................................................................................................3 - 16
2-2 Platform Leveling Cylinder............................................................................3 - 16
2-3 Platform Rotator...........................................................................................3 - 18
2-4 Platform Level Sensor..................................................................................3 - 21
2-5 Platform Overload System...........................................................................3 - 22
2-6 Platform Overload Recovery Message(Software V3.14 and later)...............3 - 25
Jib Boom Components, S-105 and S-125 Models
3-1 Jib Boom, S-105 and S-125 Models.............................................................3 - 26
3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models.........................................3 - 28
Boom Components
4-1 Cable Track...................................................................................................3 - 30
4-2 Boom............................................................................................................3 - 33
4-3 Boom Lift Cylinder........................................................................................3 - 44
4-4 Extension Cylinders......................................................................................3 - 46
4-5 Boom Extend/Retract Cables.......................................................................3 - 50
Turntable Covers
5-1 Turntable Covers..........................................................................................3 - 54

viii S-100 • S-105 • S-120 • S-125 Part No. 1268494
January 2019
table of contents
Section 3 Repair Procedures, continued

Engines
6-1 RPM Adjustment..........................................................................................3 - 56
6-2 Flex Plate......................................................................................................3 - 56
6-3 Oil Pressure and Coolant Temperature Sending Units,
Cummins and Perkins Models......................................................................3 - 58
6-4 Oil Pressure and Temperature Sending Units, Deutz Models......................3 - 58
Ground Controls
7-1 Circuit Boards...............................................................................................3 - 59
7-2 Membrane Decal..........................................................................................3 - 60
7-3 Control Relays..............................................................................................3 - 61
Limit Switches
8-1 Limit Switches..............................................................................................3 - 64
8-2 Limit Switch and Level Sensor Locations.....................................................3 - 67
8-3 Limit Switch Functions..................................................................................3 - 68
Hydraulic Pumps
9-1 Function Pumps...........................................................................................3 - 71
9-2 Drive Pump...................................................................................................3 - 72
9-3 Auxiliary Pump.............................................................................................3 - 75
Manifolds
10-1 Function Manifold Components, S-100 and S-105 Models
(serial number 136)......................................................................................3 - 77
(after serial number 136)..............................................................................3 - 81
10-3 Valve Adjustments - Function Manifold, S-100 and S-105 Models...............3 - 85
10-4 Proportional Valves - Function Manifold.......................................................3 - 86

Part No. 1268494 S-100 • S-105 • S-120 • S-125 ix

January 2019
table of contents

(before serial number 431)...........................................................................3 - 87
(from serial number 431 to 574)...................................................................3 - 91
(after serial number 574)..............................................................................3 - 95
10-8 Valve Adjustments - Function Manifold, S-120 and S-125 Models...............3 - 99
10-9 Proportional Valves - Function Manifold.....................................................3 - 100
10-10 Platform Manifold Components, S-100 and S-120 Models........................3 - 101
10-11 Platform Manifold Components, S-105 and S-125 Models........................3 - 103
10-12 Proportional Valves - Platform Manifolds....................................................3 - 105
10-13 Platform Rotate Counterbalance Valve Manifold Components...................3 - 105
10-14 Turntable Rotation Manifold Components..................................................3 - 106
10-15 Steer and Axle Extend/Retract Manifold Components - View 1.................3 - 107
10-16 Steer and Axle Extend/Retract Manifold Components - View 2.................3 - 109
10-17 Valve Adjustments - Steer and Axle Extend/Retract Manifold....................3 - 113
10-18 Traction Manifold Components
(S-100/105 before serial number 291)
(S-120/125 before serial number 1195)......................................................3 - 115
10-19 Traction Manifold Components
(S-100/105 after serial number 290)
(S-120/125 after serial number 1194)........................................................3 - 119
10-20 Valve Adjustments - Traction Manifold........................................................3 - 123
10-21 Valve Coils..................................................................................................3 - 123
x S-100 • S-105 • S-120 • S-125 Part No. 1268494

January 2019
table of contents

Fuel and Hydraulic Tanks
11-1 Fuel Tank....................................................................................................3 - 126
11-2 Hydraulic Tank............................................................................................3 - 127
Turntable Rotation Components
12-1 Turntable Rotation Hydraulic Motor and Drive Hub....................................3 - 129
Axle Components
13-1 Steer Sensors.............................................................................................3 - 133
13-2 Yoke and Hub.............................................................................................3 - 135
13-3 Drive Motor.................................................................................................3 - 137
13-4 Drive Hub...................................................................................................3 - 138
13-5 Steering Cylinders......................................................................................3 - 139
13-6 Extendable Axles........................................................................................3 - 140
Section 4 Diagnostic Codes

Introduction..............................................................................................................4 - 1
Diagnostic Code Chart.............................................................................................4 - 3
Control System Fault Codes....................................................................................4 - 9
Deutz TD 2.9 L4 Engine Fault Codes.....................................................................4 - 13
Perkins 854F-34T Engine Fault Code....................................................................4 - 28
Software.................................................................................................................4 - 37
Part No. 1268494 S-100 • S-105 • S-120 • S-125 xi

January 2019
table of contents
Section 5 Schematics
Introduction..............................................................................................................5 - 1
Circuit Numbering....................................................................................................5 - 2
Wire Color Legend...................................................................................................5 - 4
Limit Switches..........................................................................................................5 - 8
Relay Layout..........................................................................................................5 - 10
Drive Chassis Controller Pin Legend.....................................................................5 - 11
Platform Controller Pin Legend..............................................................................5 - 12
Turntable Controller Pin Legend.............................................................................5 - 13
Engine Relay and Fuse Panel Legend -
Deutz TD2011 and Perkins 1104D Models..................................................5 - 14
Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models...............................5 - 15
Engine Relay and Fuse Panel Legend - Perkins 854F Models..............................5 - 16
Telematics Connector Pin Legend.........................................................................5 - 17
Electrical Symbols Legend.....................................................................................5 - 18
Hydraulic Symbols Legend....................................................................................5 - 19
Safety Circuit Schematic........................................................................................5 - 21
(S-100 from serial number S100D-1001 to 1381)
(S-125 from serial number S125D-984 to 1333)..........................................5 - 23
(S-125 from serial number S125D-1334 to 1715)........................................5 - 25

xii S-100 • S-105 • S-120 • S-125 Part No. 1268494
January 2019
table of contents
Section 5 Schematics,continued
(S-125 from serial number S125D-1716).....................................................5 - 27
(S-125 from serial number S125D-984).......................................................5 - 29
(S-125 from serial number S125D-984 to 1333)..........................................5 - 31
(S-125 from serial number S125D-1334 to 1715)........................................5 - 33
(S-125 from serial number S125D-1716).....................................................5 - 35
Electrical Schematic - Generator Options..............................................................5 - 37
Electrical Schematic - 12 kW Generator (welder option).......................................5 - 39
Electrical Schematic (ES0509)
(S-125 from serial number S125D-984).........................located at end of manual
Perkins 1104D-44T Engine Electrical Schematic...................................................5 - 41
Perkins 854F-34T Engine Electrical Schematic.....................................................5 - 43
Perkins 854F-34T Engine Electrical Harness........................................................5 - 45
Part No. 1268494 S-100 • S-105 • S-120 • S-125 xiii

January 2019
table of contents
Section 5 Schematics,continued
Deutz TD2011L04i Engine Electrical Schematic....................................................5 - 47
Deutz TD2.9 Engine Electrical Schematic.............................................................5 - 49
Deutz TD2.9 Engine Electrical Harness.................................................................5 - 51
Hydraulic Schematic - 12 kW Generator (welder option)......................................5 - 53
Hydraulic Schematic, S-100 • S-105
(serial number 136)......................................................................................5 - 55
(from serial number 137 to 290)...................................................................5 - 57
from serial number 291 to serial number 738).............................................5 - 59
from serial number 739)...............................................................................5 - 61
(from serial number 404 to serial number 430)............................................5 - 63
(from serial number 431 to serial number 1194)..........................................5 - 65
(from serial number 1195 to serial number 2634)........................................5 - 67
(from serial number 2635 to serial number 3145)........................................5 - 69
(from serial number 3146 to serial number S12514D-921)..........................5 - 71
(from serial number S12514D-922)..............................................................5 - 73

xiv S-100 • S-105 • S-120 • S-125 Part No. 1268494
January 2019 Section 2 • Specifications
Specifications
Machine Specifications, Turning radius, inside,
axles retracted
13 ft 2 in
4.01 m
13 ft 2 in
4.01 m
S-120 and S-125 Models Turning radius, outside, 18 ft 10 in 18 ft 10 in
Stowed dimensions S-120 S-125 axles extended 5.74 m 5.74 m
Length, transport position 39 ft 11 in 39 ft 11 in Turning radius, inside, 8 ft 6 in 8 ft 6 in

12.17 m 12.17 m axles extended 2.59 m 2.59 m
Length, stowed 42 ft 8 in 46 ft 9 in Turntable rotation (degrees) 360° continuous

13 m 14.25 m Platform rotation 160°
Width, axles retracted 8 ft 2 in 8 ft 2 in Maximum allowable 150 lbs
249 cm 249 cm side force (ANSI and CSA) 667 N
Width, axles extended 11 ft 11 ft Maximum allowable 90 lbs
335 cm 335 cm side force (CE) 400 N
Height, stowed maximum 10 ft 1 in 10 ft 1 in Controls 12V DC proportional
308 cm 308 cm Platform dimensions
Weight 44,340 lbs 44,640 lbs Length 96 in
20,112 kg 20,248 kg 244 cm
Ground clearance 15 3/4 in 15 3/4 in Width 36 in
40 cm 40 cm 91 cm
Operational dimensions Tires and wheels
Platform height, maximum 120 ft 125 ft Tire size 445/65D22.5, FF
36.6 m 38.1 m
Tire ply rating 18
Working height, maximum 126 ft 131 ft
38.4 m 39.9 m Tire weight, new foam-filled (minimum) 815 lbs
370 kg
Horizontal reach maximum 75 ft 80 ft
22.9 m 24.4 m Overall tire diameter 46.5 in
118 cm
Maximum load capacity 750 lb 500 lb
340 kg 227 kg Wheel diameter 22.5 in
57 cm
Turntable tailswing, 66 in 66 in
axles retracted 168 cm 168 cm Wheel width 13 in
33 cm
Turntable tailswing 48 in 48 in
axles extended 122 cm 122 cm Wheel lugs 10 @ 3/4 -16
Wheelbase 12 ft 12 ft Lug nut torque, dry 420 ft-lbs

366 cm 366 cm 570 Nm
Turning radius, outside, 22 ft 2 in 22 ft 2 in Lug nut torque, lubricated 320 ft-lbs

axles retracted 6.75 m 6.75 m 434 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-1

Section 2 • Specifications January 2019
Specifications
Fluid capacities Performance Specifications,

Hydraulic tank 55 gallons
208 liters
S-120 and S-125 Models
Hydraulic system 80 gallons Drive speeds
(including tank) 303 liters High drive speed, stowed 8.0 - 8.4 sec 36 ft / 11 m
Fuel tank 40 gallons Low drive speed, stowed 14.4 - 16.4 sec 18 ft / 5.5 m
151 liters High drive speed,
Coolant capacity 20 quarts non-stowed < 80 ft 18 - 20 sec 18 ft / 5.5 m
18.9 liters High drive speed,
Drive hubs 47 oz non-stowed > 80 ft 32.6 - 36.6 sec 18 ft / 5.5 m
1.4 liters Braking distance, maximum
Turntable rotation 93 oz High range on paved surface 4 to 6 ft
drive hub 2.8 liters 1.2 to 1.8 m
Drive hub oil type: Gradeability (boom stowed) See Operators Manual
SAE 90 multipurpose hypoid gear oil API service
Boom function speeds, maximum
classification GL5
from platform controls
Jib boom up (S-125 models) 28 to 32 seconds
For operational specifications, refer to the Jib boom down (S-125 models) 28 to 32 seconds
Operator's Manual.
Boom up
Boom fully retracted 80 to 88 seconds
Boom extended to >4 ft / >1.2 m 100 to 110 seconds
(time between fully lowered and
a fully raised position)
(time between 53° envelope
limit and a fully raised position)
limit and a fully raised position)
Boom down
(time between fully raised and
a fully lowered position)
the 50° envelope limit)
Boom extend
vertical, 0 to 120 ft / 0 to 36.6 m 170 to 190 seconds
Boom retract
vertical, 120 ft to 0 / 36.6 m to 0 170 to 190 seconds
2 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Turntable rotate, 360°

boom horizontal and
Machine Specifications,
fully retracted 170 to 190 seconds S-100 and S-105 Models
Turntable rotate Stowed dimensions S-100 S-105
boom horizontal and 63 to 70 seconds
extended >0 ft / >0 m drive enable to drive enable Length, transport position 39 ft 11 in 39 ft 11 in
12.17 m 12.17 m
Turntable rotate
boom fully raised and 109 to 120 seconds Length, stowed 42 ft 8 in 46 ft
extended >80 ft / >24.4 m drive enable to drive enable 13 m 14 m
Platform rotate, 160° 18 to 22 seconds Width, axles retracted 8 ft 2 in 8 ft 2 in

249 cm 249 cm
Width, axles extended 11 ft 11 ft
335 cm 335 cm
Height, stowed maximum 10 ft 1 in 10 ft 1 in
308 cm 308 cm
Weight 39,700 lbs 40,000 lbs
18,007 kg 18,143 kg
Ground clearance 151/2 in 151/2 in
39 cm 39 cm
Operational dimensions
Platform height, maximum 100 ft 105 ft
120 ft / 36.6 m 30.5 m 32 m
Working height, maximum 106 ft 111 ft
110 ft / 33.5 m LSB14AO
68 O
LSB9AS
65 O 32.3 m 33.8 m
100 ft / 30.5 m Horizontal reach maximum 75 ft 80 ft
LSB2RS
LSB2RO
102 ft 101 ft (30.8 m) 22.9 m 24.4 m
90 ft / 27.4 m (31.1 m)
LSB4EO
Maximum load capacity 750 lb 500 lb
80 ft / 24.4 m
100 ft (30.5 m) 340 kg 227 kg
LSB13AO
53 O
LSB8AS
50 O
Turntable tailswing, 66 in 66 in
70 ft / 21.3 m
axles retracted 168 cm 168 cm
LSB4ES
60 ft / 18.3 m 75.5 ft Turntable tailswing 48 in 48 in
(23 m)
LSB3EO
axles extended 122 cm 122 cm
50 ft / 15.2 m 75 ft
(22.9 m) Wheelbase 12 ft 12 ft
40 ft / 12.2 m 366 cm 366 cm
Turning radius, outside, 21 ft 7 in 21 ft 7 in
30 ft / 9.1 m
axles retracted 6.58 m 6.58 m
LSB7DS
20 ft / 6.1 m LSB1DO
10 O
11 O Turning radius, inside, 13 ft 7 in 13 ft 7 in
axles retracted 4.14 m 4.14 m
10 ft / 3 m
LSB3RO LSB3RS
3 ft (0.9 m) 3.5 ft (1.1 m)
0 ft / 0 m
10 ft / 3 m
0 ft / 0 m
50 ft / 15.2 m
60 ft / 18.3 m
70 ft / 21.3 m
-10 ft / -3 m
20 ft / 6.1 m
30 ft / 9.1 m
40 ft / 12.2 m
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-3

Specifications
Turning radius, outside, 19 ft 10 in 19 ft 10 in Fluid capacities

axles extended 6.05 m 6.05 m Hydraulic tank 55 gallons
Turning radius, inside, 9 ft 9 ft 208 liters
axles extended 2.74 m 2.74 m Hydraulic system 80 gallons
Turntable rotation (degrees) 360° continuous (including tank) 303 liters
Platform rotation 160° Fuel tank 40 gallons
Maximum allowable 150 lbs 151 liters
side force (ANSI and CSA) 667 N Coolant capacity 20 quarts
Maximum allowable 90 lbs 18.9 liters
side force (CE) 400 N Drive hubs 47 oz
Controls 12V DC proportional 1.4 liters
Platform dimensions Turntable rotation 93 oz

drive hub 2.8 liters
Length 96 in
244 cm Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
Width 36 in classification GL5
91 cm
Tires and wheels
For operational specifications, refer to the
Tire size IN385/65D22.5, FF
Operator's Manual.
Tire ply rating 18
Tire weight, new foam-filled (minimum) 622 lbs
282 kg
Overall tire diameter 43.1 in
109.5 cm
Wheel diameter 22.5 in
57 cm
Wheel width 11.75 in
30 cm
Wheel lugs 10 @ 3/4 -16
Lug nut torque, dry 420 ft-lbs
570 Nm
Lug nut torque, lubricated 320 ft-lbs
434 Nm
2 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Performance Specifications, Boom extend, boom fully raised

0 to 100 ft / 0 to 30.5 m 120 to 140 seconds
S-100 and S-105 Models Boom retract, boom fully raised
Drive speeds 100 ft to 0 / 30.5 m to 0 120 to 140 seconds
High drive speed, stowed 8.0 - 8.4 sec 36 ft / 11 m Turntable rotate, 360°
boom horizontal and
Low drive speed, stowed 14.4 - 16.4 sec 18 ft / 5.5 m
fully retracted 170 to 190 seconds
High drive speed,
non-stowed < 80 ft 18 - 20 sec 18 ft / 5.5 m Turntable rotate
boom horizontal and 63 to 70 seconds
High drive speed,
extended >0 ft / >0 m drive enable to drive enable
non-stowed > 80 ft 32.6 - 36.6 sec 18 ft / 5.5 m
Turntable rotate
Braking distance, maximum
boom fully raised and 109 to 120 seconds
High range on paved surface 4 to 6 ft extended >80 ft / >24.4 m drive enable to drive enable
1.2 to 1.8 m
Platform rotate, 160° 18 to 22 seconds
Gradeability (boom stowed) See Operator's Manual
Boom function speeds, maximum
from platform controls
Jib boom up (S-105 models) 28 to 32 seconds
Jib boom down (S-105 models) 28 to 32 seconds
Boom up
(time between fully lowered and
a fully raised position) 120 ft / 36.6 m
Boom extended to >80 ft / >24.4 m 50 to 55 seconds 110 ft / 33.5 m

limit and a fully raised position) 100 ft / 30.5 m
Boom down 90 ft / 27.4 m

80 ft / 24.4 m LSB13AO LSB8AS
Boom extended to >4 ft / >1.2 m 100 to 110 seconds 53 50
(time between fully raised and 70 ft / 21.3 m

a fully lowered position) LSB3EO LSB4ES
75 ft 75.5 ft
(22.9 m)
Boom extended to >80 ft / >24.4 m 50 to 55 seconds 60 ft / 18.3 m (23 m)
(time between fully raised and 50 ft / 15.2 m

40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS
LSB1DO 11
20 ft / 6.1 m 10
10 ft / 3 m
LSB3RO LSB3RS
3 ft (0.9 m) 3.5 ft (1.1 m)
0 ft / 0 m
10 ft / 3 m
0 ft / 0 m
50 ft / 15.2 m
70 ft / 21.3 m
60 ft / 18.3 m
-10 ft / -3 m
20 ft / 6.1 m
30 ft / 9.1 m
40 ft / 12.2 m
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-5

Specifications
Hydraulic Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic
Hydraulic Fluid Specifications fluids may be incompatible
Genie specifications require hydraulic oils which are due to the differences in base
designed to give maximum protection to hydraulic additive chemistry. When
systems, have the ability to perform over a wide incompatible fluids are mixed,
temperature range, and the viscosity index should insoluble materials may form and
exceed 140. They should provide excellent antiwear, deposit in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression
control valves and may result in
properties.
component damage.
Cleanliness level, minimum ISO 15/13
Note: Do not operate the machine when the ambient
Water content, maximum 250 ppm
air temperature is consistently above 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium
Viscosity grade 32
Hydraulic Fluid Temperature
Viscosity index 200
Range
Optional Hydraulic fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
1
Chevron 5606A
Biodegradable Petro Canada Environ MV 46 2
Fire resistant UCON Hydrolube HP-5046 3
4
Note: Genie specifications require additional
equipment and special installation instructions for the
approved optional fluids. Consult the Genie Product -40 -22 -4 14 32 50 68 86 104 122 F
Support before use. -40 -30 -20 -10 -0 10 20 30 40 50 C
Optional fluids may not have the Ambient air temperature

same hydraulic lifespan and may
1 Chevron hydraulic oil 5606A
result in component damage.
2 Petro-Canada Environ MV 46
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's 3 UCON Hydrolube HP-5046D
maximum allowable range. if the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an 4 Chevron Rando HD premium oil MV
optional oil cooler may be required.
2 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
Brookfield Viscosity cSt @ -40°F / -40°C 510
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310 Pour point -81°F / -63°C
Flash point 375°F / 190°C Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C
temperature Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
Note: An hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil heating
recommended when the ambient temperature is system is used.
consistently below 0°F / -18°C .
Continued use of Chevron
Note: Do not operate the machine when the ambient 5606A hydraulic fluid, or
temperature is below -20°F / -29°C with Rando HD equivalent, when ambient
Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-7

Specifications
Petro-Canada Environ MV 46 Hydraulic Component

Fluid Properties Specifications
ISO Grade 46 Drive pump
Viscosity index 154 Type: bi-directional variable displacement piston pump
Kinematic Viscosity Displacement 0 to 2.8 cu in
cSt @ 200°F / 100°C 8.0 0 to 46 cc
cSt @ 104°F / 40°C 44.4 Flow rate @ 2350 rpm, maximum 28.5 gpm
Flash point 482°F / 250°C 108 L/min
Pour point -49°F / -45°C Drive pressure, maximum 3625 psi
Maximum continuous operating 180°F / 82°C 250 bar
temperature Charge pump
Type: gerotor
UCON Hydrolube HP-5046 Fluid Displacement

0.85 cu in
13.9 cc
Properties Flow rate @ 2350 rpm 9 gpm
ISO Grade 46 34 L/min
Viscosity index 192 Charge pressure @ 2350 rpm 315 psi

Neutral position 21.7 bar
Kinematic Viscosity
cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 46 Function pump
cSt @ 0°F / -18°C 1300 Type: variable displacement piston pump
Flash point None Front Section
Pour point -81°F / -63°C Displacement 0 to 1.71 cu in
Maximum continuous operating 189°F / 87°C 0 to 28 cc
temperature Flow rate @ 2350 rpm, maximum 17.4 gpm
65.9 L/min
2 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Rear Section Steer/Axle manifold

Displacement 0 to 1.1 cu in Axle extend relief pressure 1800 psi
0 to 18 cc 124 bar
Flow rate @ 2350 rpm, maximum 11.2 gpm Drive manifold
42.4 L/min Hot oil relief pressure:
Pressure, maximum continuous 3350 psi S-100/105 before serial number 291 250 psi
231 bar S-120/125 before serial number 1195 17.2 bar
Standby pressure 250 psi Hot oil relief pressure:
17 bar S-100/105 after serial number 290 280 psi
S-120/125 after serial number 1194 19.3 bar
Auxiliary pumps Brakes
Type: fixed displacement gear pump Brake release pressure 174-189 psi
12-13 bar
Displacement 0.15 cu in
2.47 cc Drive motors
Displacement per revolution, 0.8 cu in
high speed 13.3 cc
Function manifold
Displacement per revolution, 2.7 cu in
Function relief pressure 2600 psi low speed 45 cc
(measured at test port) 179.3 bar
Platform relief pressure 3000 psi
(measured at test port 2) 207 bar
Jib and platform manifolds
Platform rotate and platform level 0.3 gpm
flow regulator 1.14 L/min
Jib manifold flow regulator 2 gpm
7.6 L/min
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-9

Specifications
Hydraulic filters
High pressure filter Beta 3 ≥ 200
High pressure filter 102 psi
bypass pressure 7 bar
Medium pressure filter Beta 3 ≥ 200
Medium pressure filter 25 psi
bypass pressure 1.7 bar
Hydraulic tank 10 micron with
return filter 25 psi / 1.7 bar bypass
Drive motor case drain Beta 10 ≥ 2
return filter
2 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Deutz Engine F4L 913 Injection system

Injection pump make IMSA
Displacement 249.3 cu in
Injection pump pressure 8702 psi
4.086 liters
600 bar
Number of cylinders 4
Injector opening pressure 3626 psi
Bore and stroke 4.02 x 4.92 inches 250 bar
102 x 125 mm
Fuel requirement
Horsepower 77 @ 2200 rpm
For fuel requirements, refer to the engine Operator's
Firing order 1-3-4-2 Manual on your machine.
Compression ratio 18:1 Alternator output 55A, 12 VDC
Compression pressure Fan belt deflection 3/8 to 1/2 inch
pressure (psi or bar) of the lowest cylinder must be at 9 to 12 mm
least 75% of the highest cylinder.
Battery - Engine starting
Low idle rpm 1300 rpm
Type 12V, Group 31
Frequency 385.7 Hz
Quantity 1
High idle rpm 2350 rpm Cold cranking ampere 1000A
Frequency 570.4 Hz Reserve capacity @ 25A rate 175 minutes
Valve clearance, cold Battery - Control system
Intake 0.006 in Type 12V DC, Group 4D
0.15 mm Quantity 1
Exhaust 0.006 in Cold cranking ampere 1020A
0.15 mm Reserve capacity @ 25A rate 300 minutes
Lubrication system
Oil pressure 40 to 60 psi
2.75 to 4.14 bar
Oil capacity 14.3 quarts
(including filter) 13.5 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 11

Specifications
Deutz BF4L 2011 Engine Oil temperature switch

Torque 8-18 ft-lbs
Displacement 189.6 cu in 11-24 Nm
3.1 liters
Oil temperature switch point 275°F
Number of cylinders 4 135°C
Bore and stroke 3.7 x 4.409 inches Oil pressure switch
94 x 112 mm
Torque 8-18 ft-lbs
Horsepower 11-24 Nm
Continuous @ 2500 rpm 69.1 Oil pressure switch point 7 psi
Net intermittent @ 2500 rpm 72.8 0.48 bar
Firing order 1-3-4-2 Fuel injection system
Low idle rpm 1500 rpm Injection pump make Bosch
Frequency 382.5 Hz
Injection pump pressure, maximum 15,000 psi
High idle rpm 2350 rpm 1034 bar
Frequency 599.25 Hz
Compression ratio 17.5:1 210 bar
Compression pressure Fuel requirement
Pressure (psi or bar) of the lowest cylinder must be at
Manual on your machine.
Governor centrifugal mechanical
Starter motor
Valve clearance, cold
Current draw, normal load 140-200A
Intake 0.012 in
Cranking speed 200-250 rpm
0.3 mm
Battery - Engine starting
Exhaust 0.020 in
0.5 mm Type 12V, Group 31
Quantity 1
Lubrication system
Cold cranking ampere 1000A
Oil pressure, hot 40 to 60 psi Reserve capacity @ 25A rate 175 minutes
(at 2000 rpm) 2.8 to 4.1 bar
Battery - Control system
Type 12V DC, Group 4D
Quantity 1
Oil viscosity requirements Cold cranking ampere 1020A
Units ship with 15W-40. Reserve capacity @ 25A rate 300 minutes
Extreme operating temperatures my require the use of Alternator output 80A @ 14V DC
alternative engine oils. For oil requirements, refer to the 3/8 to 1/2 inch
Fan belt deflection
9 to 12 mm
2 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Deutz TD2011L04i Engine Oil temperature switch

Installation torque 8-18 ft-lbs
3.62 liters
Temperature switch point 275°F
96 x 125 mm
Horsepower net intermittent @ 74hp 11-24 Nm
2400 rpm 55KW
Pressure switch point 22 psi
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle 1300 rpm Injection pump pressure, maximum 15,000 psi
High idle 2450 rpm 1034 bar
Compression ratio 17.5:1 Injector opening pressure 3046 psi
210 bar
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest Fuel requirement
cylinder. For fuel requirements, refer to the engine Operator
Governor centrifugal Manual for your engine.
mechanical Starter motor
Valve Clearance, cold Current draw, normal load 140-200 A
Intake 0.012 in Cranking speed 250-350 rpm
0.3 mm Battery - Engine starting and control system
Exhaust 0.020 in Type 6V DC
0.5 mm Quantity 2
Lubrication system Battery capacity, maximum 1000A
Reserve capacity @ 25A rate 200 Minutes
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar Alternator output 80A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch
Oil capacity (including filter) 12.8 quarts
12.1 liters 9 to 12 mm
-22°F to 86°F / -30°C to 30°C 5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to
the Engine Operator Manual for your engine.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 13

Specifications
Deutz TD 2.9 Engine Oil temperature switch

Displacement 177 cu in 11-24 Nm
2.9 liters
92 x 110 mm
Horsepower net intermittent @ 74.2hp 11-24 Nm
2600 rpm 55KW
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle 1000 rpm Injection pump pressure, maximum 15,000 psi
High idle 2500 rpm 1034 bar
Compression ratio 17.4:1 Injector opening pressure 3046 psi
210 bar
lowest cylinder must be at least 75% of the highest Fuel requirement
cylinder. For fuel requirements, refer to the engine Operator
Governor electronic Manual for your engine.
Lubrication system Starter motor
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Current draw, normal load 140-200 A
2.8 to 4.1 bar Cranking speed 250-350 rpm
Oil capacity (including filter) 9.4 quarts Battery - Engine starting and control system
8.9 liters
Type 12V DC, Group 31
Oil viscosity requirements Quantity 1
-22°F to 86°F / -30°C to 30°C 5W-30 Battery capacity, maximum 1000A
(synthetic) Reserve capacity @ 25A rate 200 Minutes
-4°F to 104°F / -20°C to 40°C 10W-40 Alternator output 95A @ 14V DC
Above 5°F / -15°C 15W-40
9 to 12 mm
Engine Operator Manual for your engine.
2 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Perkins 1104D-44T Oil temperature switch

4.4 liters
Number of cylinders 4 0.55 bar
Bore and stroke 4.13 x 5 inches Oil Sensor Settings
105 x 127 mm
0 psi 10 ohms
Horsepower net intermittent @
50 psi 120 ohms
2200 rpm 68 ph / 50.7KW
74 hp / 55.2 KW Fuel injection system Motorpal
Induction system turbocharged Transfer pump pressure 10-12 psi /
0.69-0.83 bar
Firing order 1-3-4-2
Injector pressure (4264+116 psi) /
Low idle 1300 rpm
(294+8 bar)
High idle 2450 rpm
Fuel requirement
Compression ratio 18.2:1
For fuel requirements, refer to the engine Operator
Compression pressure pressure (psi or bar) of the Manual for your engine.
lowest cylinder must be at least 75% of the highest
Starter motor
cylinder.
Current draw, normal load 115 A
Governor centrifugal
mechanical Cranking speed 200-250 rpm
Battery - Auxiliary power units
Valve Clearance, cold
Type 6V DC
Intake 0.008 in
Quantity 2
0.2 mm
Battery capacity, maximum 285AH
Exhaust 0.018 in Reserve capacity @ 25A rate 745 Minutes
0.45 mm
Battery - Engine starting and control system
Lubrication system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Quantity 1
2.8 to 4.1 bar Battery capacity, maximum 1000A
Oil capacity (including filter) 10.4 quarts Reserve capacity @ 25A rate 200 Minutes
9.8 liters
-22°F to 86°F / -30°C to 30°C 5W-20
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 15

Specifications
Perkins 1104D-44T Perkins 854F-34T

Engine coolant
Displacement 207 cu in
Capacity 9.5 quarts
3.4 liters
(engine only) 9 liters
Coolant temperature switch
Bore and stroke 3.89 x 4.33 inches
99 x 110 mm
11-24 Nm
Horsepower net intermittent @
2500 rpm 74 hp / 55.2 KW
110°C
Induction system turbocharged
Temperature Sensor Settings
215°F 37 ohms
102°C speed Standby 1000 rpm
170°F 78 ohms Low idle 1500 rpm
82°C High idle 2500 rpm
Alternator output 85A @ 12V DC Compression ratio 17.0:1
Fan belt deflection 3/8 to 1/2 in
9 to 12 mm lowest cylinder must be at least 75% of the highest
cylinder.
Governor Electronic
Lubrication system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar
Minimum oil pressure 12 psi
0.82 bar
Oil capacity (including filter) 7.7 quarts
7.3 liters
-22°F to 86°F / -30°C to 30°C 5W-20
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
2 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Oil temperature switch Perkins 854F-34T cont.

Installation torque 18.4 ft-lbs Engine coolant
25 Nm Capacity 16.5 quarts
Pressure switch point 12 psi (50/50 extended life) 15.6 liters
0.82 bar Coolant temperature switch
Oil Sensor Settings Installation torque 18.4 ft-lbs
0 psi 10 ohms 25 Nm
50 psi 120 ohms Maximum continuous temperature 226°F
Fuel injection system 108°C
Transfer pump pressure 10-12 psi / Temperature Sensor Settings

0.69-0.83 bar 215°F 37 ohms
Injector pressure 23000 psi / 102°C
(1600 bar) 170°F 78 ohms
Fuel requirement 82°C
For fuel requirements, refer to the engine Operator Alternator output 120A @ 12V DC
Manual for your engine. Fan belt deflection 3/8 to 1/2 in
Glow plugs 9 to 12 mm
Initial load (0-10 sec) 80A

Continuous load (>10 sec) 40A
Starter motor
Current draw, normal load 68 A
Type 6V DC
Quantity 2
Battery capacity, maximum 285AH
Quantity 1
Battery capacity, maximum 1000A
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 17

Specifications
Perkins Engine 1004-42 Injection system

Injection pump make Zexel
4.23 liters
152 bar
Fuel requirement
Bore & stroke 4.06 x 5 inches
103.1 x 127 mm
Alternator output 55A, 12V DC
Firing order 1-3-4-2 3/8 to 1/2 inch
Fan belt deflection
Compression ratio 18.5:1 9 to 12 mm
Compression pressure Battery - System
pressure (psi or bar) of the lowest cylinder must be at
Type 12V, Group 27TM
Quantity 1
Low idle rpm 1300 rpm AH rating 109AH
Frequency 303.3 Hz Cold cranking ampere 630A
High idle rpm 2350 rpm Reserve capacity @ 25A rate 160 minutes
Frequency 548.3 Hz Battery - Engine starting
Valve clearance, cold Type 12V, Group 4D
Intake 0.008 in Quantity 1
0.20 mm AH rating 190AH
Exhaust 0.018 in
Reserve capacity @ 25A rate 325 minutes
0.45 mm
Cooling system
Lubrication system
Engine capacity 9.5 quarts
Oil pressure 51 psi
9 liters
3.45 bar
System capacity 20 quarts
18.9 liters
2 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Perkins 1104C-44 Engine Lubrication system

Oil pressure, hot 40 to 60 psi
Displacement 268.5 cu in (at 2000 rpm) 2.8 to 4.1 bar
4.4 liters
Number of cylinders 4 (including filter) 6.9 liters
Bore and stroke 4.13 x 5 inches Oil viscosity requirements
105 x 127 mm
Horsepower Extreme operating temperatures my require the use of
Gross intermittent @ 2400 rpm 86 alternative engine oils. For oil requirements, refer to the
Net intermittent @ 2400 rpm 83 Engine Operator Handbook on your machine.
Low idle rpm 1300 rpm Oil pressure sending unit
Frequency 316.3 Hz Torque 8-18 ft-lbs
Low Idle with belt-driven generator option 1400 rpm 11-24 Nm
Frequency 340.7 Hz Oil pressure switch point 8 psi
High idle rpm 2350 rpm 0.55 bar
Frequency 571.8 Hz Fuel injection system
Compression ratio 18.2:1 Injection pump make Bosch
Compression pressure Injector opening pressure 2200 psi
Pressure (psi or bar) of the lowest cylinder must be at 152 bar
Fuel requirement
Governor centrifugal mechanical
Valve clearance, cold Manual on your machine.
Intake 0.008 in
0.2 mm
Exhaust 0.018 in
0.45 mm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 19

Specifications
Battery - Engine starting Perkins 804D-33T Engine

Type 12V, Group 31
Quantity 1 Displacement 203 cu in
Cold cranking ampere 1000A 3.33 liters
Reserve capacity @ 25A rate 175 minutes Number of cylinders 4
Battery - Control system Bore and stroke 3.7 x 4.72 inches
Type 12V DC, Group 4D 94 x 120 mm
Quantity 1 Horsepower
Gross intermittent @ 2500 rpm 83 / 62 kW
Induction system turbocharged
Starter motor
Current draw, normal load 140-200A
Low idle 1300 rpm
316 Hz
Engine coolant
High idle 2350 rpm
Capacity 14 quarts 572 Hz
13.2 liters
Compression ratio 19.5:1
Coolant temperature sending unit
Compression pressure
Torque 8-18 ft-lbs Pressure (psi or bar) of the lowest cylinder must be at
11-24 Nm least 75% of the highest cylinder.
Temperature switch point 230°F Governor centrifugal mechanical
110°C
Valve clearance, cold
Alternator output 85A @ 13.8V DC
Intake 0.0098 in
Fan belt deflection 3/8 inch
0.25 mm
10 mm
Exhaust 0.0098 in
0.25 mm
Lubrication system
Oil pressure, hot 40 to 60 psi
(at 2000 rpm) 2.8 to 4.1 bar
(including filter) 10 liters
2 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Oil viscosity requirements Starter motor

Below 86°F / 30°C 5W-30 Current draw, normal load 200A
-4°F to 104°F / -20°C to 40°C 10W-30 Cranking speed 250 rpm
Above 14°F / -10°C 15W-40 Engine coolant
Units ship with 15W-40. Capacity 12.5 quarts
Extreme operating temperatures may require the use of 11.8 liters
alternative engine oils. For oil requirements, refer to the Coolant temperature sending unit
Oil pressure sending unit 11-24 Nm
Installation torque 8-18 ft-lbs Temperature switch point 230°F
11-24 Nm 110°C
Oil pressure switch point 8 psi Alternator output 90A @ 12V DC
0.55 bar 3/8 to 1/2 in
Fan belt deflection
Fuel injection system 9 to 12 mm
Injection pump make Bosch
152 bar
Fuel requirement
Type 6V DC
Quantity 2
AH rating 285AH
Quantity 1
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 21

Specifications
Cummins B3.3T Engine Fuel injection system

Injection pump make Zexel
Injection pressure 12,000 psi
3.26 liters
827 bar
Fuel requirement
Bore and stroke 3.74 x 4.53 inches
95 x 115 mm
60 kW @ 2200 rpm
Type 6V DC
Quantity 2
Low idle 1300 rpm AH rating 285AH
368 Hz Reserve capacity @ 25A rate 745 minutes
High idle 2350 rpm Battery - Engine starting and control system
666 Hz
Compression ratio 17:1 Quantity 1
Compression pressure Cold cranking ampere 1000A
Pressure (psi or bar) of the lowest cylinder must be at Reserve capacity @ 25A rate 200 minutes
least 75% of the highest cylinder. Starter motor
Valve clearance, cold Current draw, maximum 550A
Intake 0.014 in Engine cranking speed, minimum 130 rpm
0.35 mm
Engine coolant
Exhaust 0.020 in
Capacity 9.1 quarts
0.5 mm
8.6 liters
Lubrication system
Oil pressure, hot 31 to 72 psi 3/8 to 1/2 inch
Fan belt deflection
(at 2000 rpm) 2 to 5 bar
10 to 12.5 mm
Oil capacity 9 quarts
Below 68°F / 20°C 5W-30
-10° to 68°F / -23° to 20°C 10W-30
Above 14°F / -10°C 15W-40
2 - 22 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Cummins B3.9L Engine Injection system

Injection pump make Bosch
Injection pump pressure 5500 psi
3.9 liters
379.2 bar
102 x 120 mm
Fuel requirement
Compression ratio 16.5:1 Alternator output 63A, 12V DC
Compression pressure Battery - System
pressure (psi or bar) of the lowest cylinder must be at
Type 12V, Group 27TM
Quantity 1
Low idle rpm 1300 rpm AH rating 109AH
Frequency 368.3 Hz Cold cranking ampere 630A
High idle rpm 2350 rpm Reserve capacity @ 25A rate 160 minutes
Frequency 665.8 Hz Battery - Engine starting
Valve clearance, cold Type 12V, Group 4D
Intake 0.010 in Quantity 1
0.254 mm AH rating 190AH
Exhaust 0.020 in
0.508 mm
Cooling system
Lubrication system
Engine capacity 8.8 quarts
Oil pressure 50 psi
8.3 liters
3.45 bar
System capacity 20 quarts
18.9 liters
(including filter) 9 liters
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 23

Specifications
Cummins B4.5L Engine Fuel injection system

Injection pump make Delphi
Injection pump pressure 3480 to 3680 psi
4.5 liters
240 to 254 bar
102 x 138 mm
Fuel requirement
Compression ratio 18:1 Battery - Engine starting
Compression pressure Type 12V, Group 31
Pressure (psi or bar) of the lowest cylinder must be at Quantity 1
least 75% of the highest cylinder. Cold cranking ampere 1000A
Low idle rpm 1300 rpm Reserve capacity @ 25A rate 175 minutes
Frequency 368.3 Hz Battery - Control system
High idle rpm 2350 rpm Type 12V DC, Group 4D
Frequency 665.8 Hz Quantity 1
Valve clearance, cold Cold cranking ampere 1020A
Intake 0.010 in
0.254 mm Starter motor
Exhaust 0.020 in Current draw, no load 125A
0.508 mm Brush length, minimum 0.72 in
Lubrication system 18.3 mm
Oil pressure, hot 50 psi Engine coolant
(at 2000 rpm) 3.45 bar Capacity 17 quarts
Oil capacity 9.5 quarts 16 liters
(including filter) 9 liters Coolant temperature sending unit
Oil viscosity requirements Torque 8-18 ft-lbs
Units ship with 15W-40. 11-24 Nm
Extreme operating temperatures my require the use of Temperature switch point 230°F
alternative engine oils. For oil requirements, refer to the 110°C
10 to 12.5 mm
2 - 24 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Machine Torque Specifications Manifold Plug Torque

Platform rotator Specifications
1-8 center bolt, GR 5, dry 640 ft-lbs Plug torque
868 Nm
SAE No. 2 50 in-lbs / 6 Nm
1-8 center bolt, GR 5, lubricated 480 ft-lbs
SAE No. 4 14 ft-lbs / 18.9 Nm
651 Nm
3/8 SAE No. 6 23 ft-lbs / 31.2 Nm
-16 bolts, GR 8, lubricated 35 ft-lbs*
*use blue thread-locking compound 47.5 Nm SAE No. 8 36 ft-lbs / 48.8 Nm
Turntable rotate assembly SAE No. 10 62 ft-lbs / 84.1 Nm
Rotate bearing mounting bolts, lubricated 180 ft-lbs SAE No. 12 84 ft-lbs / 113.9 Nm
244 Nm
Rotate drive hub mounting bolts, dry 380 ft-lbs
515 Nm
Rotate drive hub mounting bolts, lubricated 280 ft-lbs*
*use blue thread-locking compound 380 Nm
Rotate drive motor mounting bolts, dry 110 ft-lbs
149 Nm
Rotate drive motor mounting bolts, lubricated 80 ft-lbs
108 Nm
Drive motor and hubs
Drive hub mounting bolts, dry 269 ft-lbs
365 Nm
Drive hub mounting bolts, lubricated 202 ft-lbs
274 Nm
Drive motor mounting bolts, dry 110 ft-lbs
149 Nm
Drive motor mounting bolts, lubricated 80 ft-lbs
108 Nm
Drive hub oil plug, O-ring seal 13 ft-lbs
18 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 25

Specifications
Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-
LokTM fittings and hose ends. Genie specifications SAE Dash size Torque
require that fittings and hose ends be torqued to -4 14 ft-lbs / 19 Nm
specification when they are removed and installed -6 23 ft-lbs / 31.2 Nm
or when new hoses or fittings are installed. -8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
Seal-LokTM Fittings
(hose end - ORFS) -12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
SAE Dash size Torque
-20 151 ft-lbs / 204.7 Nm
-4 10 ft-lbs / 13.6 Nm
-24 184 ft-lbs / 249.5 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Adjustable Fitting Non-adjustable fitting
JIC 37° Fittings a jam nut

(swivel nut or hose connection)
SAE Dash Size Thread Size Flats

-4 7/16-20 2
SAE O-ring Boss Port
(tube fitting - installed into Steel)
-6 9/16-18 1 1/4
-8 3/4-16 1 SAE Dash size Torque
-10 7/8-14 1 -4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm

ORFS / (Non-Adj) 26 ft-lbs / 35.3 Nm
-12 1 1/16-12 1 37° (Non-Adj) 22 ft-lbs / 30 Nm
-16 1 5/16-12 1 -6 ORFS / (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-24 1 7/8-12 1 -8 ORFS / (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS / 37° (Adj) 100 ft-lbs / 135.6 Nm
37° (Non-Adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
2 - 26 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
Torque Procedure JIC 37° fittings
Seal-LokTM fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
1 Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight,
replaced anytime the seal has been broken. approximately 30 in-lbs / 3.4Nm.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger 2 Using a permanent ink marker, make a
tight. reference mark on one the flats of the hex nut
and continue the mark onto the body of the hex
Note: The O-rings used in the Parker Seal Lok® fitting. Refer to illistration 1.
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).
2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight. Illustration 1
5 Tighten the nut or fitting to the appropriate a hex nut

torque per given size as shown in the table. b reference mark
c body hex fitting
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 27

Specifications
3 Working clockwise on the body hex fitting, make 4 Tighten the hex nut until the mark on the hex
a second mark with a permanent ink marker to nut is aligned with the second mark on the body
indicate the proper tightening position. Refer to hex fitting.
illustration 2.
5 Operate all machine functions and inspect
Note: Using the JIC 37° Fitting table in this section the hose, fittings and related components to
to determine the correct number of flats, for the confirm there are no leaks.
proper tightening position.
Note: The marks indicate the correct tightening

positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
a body hex fitting
b reference mark
c second mark
2 - 28 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Specifications
SAE FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
1/4
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
5/16
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
3/8
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
7/16
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
1/2
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
9/16
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
5/8
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
3/4
16 220 298 300 406 310 420 420 569 350 474
9 320 433 430 583 450 610 610 827 510 691
7/8
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
1 7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 /8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
1 7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 /4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHAR T

This chart is to be used as a guide only unless noted elsewhere in this manual
Size Class 4.6 Class 8.8 Class 10.9 Class 12.9

(mm) LUBED DRY LUBED DRY LUBED DRY LUBED DRY
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
Part No. 1268494 S-100 • S-105 • S-120 • S-125 2 - 29

pecifications
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2 - 30 S-100 • S-105 • S-120 • S-125 Part No. 1268494

January 2019 Section 3 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
Repair procedures shall be completed by a where repairs can be completed. Then to
person trained and qualified on the repair of re-assemble, perform the disassembly steps in
this machine. reverse order.
Immediately tag and remove from service a Symbols Legend

damaged or malfunctioning machine.
Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Used to indicate the presence of
and operating instructions in the Genie S-100 & an imminently hazardous situation
Genie S-105 Operator’s Manual and the which, if not avoided, will result in
Genie S-120 & Genie S-125 Operator’s Manual. death or serious injury.
Be sure that all necessary tools and parts are Used to indicate the presence of
available and ready for use. a potentially hazardous situation
which, if not avoided, could result
Read each procedure completely and adhere in death or serious injury.
to the instructions. Attempting shortcuts may
produce hazardous conditions. With safety alert symbol—used
to indicate the presence of a
Use only Genie approved replacement parts. potentially hazardous situation
Unless otherwise specified, perform each which, if not avoided, may cause
repair procedure with the machine in the minor or moderate injury.
following configuration:
• Machine parked on a firm, level surface a potentially hazardous situation
• Boom in the stowed position which, if not avoided, may result in
property damage.
• Turntable rotated with the boom between
the circle-end wheels Indicates that a specific result is expected after
• Turntable secured with the turntable performing a series of steps.
rotation lock pin Indicates that an incorrect result has occurred
• Key switch in the off position with the after performing a series of steps.
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3-1

Section 3 • Repair Procedures January 2019
Display Module
This table lists the various screens and menu options of the operating software. Some display menus are
for informational purpose only, while others can be changed to alter the machine operating parameters.
The key switch must be in the off position before entering the programming mode.
Use the or buttons to scroll through the screens.
To change parameter values, use the button (to increase) or the button (to decrease) or to select
a setting. Press the button to save the new value to memory. An audible beep will indicate a save to
memory.
You must exit the programming mode for the changes to take effect.
To Exit Programming Mode:

Use the scroll button to scroll through the menu until the screen displays exit, then press the
plus button once, and change no to yes, then press the enter button once to accept change.
Note: If Programming mode is not exited properly, all machine programming may be lost.
Screen or Procedure Description Range or Selection

Menu
Operator Default Hour meter (on power up)
Engine speed
Engine oil pressure PSI (English)
Engine oil pressure kPa (metric)
Engine temperature is not
Engine temperature °F (English)
displayed until engine is
Engine temperature °C (metric) above 100°F / 38°C
Primary boom angle sensor
Turntable level sensor X°
Turntable level sensor Y°
Platform angle
Battery voltage
Machine With key switch Hydraulic pressure PSI (English)

on, press the Hydraulic pressure kPa (metric)
Status Boom angle
and at the
Axle status
same time.
Unit of With key switch Metric/English measurements Use +/- buttons to change
off, press and
Measure hold the
and button and turn Language selection English, German, French,
the key switch to
Language the on position.
Spanish, Portuguese, Italian,
Dutch and Swedish.
Release the
button and press Deutz 2.9L Turbo (D2.9T)
Deutz TD2011L0.4i (DL04i)
Perkins 1104D-44T (P1104)
Perkins 854F (P854T)
3 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Display Module

Menu
Drive With key switch Drive output max forward 100% max and 10% min,
off, press and 100 % (default)
Functions hold the Drive output max reverse 100% max and 10% min,
button and turn 90% (default)
the key switch to Elevated drive (>75 ft / 24 m) % 120% max and 50% min,
the on position. 100% (default)
Release the Elevated drive (<75 ft / 24 m) % 120% max and 50% min,
button and press 100% (default)
. Stowed drive % 120% max and 50% min,
100% (default)
Drive acceleration % 125% max and 25% min,
100% (default)
Drive deceleration % 125% max and 25% min,
100% (default)
Speed limit on steer angle 100% max and 0% min, 50%
(default)
Boom With key switch Boom up speed stowed % 120% max and 10% min,
off, press and 100% (default)
Function Boom down speed stowed %
hold the 120% max and 10% min,
Speeds button and turn 100% (default)
the key switch to Boom up speed % <75 ft 80% max and 10% min, 80%
the on position. (default)
Release the Boom down speed % <75 ft 80% max and 10% min, 80%
button and (default)
press Boom up speed % >75 ft 35% max and 10% min, 29%
(default)
Boom down speed % >75 ft 35% max and 10% min, 29%
(default)
Boom up speed % >100 ft 25% max and 10% min, 20%
(default)
Boom down speed % >100 ft 25% max and 10% min, 20%
(default)
Boom extend speed % 60% max and 10% min, 60%
(default)
Boom retract speed % 40% max and 10% min, 35%
(default)
Turntable rotate speed % <75 ft 120% max and 75% min,
100% (default)
Turntable rotate speed % >75 ft 120% max and 50% min,
100% (default)
Jib boom up/down speed % 120% max and 50% min,
100% (default)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3-3

Display Module

Menu
Lift With key switch Boom up/down 5000 max and 100 min,
off, press and ramp acceleration % 5000 (5.0 sec) (default)
Function hold the Boom up/down 2600 max and 100 min,
Ramp button and turn ramp deceleration % 500 (0.50 sec) (default)
Settings the key switch to Boom extend/retract 1600 max and 100 min,
the on position. ramp acceleration % 500 (0.50 sec) (default)
Release the Turntable rotate
5000 max and 100 min,
button and press ramp acceleration %
2000 (2.0 sec) (default)
Turntable rotate
ramp deceleration % 3000 max and 100 min,
Jib up/down ramp 250 (0.25 sec) (default)
deceleration % 3000 max and 0 min,
250 (0.25 sec) (default)
Valve With key switch Reset drive valve defaults (yes/no)

off, press and
Calibration hold the Reset boom up/down (yes/no)
button and turn valve defaults
the key switch to Reset boom extend/retract (yes/no)
the on position. valve defaults
Release the Reset turntable rotate (yes/no)
button and press valve defaults
Allow boom up/down (yes/no)
speed calibration
Allow turntable rotate (yes/no)
speed calibration
Reset drive joystick (yes/no)
defaults
Reset boom up/down (yes/no)
joystick defaults
Reset boom extend/retract (yes/no)
joystick defaults
reset turntable rotate (yes/no)
joystick defaults
Reset steer joystick
(yes/no)
defaults
Level With key switch Set unit level to gravity (yes/no)

off, press and Turntable Y-axis millivolts
Sensor per degree
hold the
Calibration button and turn Turntable X-axis millivolts
the key switch to per degree
the on position. Platform level to gravity (yes/no)
Release the Platform millivolts per degree
button and press
3 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Display Module

Menu
Default With key switch Reset drive functions (yes/no)
off, press and
Reset Reset boom function speeds
hold the (yes/no)
button and turn
the key switch to Reset lift function ramps (yes/no)
the on position.
Release the Reset all (Contact Genie Industries (yes/no)
button and press Service Department before using this
option)
Clear all safety switch faults (yes/no)
Overload With key switch Clear Overload Recovery A passcode is required to clear
Recovery off, press and the message
hold the
button and turn
the key switch to
the on position.
Release the
button and press
Options With key switch Limit boom height to 100 ft / 80 ft (100 ft / 80 ft)
off, press and AC generator (none, belt, hyd)
hold the Alarm (no, motion, travel, descent, travel
button and turn and descent)(0, 1, 2, 3, 4, 5)
the key switch to Lift / drive cutouts (no, drive cutout while not stowed,
the on position. lifting or driving)
Release the Auxiliary drive (yes/no)

button and press Proximity kill switch (none/prox)
Platform overload sensing (none/pltfs)
Work lights (yes/no)
Flashing beacon (yes/no)
Drive lights (yes/no)
Disable steer mode change (yes/no)
while driving
Rocker joystick steering (yes/no)
Generator off delay (0-10 sec) (o to 10 seconds, 2 is the default.
shown only when hyd gen is selected)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3-5

Platform Controls
The platform controls contains two printed circuit a b
boards:
The membrane circuit board is mounted to the

underside of the control box lid which contains
the LEDs and touch-sensitive buttons for machine
functions. The membrane circuit board sends the
input from the operator to the platform controls
ECM circuit board. The ECM circuit board sends
the data to the turntable control box for processing. e c
The platform controls ECM circuit board

communicates with the turntable controls. The
joystick controllers at the platform controls utilize
Hall Effect technology and require no adjustment. d
The operating parameters of the joysticks are
stored in memory at the turntable controls. If a a platform ECM circuit board
b boom extend/retract
joystick controller error occurs or if a joystick is joystick controller
replaced, it will need to be calibrated before that c drive/steer joystick controller
particular machine function will operate. See 1-3, d membrane circuit board
How to Calibrate a Joystick Controller. e boom up/down and turntable rotate
left/right joystick controller
Each joystick controller should operate smoothly
and provide proportional speed control over its
entire range of motion.
3 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494

platform controls
1-1 7 Locate the ECM circuit board mounted to the

inside of the platform control box.
Circuit Boards
Electrocution/burn hazard. Contact
Note: When an ECM circuit board is replaced, the with electrically charged circuits
joystick controllers will need to be calibrated. See could result in death or serious
1-3, How to Calibrate a Joystick Controller. injury. Remove all rings, watches
and other jewelry.
How to Remove the ECM Component damage hazard.
Circuit Board Electrostatic discharge (ESD)
can damage printed circuit board
1 Push in the Emergency Stop button to the components. Maintain firm contact
off position at both the ground and platform
with a metal part of the machine
controls. that is grounded at all times when
2 Remove the platform control box mounting handling printed circuit boards OR
fasteners. Remove the platform control box use a grounded wrist strap.
from the machine. 8 Remove the ECM circuit board mounting
Component damage hazard. fasteners.
Cables can be damaged if they 9 Carefully remove the ECM circuit board from
are kinked or pinched. the platform control box.
3 Locate the cables that connect to the bottom
of the control box. Number each cable and its How to Remove the Membrane
location at the control box. Circuit Board
4 Disconnect the cables from the bottom of the 1 Push in the Emergency Stop button to the
platform control box. off position at both the ground and platform
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.
6 Remove the platform control box lid retaining
fasteners. Open the control box lid.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3-7

platform controls REV B
3 Locate the membrane circuit board mounted to 1-2

the inside of the platform control box lid.
Membrane Decal
with electrically charged circuits
could result in death or serious
How to Replace the Membrane
injury. Remove all rings, watches Decal
and other jewelry.
The membrane decal is a special decal that
Note: Component damage hazard. Electrostatic consists of a decal with an electronic membrane
discharge (ESD) can damage printed circuit board on the backside. The membrane contains touch
components. Maintain firm contact with a metal sensitive areas that, when pushed, activates the
part of the machine that is grounded at all times machine functions. The membrane buttons activate
when handling printed circuit boards OR use a machine functions similar to toggle switches, but
grounded wrist strap. do not have any moving parts.
4 Carefully disconnect the two ribbon cables from 1 Push in the Emergency Stop button to the
the membrane circuit board. off position at both the ground and platform
controls.
5 Remove the membrane circuit board retaining
fasteners. 2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
6 Carefully remove the membrane circuit board
from the platform control box lid. 3 Carefully disconnect the two ribbon cables from
the membrane circuit board.
injury. Remove all rings, watches
and other jewelry.
Note: Component damage hazard. Electrostatic
discharge (ESD) can damage printed circuit board
components. Maintain firm contact with a metal
part of the machine that is grounded at all times
when handling printed circuit boards OR use a
grounded wrist strap.
3 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494

REV B platform controls
4 Close the control box lid. 1-3

5 Remove the decal from the platform control Joysticks
box.
6 Carefully remove the membrane decal from the How to Calibrate a Joystick
platform control box while guiding the ribbon
The joystick controllers on this machine utilize
cables out of the control box lid.
digital Hall Effect technology for proportional
7 Remove any decal adhesive from the control control. If a joystick controller is disconnected
box lid with a mild solvent. or replaced, it must be calibrated before that
particular machine function will operate.
Note: Do not allow any solvent to come in contact
with the membrane circuit board. Note: The joystick must be calibrated before the
threshold, max-out or ramp rate can be set.
8 Install the new membrane decal while guiding
the ribbon cables through the control box lid. Note: It is possible to reset multiple joystick
Note: Be sure that all LED locations on the defaults before exiting the programming mode.
membrane decal align with the LED's on the Note: After each joystick is calibrated, check the
membrane circuit board. display at the ground control box. There should
9 Install a new platform controls decal over the be no calibration faults shown on the display. If
membrane decal. calibration faults exist, repeat steps 1 through 8 for
that joystick controlled function.
10 Open the control box lid and carefuly connect
the ribbon cables from the membrane decal to Note: Contact Genie Product Support Department
the membrane circuit board. before using the reset all joystick default option.
Note: Perform this procedure with the engine off.
The calibration procedure for each joystick begins

on the next page.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3-9

Drive functions: Steer functions:

Note: If the calibration fault is already displayed at Note: If the calibration fault is already displayed at
the ground box begin with step 6. the ground box begin with step 6.
1 Turn the key switch to the off position. Confirm 1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform the red Emergency Stop button at the platform
and ground controls is in the on position. and ground controls is in the on position.
2 Press and hold the enter button on the 2 Press and hold the enter button on the
ground control panel while turning the key ground control panel while turning the key
switch to platform controls. Hold the enter switch to platform controls. Hold the enter
button for approximately 5 seconds. button for approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until reset drive joystick defaults is menu until reset steer joystick defaults is
displayed. Press the button to select yes, displayed. Press the button to select yes,
then press the button. then press the button.
5 Exit programming mode. 5 Exit programming mode.
Note: To exit programming mode, use the scroll Note: To exit programming mode, use the scroll
button to scroll through the menu until the button to scroll through the menu until the
screen displays exit, then press the plus button screen displays exit, then press the plus button
once, change the NO to YES, and press the enter once, change the NO to YES, and press the enter
button . button .
6 Do not start the engine. 6 Do not start the engine.
7 Locate the drive/steer joystick. 7 Locate the drive/steer joystick.
8 Move the drive/steer joystick full stroke in the 8 Move the drive/steer joystick full stroke in the
forward direction and hold for 5 seconds, then left direction and hold for 5 seconds, then return
return to the center or neutral position. to the center or neutral position.
9 Move the drive/steer joystick full stroke in the 9 Move the drive/steer joystick full stroke in the
reverse direction and hold for 5 seconds, then right direction and hold for 5 seconds, then
return to the center or neutral position. return to the center or neutral position.
Result: The alarm at the ground controls should Result: The alarm at the ground controls should
sound for a successful calibration. sound for a successful calibration.
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.
3 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Primary boom extend/retract functions: Primary boom up/down functions:
Note: If the calibration fault is already displayed at Note: If the calibration fault is already displayed at
the ground box begin with step 6. the ground box begin with step 6.
1 Turn the key switch to the off position. Confirm 1 Turn the key switch to the off position. Confirm
the red Emergency Stop button at the platform the red Emergency Stop button at the platform
and ground controls is in the on position. and ground controls is in the on position.
2 Press and hold the enter button on the 2 Press and hold the enter button on the
ground control panel while turning the key ground control panel while turning the key
switch to platform controls. Hold the enter switch to platform controls. Hold the enter
button for approximately 5 seconds. button for approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until reset primary boom extend/retract menu until reset primary boom up/down joystick
joystick defaults is displayed. Press the defaults is displayed. Press the button to
button to select yes, then press the button. select yes, then press the button.
5 Exit programming mode. 5 Exit programming mode.
Note: To exit programming mode, use the scroll Note: To exit programming mode, use the scroll
button to scroll through the menu until the button to scroll through the menu until the
screen displays exit, then press the plus button screen displays exit, then press the plus button
once, change the NO to YES, and press the enter once, change the NO to YES, and press the enter
button . button .
6 Do not start the engine. 6 Do not start the engine.

7 Locate the primary boom/turntable rotate 7 Locate the primary boom/turntable rotate
joystick. joystick.
8 Move the primary boom extend/retract joystick 8 Move the boom/turntable rotate joystick
full stroke in the extend direction and hold for full stroke in the up direction and hold for 5
5 seconds, then return to the center or neutral seconds, then return to the center or neutral
position. position.
9 Move the primary boom extend/retract joystick 9 Move the boom/turntable rotate joystick full
full stroke in the retract direction and hold for stroke in the down direction and hold for 5
5 seconds, then return to the center or neutral seconds, then return to the center or neutral
position. position.
Result: The alarm at the ground controls should Result: The alarm at the ground controls should
sound for a successful calibration. sound for a successful calibration.
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. 1268494 S-100 • S-105 • S-120 • S-125 3 - 11

Turntable rotate functions: How to Reset a Proportional

Note: If the calibration fault is already displayed at Valve Coil Default
the ground box begin with step 6.
Note: Use this procedure for any software version
1 Turn the key switch to the off position. Confirm other than 2.00. For software version 2.00 refer to
the red Emergency Stop button at the platform the following procedure.
and ground controls is in the on position.
Note: This procedure only needs to be performed
2 Press and hold the enter button on the if a proportional valve has been replaced.
ground control panel while turning the key
switch to platform controls. Hold the enter Note: After the valve coil defaults have been set,
button for approximately 5 seconds. each machine function threshold and default
function speed must be set. See How to Set the
3 Press the minus button twice, then press the Function Thresholds and Default Function Speeds.
enter button twice.
1 Turn the key switch to the off position.
4 Use the scroll button to scroll through the
menu until reset turntable rotate joystick 2 Press and hold the enter button on the
defaults is displayed. Press the button to ground control panel while turning the key
select yes, then press the button. switch to platform controls. Hold the enter
button for approximately 5 seconds.
5 Exit programming mode.
3 Press the minus button twice, then press the
Note: To exit programming mode, use the scroll
enter button twice.
button to scroll through the menu until the
screen displays exit, then press the plus button 4 Use the scroll button to scroll through the
menu until the function valve that needs to be
once, change the NO to YES, and press the enter
reset is displayed. Press the button to
button .
select yes, then press the button to save the
6 Do not start the engine. setting.
7 Locate the primary boom/turntable rotate Note: Choices are: Propel (drive) valve reset;
joystick. Boom up/down valve reset; Boom extend/retract
valve reset; or TT rotate valve reset.
8 Move the boom/turntable joystick full stroke in
the left direction and hold for 5 seconds, then 5 Push one of the LCD
return to the center or neutral position. screen buttons shown
until exit is displayed.
9 Move the boom/turntable joystick full stroke in
the right direction and hold for 5 seconds, then 6 Press the plus button or minus button to
return to the center or neutral position. select yes and then press the enter button .
Result: The alarm at the ground controls should

sound for a successful calibration.
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
3 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494

How to Reset a Proportional How to Set the Function

Valve Coil Default Thresholds and Function Speeds
(software version 2.00) Note: Before the threshold and default function
Note: Software version 2.00 requires the use of speeds can be set, the boom function proportional
Web GPI to perform this procedure. valve coil defaults must be set first.
Refer to Diagnostic Code, Software. See How to Reset a Proportional Valve Coil
Default.
Note: This procedure only needs to be performed
if a proportional valve has been replaced. Note: If a boom function proportional valve coil
has not been replaced and just want to reset the
Note: After the valve coil defaults have been set, function speed to original factory settings, begin
each machine function threshold and default with step 10.
function speed must be set. See How to Set the
Function Thresholds and Default Function Speeds. 1 Start the engine from the platform controls.
2 Press down the foot switch.
1 Open Web GPI and connect to the TCON.
Note: Be sure the engine rpm is set to foot switch
2 Select the valve screen of the proportional
activated high idle.
valve you want to reset.
Note: Choices are: Propel (drive) valve reset; Function threshold:
Boom up/down valve reset; Boom extend/retract 3 Select a joystick controlled function that needs
valve reset; or TT rotate valve reset. to have the threshold set.
3 Press "set Defaults" and enter the level 4 Slowly move the joystick off center in either
2 password (obtained from field service direction just until the machine function starts
personnel). to move, then move the joystick very slowly
4 Enter "0" (zero) into the threshold boxes. towards the neutral or center position just
before the machine function stops.
5 Press "send" and enter the level 2 password Do not let go of the joystick.
(obtained from field service personnel).
5 While holding the joystick in position, press the
6 Disconnect from the TCON and proceed with engine start button at the platform controls
calibration. to set the joystick controller threshold.
6 Slowly move the joystick off center in the
opposite direction just until the machine
function starts to move, then move the joystick
very slowly towards the neutral or center
position just before the machine function stops.
Do not let go of the joystick.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 13

7 While holding the joystick in position, press the Boom extend/retract functions: Raise the
engine start button at the platform controls boom until the low-speed drive function is
to set the joystick controller threshold. enabled. Move the joystick full stroke in the
extend direction. When the alarm sounds,
8 Repeat steps 3 through 7 for each joystick move the joystick in the opposite direction full
controlled machine function (boom up/down stroke until the alarm sounds again. Return the
and turntable rotate left/right, boom extend/ joystick to center.
retract, and drive forward/reverse).
Turntable rotate functions: Raise the boom
9 Once all the joystick controllers have been until the low-speed drive function is enabled.
calibrated, push in the Emergency Stop button Move the joystick full stroke to the left (cw) until
at the platform controls to save the settings in the drive enable light turns on. Then move the
memory. joystick full stroke to the right (ccw). When the
Note: The red Emergency Stop button at the alarm sounds, move the joystick in the opposite
platform controls must be pushed in to the off direction full stroke until the alarm sounds
position following calibration of the joystick again. Return the joystick to center.
controllers to save the settings in memory. 15 Once all the joystick controllers have been
calibrated, push in the red Emergency Stop
10 At the ground controls, turn the key switch to
button at the platform controls to save the
the off position, wait a moment and then turn
settings in memory.
the key switch to platform controls.
Note: The red Emergency Stop button at the
11 Check the display at the ground controls to be
platform controls must be pushed in to the off
sure there are no calibration faults.
position following calibration of the joystick
Note: There should be no calibration faults shown controllers to save the settings in memory.
on the display. If calibration faults exist, repeat this
procedure. 16 At the ground controls, turn the key switch to
the off position, wait a moment and then turn
Function speeds: the key switch to platform controls.
Note: Be sure the machine is in the stowed 17 Check the display at the ground controls to be
position and the boom is rotated between the circle sure there are no calibration faults.
end tires.
Note: There should be no calibration faults shown
Note: Perform this procedure with the machine on the display. If calibration faults exist, repeat this
parked on a firm, level surface which is free of procedure.
obstructions.
How to Adjust the Function
12 Start the engine from the platform controls.
Speeds
13 Select a boom function that needs the function
speed set. 1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
14 Boom up/down functions: Starting in the controls.
stowed position, move the joystick full stroke
in the up direction. When the alarm sounds,
move the joystick in the opposite direction full
stroke until the alarm sounds again. Return the
joystick to center.
3 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494

2 Press and hold the enter button on the ground control panel while turning the key
ground control panel while turning the key switch to ground controls. Hold the enter
switch to ground controls. Hold the enter button for approximately 5 seconds.
button for approximately 5 seconds.
3 Press the plus button twice, then press the
3 Press the plus button twice, then press the scroll button twice.
minus button twice.
4 Press the scroll button until the function to
4 Press the scroll button until the function to be adjusted is displayed.
be adjusted is displayed.
5 Press the plus button to increase the ramp
5 Press the plus button to increase the speed rate or press the minus button to decrease
or press the minus button to decrease the the ramp rate.
speed.
6 Press the enter button to save the setting in
6 Press the enter button to save the setting in memory.
memory.
7 Push one of the LCD screen buttons shown
7 Push one of the LCD until exit is displayed.
screen buttons shown
until exit is displayed. 8 Press the plus
button to select yes and
8 Press the plus button to select yes and then then press the enter button .
press the enter button .
9 Continue to perform this procedure until the
machine function speed meets specification.
Specifications
Refer to Specifications for function speeds. Ramp rate (factory settings)
Turntable rotate
How to Adjust the Function accelerate 2 seconds
Ramp Rate Setting decelerate 0.25 second
Primary boom up/down
The ramp rate setting of a joystick controls the time
accelerate 3 seconds
at which it takes for the joystick to reach maximum decelerate 0..25 second
output, when moved out of the neutral position.
Primary boom extend/retract
The ramp rate settings of a joystick can be
accelerate 2 seconds
changed to compensate for hydraulic pump wear
decelerate 0.25 second
to maintain peak performance from the machine.
Jib boom up/down
Note: Perform this procedure with the boom in the accelerate 2 seconds
stowed position. decelerate 0.25 second
Drive
1 Pull out the red Emergency Stop button to the accelerate 2 seconds
on position at both the ground and platform
controls.
2 Press and hold the enter button on the
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 15

Platform Components
2-1 2-2
Platform Platform Leveling Cylinder
How to Remove the Platform The platform leveling cylinder keeps the platform
level through the entire range of boom motion.
1 Separate the foot switch quick disconnect plug. The platform is maintained level to the turntable.
The ECM at the ground controls compares the
2 Support the platform with an appropriate lifting
difference in readings between the platform angle
device.
sensor and the turntable level sensor. The ECM at
3 Locate the cables that connect to the bottom the ground controls sends a signal to the platform
of the control box. Number each cable and its controls to open or close the appropriate platform
location at the platform control box. level proportional valve on the platform manifold
to maintain a level platform. The platform leveling
4 Disconnect the cables from the bottom of the
cylinder is equipped with counterbalance valves to
platform control box.
prevent movement in the event of a hydraulic line
5 Remove the platform control box mounting failure.
fasteners. Remove the platform control box and
set it aside. How to Remove the Platform
6 Remove the air line to platform bracket retaining Leveling Cylinder
fasteners (if equipped). Note: When removing a hose assembly or fitting,
7 Remove the weld cables from the platform the O-ring on the fitting and/or hose end must be
(if equipped). replaced and then torqued to specification during
installation. Refer to Specifications, Hydraulic
Electrocution/burn hazard. Contact Hose and Fitting Torque Specifications.
could result in death or serious 1 Extend the boom until the platform leveling
injury. Remove all rings, watches cylinder barrel-end pivot pin is accessible.
and other jewelry.
2 Raise the boom slightly and place blocks under
8 Remove the platform mounting fasteners and the platform.
remove the platform from the machine.
3 Lower the boom until the platform is resting on
Crushing hazard. The platform the blocks just enough to support the platform.
may become unbalanced and
Note: Do not rest the entire weight of the boom on
fall when it is removed from
the blocks.
the machine if it is not properly
supported.
3 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494

platform components
4 Tag, disconnect and plug the hydraulic hoses 8 Use a soft metal drift to remove the rod-end
from the platform leveling cylinder at the pivot pin.
bulkhead fittings located inside the boom tube
at the platform end and connect them together Crushing hazard. The platform
(S-100 and S-120 models) or
using a connector. Cap the bulkhead fittings on
jib boom (S-105 and S-125
the boom tube.
models) will fall when the platform
Bodily injury hazard. Spraying leveling cylinder rod-end pivot
hydraulic oil can penetrate and pin is removed if it is not properly
burn skin. Loosen hydraulic supported.
connections very slowly to allow
the oil pressure to dissipate Crushing hazard. The platform
leveling cylinder will fall if it is not
gradually. Do not allow oil to
properly supported when the rod-
squirt or spray.
end pivot pin is removed.
5 Remove the pin retaining fastener from
the platform leveling cylinder rod-end pivot pin. Component damage hazard. The
platform leveling cylinder rod can
Do not remove the pin.
become damaged if it is allowed to
6 Remove the external snap ring from the barrel- fall.
end pivot pin. Do not remove the pin.
9 Use a soft metal drift to remove the barrel-end
7 Support the platform leveling cylinder with a pivot pin.
suitable lifting device. Protect the cylinder rod
10 Carefully pull the platform leveling cylinder out
from damage.
of the boom.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 17

platform components
How to Bleed the Platform 2-3

Leveling Cylinder Platform Rotator
Note: Do not start the engine. Use auxiliary power The platform rotator is a hydraulically activated
for all machine functions in this procedure. helical gear assembly used to rotate the platform
Note: The boom must remain below 10° to properly 160 degrees.
perform this procedure.
How to Remove the
1 Raise the boom to a horizontal position. Platform Rotator
2 Activate auxiliary power.
Component damage hazard. Mark
3 Push the platform level up and down buttons the platform mounting weldment
through two complete platform leveling cycles and the rotator flange before
to remove any air that might be in the system. removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal.
If a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way
to the left and then installing the
platform mounting weldment all
the way in the left position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
Hose and Fitting Torque Specifications.
1 Remove the platform. See Repair Procedure,

How to Remove the Platform.
2 Disconnect the electrical connector from the
platform angle sensor.
3 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494

platform components
3 Tag, disconnect and plug the hydraulic hoses 8 Support the platform mounting weldment, but
from the "V1" and "V2" ports on platform rotator do not apply any lifting pressure.
manifold. Cap the fittings on the manifold.
9 Remove the eight mounting bolts from the
Bodily injury hazard. Spraying platform mounting weldment.
hydraulic oil can penetrate and
10 Remove the center bolt and slide the platform
burn skin. Loosen hydraulic
mounting weldment off of the platform rotator.
the oil pressure to dissipate Crushing hazard. The platform
gradually. Do not allow oil to squirt mounting weldment may become
or spray. unbalanced and fall if it is not
properly supported.
4 Remove the platform manifold mounting
fasteners. Lay the platform manifold to the side. 11 Support the platform rotator. Do not apply
any lifting pressure.
Cables can be damaged if they S-100 and S-120 models:
are kinked or pinched.
12 Support the rod end of the platform leveling
5 Remove the power to platform cover plate from cylinder. Protect the cylinder rod from damage.
the electrical outlet box. Do not disconnect the
wiring. 13 Remove the pin retaining fastener from the
platform level cylinder rod-end connecting link
Electrocution/burn hazard. Contact pivot pin and the platform rotator pivot pin. Do
with electrically charged circuits not remove the pins.
injury. Remove all rings, watches 14 Use a soft metal drift to remove both pins and
and other jewelry. remove the platform rotator from the machine.
6 Remove the power to platform electrical outlet Crushing hazard. The platform
box from the platform and lay it to the side. rotator may become unbalanced
and fall if it is not properly
7 Remove the weld cable from the platform supported.
(if equipped).
Component damage hazard. The
Electrocution/burn hazard. Contact platform angle sensor is a very
with electrically charged circuits sensitive instrument. It can be
could result in death or serious damaged internally if the platform
injury. Remove all rings, watches rotator is dropped or sustains
and other jewelry. any physical shock, even if the
damage is not visible.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 19

platform components
S-105 and S-125 models: 2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
12 Remove the pin retaining fasteners from the jib to collect any drainage. Secure the container to
boom and jib boom leveling arms to platform the boom.
rotator pivot pins. Do not remove the pins.
3 Slowly open the top bleed valve on the rotator.
13 Support the jib boom leveling arms with a Do not remove the bleed valve from the
suitable lifting device. platform rotator.
14 Use a soft metal drift to remove both pins and Bodily injury hazard. Spraying
remove the platform rotator from the machine. hydraulic oil can penetrate and
Crushing hazard. The jib boom burn skin. Loosen hydraulic
leveling arms may fall if they are connections very slowly to allow
not properly supported when the the oil pressure to dissipate
jib boom leveling arm pivot pin is gradually. Do not allow oil to squirt
removed. or spray.

platform angle sensor is a very a
sensitive instrument. It can be
damaged internally if the platform
rotator is dropped or sustains
any physical shock, even if the
damage is not visible.
How to Bleed the Platform

Rotator
Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure. d c b
S-105 (Before serial number 251) and a top bleed valve

S-125 models (Before serial number 999): b bottom bleed valve
c clear hose
1 At the ground controls, simultaneously hold the d container
auxiliary power button and the platform rotate
right button until the platform is fully rotated to
the right.
3 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494

platform components
4 Hold the platform rotate left button until the 2-4

platform is fully rotated. Continue holding the
button until air stops coming out of the bleed Platform Level Sensor
valve. Close the bleed valve.
The platform level sensor is mounted to the side
Crushing hazard. Keep clear of of the platform rotator. The platform level sensor
the platform during rotation. is monitored by the control system to maintain a
5 Connect the clear hose to the bottom bleed level platform throughout boom range of motion.
valve and slowly open the valve. Do not remove If a platform level sensor is replaced, it must be
the bleed valve. calibrated prior to machine operation.
6 Hold the platform rotate right button until the

platform is fully rotated. Continue holding the How to Calibrate the
button until air stops coming out of the bleed Platform Level Sensor
valve. Close the bleed valve.
Note: Perform this procedure with the machine on
Crushing hazard. Keep clear of a firm, level surface and in the stowed position.
the platform during rotation.
1 Secure a digital level to one of the side railings
7 Remove the hose from the bleed valve and of the platform.
clean up any hydraulic oil that may have spilled.
2 Start the machine and level the platform to
8 Rotate the platform full right then left and gravity. Push the red Emergency stop button in
inspect the bleed valves for leaks. to stop the engine.
9 Clean up any oil that may have spilled during
3 Press and hold the enter button on the
this procedure. ground control panel while pulling out the red
S-100, S-120, S-105 (after serial number 250) and Emergency Stop button.
S-125 models (after serial number 998):
4 Press the plus button , then press the enter
1. Rotate the platform full right, then full left until button twice before again pressing the plus
air is completely out of the rotator. Bleeding the button .
valve is not necessary.
5 Press the enter button three timees until
Platform Level to Gravity is displayed on the
LCD screen.
6 Press the plus button once.
7 Press the enter button to save the setting in
memory.
8 Push one of the LCD
screen buttons shown
until platform level sensor
mv per degree is displayed.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 21

platform components
9 Confirm that the number shown on the display 2-5

is the same as that shown on the data sheet
supplied with the new platform level sensor. Platform Overload System
Result: If the number shown on the display The platform overload system is designed to
is the same as that shown on the data sheet prevent the machine from continuing to operate
supplied with the new platform level sensor, when the load in the platform exceeds maximum
continue to step 10. rated capacity. Refer to the machine serial label
Result: If the number shown on the display is for maximum capacity information.
not the same as that shown on the data sheet If maximum platform capacity is exceeded, the
supplied with the new platform level sensor, alarm will sound at the platform controls and the
continue to step 9. platform overload indicator lights will flash at both
10 Press the plus button or the minus the ground and platform controls. The ground and
button to correct the display to match the data platform controls will become disabled. Before
sheet. Then press the enter button to save normal machine operation can continue, the
the setting in memory. excess load will need to be removed from the
platform.
11 Push one of the LCD
screen buttons shown If the excess load cannot be removed or if the
until exit is displayed. operator at the platform controls is unable to
correct the overloaded condition, another person
11 Press the plus button to select yes and then at the ground controls can operate the machine
press the enter button . using auxiliary power. There will be limited control
of boom functions from the ground controls when
using auxiliary power. Auxiliary power can be
used to correct the overloaded platform condition
in order to resume normal, safe operation of the
machine.
How to Calibrate the Platform

Overload System (if equipped)
Calibration of the platform overload system is
essential to safe machine operation. Continued
use of an improperly calibrated platform overload
system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
Note: Perform this procedure with the machine on

a firm, level surface.
1 Turn the key switch to platform control. Start
the engine and level the platform.
3 - 22 S-100 • S-105 • S-120 • S-125 Part No. 1268494

platform components
2 Determine the maximum platform capacity. 6 Move the platform up and down by hand, so
Refer to the machine serial plate. it bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
3 Remove all weight, tools and accessories from
the platform. Result: The alarm should be off. The platform
overload indicator light should be off at the
Note: Failure to remove all weight, tools and
platform controls and there should be no
accessories from the platform will result in an
error message on the LCD display at the
incorrect calibration.
ground controls. Slowly loosen the load spring
4 Using a suitable lifting device, place a test adjustment nut in a counterclockwise direction
weight equal to the maximum platform capacity in 10° increments until the overload indicator
at the enter of the platform floor. light flashes at both the platform and ground
controls, and the alarm sounds. Proceed to
5 Move the platform up and down by hand, so step 7.
it bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. Result: The alarm should be sounding.
The platform overload indicator light should be
Result: The alarm should be off. The platform flashing at the platform controls and “PLATFORM
overload indicator light should be off at the OVERLOAD” should be displayed on the LCD
platform controls and there should be no error screen at the ground controls. Repeat this
message on the LCD display at the ground procedure beginning with step 5.
controls. Proceed to step 6.
Note: The platform will need to be moved up
Result: The alarm is sounding. The and down and allowed to settle between each
platform overload indicator light is flashing adjustment.
at the platform controls and “PLATFORM
OVERLOAD” should be displayed on the LCD Note: There may be a 2 second delay before
screen at the ground controls. Slowly tighten the platform overload indicator lights and alarm
the load spring adjustment nut in a clockwise responds.
direction in 10° increments until the overload
indicator light turns off, and the alarm does not
sound. Proceed to step 8.
Note: The platform will need to be moved up
and down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before

the platform overload indicator light and alarm
responds.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 23

platform components
7 Move the platform up and down by hand, so 9 Test all machine functions from the platform
it bounces approximately 2.5 to 5 cm / 1 to 2 controls.
inches. Allow the platform to settle.
Result: All platform control functions should not
Result: The alarm should be off. The platform operate.
overload indicator light should be off at the
10 Turn the key switch to ground control.
platform controls and there should be no error
message on the LCD display at the ground 11 Test all machine functions from the ground
controls. Proceed to step 8. controls.
Result: The overload indicator lights are flashing Result: All ground control functions should not
at the platform and ground controls, and the operate.
alarm is sounding. Repeat this procedure
beginning with step 5. 12 Using a suitable lifting device, lift the test weight
off the platform floor.
the platform overload indicator light and alarm Result: The alarm should be off. The platform
responds. overload indicator light should be off at the
8 Add an additional test weight to the platform. message on the 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.
Note: There may be a 2 second delay before the
Result: The alarm should be sounding. overload indicator lights and alarm turn off.
The platform overload indicator light should be
flashing at the platform controls and “PLATFORM 13 Test all machine functions from the ground
OVERLOAD” should be displayed on the LCD controls.
screen at the ground controls. Proceed to step 9. Result: All ground control functions should
Result: The alarm should be off. The platform operate normally.
overload indicator light should be off at the 14 Turn the key switch to platform control.
message on the LCD display at the ground 15 Test all machine functions from the platform
controls. Remove the additional 10 lb / 4.5 kg controls.
test weight. Repeat this procedure beginning Result: All platform control functions should
with step 6. operate normally.
the platform overload indicator light and alarm
responds.
3 - 24 S-100 • S-105 • S-120 • S-125 Part No. 1268494

platform components
2-6 3 Press the buttons on the ground

controls in the following sequence:
Platform Overload Recovery (plus)(minus)(minus)(plus).
Message (software V3.14 and 4 Press the enter or previous button on the LCD
later) screen until CLEAR OVERLOAD RECOVERY
is displayed.
If the ground controls LCD screen displays
5 Press the plus button or minus
OVERLOAD RECOVERY, the emergency lowering
button to select YES. Then press
system has been used while the platform was
the buttons in following sequence:
overloaded.
(plus)(plus)(plus)(minus) and press the enter
How to Clear the Platform button to accept.
Overload Recovery Message Note: The passcode buttons

(plus)(plus)(plus)(minus) must be entered in
Note: This message shall be cleared by a person the proper sequence before the enter button is
trained and qualified on the troubleshooting and pressed.
repair of this machine.
6 Press the enter or previous button on the LCD
Note: Use the following chart to identify the screen until EXIT is displayed.
description of each LCD screen control button
used in this procedure. 7 Press the plus button or minus button to select
YES and then press the enter button.

Plus Minus Previous Enter
1 Turn the key switch to platform control. Start

the engine and level the platform.
2 Press and hold the enter button on the ground
sontrol panel while turning the key switch to
ground controls. Hold the enter button for
approximately 5 seconds.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 25

Jib Boom Components, S-105 / S-125 Models
3-1 5 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the
Jib Boom, cylinder.
S-105 and S-125 Models Bodily injury hazard. Spraying
How to Remove the Jib Boom burn skin. Loosen hydraulic
Note: Perform this procedure with the boom in the
the oil pressure to dissipate
stowed position.
Note: When removing a hose assembly or fitting, squirt or spray.
the O-ring on the fitting and/or hose end must be 6 Support the barrel end of the cylinder with a
replaced and then torqued to specification during suitable lifting device.
Hose and Fitting Torque Specifications. 7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
1 Remove the platform. See Repair Procedure,
How to Remove the Platform. 8 Use a soft metal drift to remove the pin and let
the cylinder hang down.
2 Remove the platform mounting weldment
and the platform rotator. See Repair Procedure, 9 Attach a lifting strap from an overhead crane to
How to Remove the Platform Rotator. the jib boom.
3 Remove the hose and cable cover retaining 10 Remove the pin retaining fastener from the jib
fasteners from the jib boom leveling arm. boom pivot pin.
Remove the hose and cable cover from the 11 Use a soft metal drift to remove the pin and
machine. remove the jib boom from the primary boom.
4 Support the jib boom with a suitable lifting Crushing hazard. The jib boom
device. may become unbalanced and
fall when it is removed from
supported.
3 - 26 S-100 • S-105 • S-120 • S-125 Part No. 1268494

jib boom components, S-105 and S-125 Models
12 Remove the pin retaining fasteners from the 18 Remove the pin retaining fastener from the
jib boom lift cylinder rod-end pivot pin. Do not platform leveling cylinder rod-end pivot pin.
remove the pin.
19 Use a soft metal drift to remove the platform
13 Slide both of the jib boom leveling arms off of leveling cylinder rod-end pivot pin.
the jib boom pivot pin and lay them off to the
side. Crushing hazard. The platform
leveling cylinder may fall if it is not
14 Attach a lifting strap from an overhead crane properly supported when the rod-
to the lug on the rod end of the jib boom lift end pivot pin is removed.
cylinder.
Crushing hazard. The jib boom
15 Use a soft metal drift to remove the jib boom bellcrank may fall if it is not
lift cylinder rod-end pivot pin. Remove the jib properly supported when the
boom lift cylinder from the jib boom bellcrank. platform leveling cylinder rod-end
pivot pin is removed.
Crushing hazard. The jib boom lift
cylinder may become unbalanced 20 Remove the pin retaining fastener from the jib
and fall when it is removed from boom bellcrank pivot pin.
21 Use a soft metal drift to remove the jib boom
supported.
bellcrank pivot pin. Remove the jib boom
16 Attach a lifting strap from an overhead crane to bellcrank from the machine.
the jib boom bellcrank.
Crushing hazard. The jib boom
17 Support the rod end of the platform leveling bellcrank may become unbalanced
cylinder with a suitable lifting device. Protect and fall if it is not properly
the cylinder rod from damage. supported when it is removed from
the machine.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 27

jib boom components, S-105 and S-125 Models
3-2 2 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the
Jib Boom Lift Cylinder, cylinder.
S-105 and S-125 Models Bodily injury hazard. Spraying
How to Remove the Jib Boom burn skin. Loosen hydraulic
Lift Cylinder connections very slowly to allow
Note: Perform this procedure with the boom in the gradually. Do not allow oil to
stowed position. squirt or spray.
Note: When removing a hose assembly or fitting, 3 Remove the hose and cable cover retaining
the O-ring on the fitting and/or hose end must be fasteners from the jib boom leveling arm.
replaced and then torqued to specification during Remove the hose and cable cover from the
installation. Refer to Specifications, Hydraulic machine.
4 Remove the pin retaining fasteners from the
1 Raise the jib boom slightly and place blocks jib boom lift cylinder rod-end pivot pin. Do not
under the platform mounting weldment. Lower remove the pin.
the jib boom until the platform is resting on the
5 Use a soft metal drift to tap the jib boom lift
blocks just enough to support the platform.
cylinder rod-end pivot pin half way out and
Note: Do not rest the entire weight of the boom on lower one of the leveling arms to the ground.
the blocks. Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
6 Support the jib boom lift cylinder with a suitable
lifting device.
7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin.
8 Use a soft metal drift to remove the jib boom
lift cylinder rod-end pivot pin. Remove the jib
boom lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder may become unbalanced
and fall when it is removed from
supported.
3 - 28 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Boom Components
Pivot end
a
a Number 1 Platform end

b Number 2
c Number 3

Pivot end
a
Platform end
a Number 0
b Number 1
c Number 2
d Number 3
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 29

Boom Components
4-1 4 Tag and disconnect the black electrical

connector from the bottom of the control box.
Cable Track
5 Remove the platform-end boom cable tube
The cable track and boom cable tube guides mounting fasteners at the engine side of the
cables and hoses running up the boom. The machine.
cable track can be repaired link by link without 6 Remove the cable track mounting fasteners
removing the cables and hoses that run through from the cable track support at the engine side
it. Removing the entire cable track assembly may of the machine.
be necessary when performing major repairs that
involve removing the boom. 7 Remove the wear pad mounting weldment from
the cable track support bracket at the engine
How to Remove the Boom side of the machine.
Cable Track 8 Remove the hose and cable clamp from the
cable track support bracket at the engine side
of the machine.
replaced and then torqued to specification during 9 Place blocks between the cable track and the
installation. boom cable tube for support.
Refer to Specifications, Hydraulic Hose and Fitting
10 Strap together the boom cable tube, blocks of
Torque Specifications.
wood, and the cable track at the engine side of
Note: Perform this procedure with the boom fully the machine.
stowed.
1 Remove the hose and cable cover retaining Cables, hoses, boom cable tube
fasteners from the jib boom leveling arm. and cable track can be damaged if
Remove the hose and cable cover from the they are kinked or pinched.
machine. 11 Remove the limit switch cover retaining
2 Remove the protective coil sleeve from the fasteners from the top of the number 2 boom
hose and cable bundle at the platform end of tube at the platform end of the machine.
the boom cable tube. Remove the limit switch cover.
3 Tag, disconnect and plug all hydraulic hoses 12 Tag and disconnect the wiring connectors from
from the boom cable tube to the platform the proximity and limit switches on top of the
manifold. number 2 boom tube at the platform end of the
machine.
Note: If your machine is equipped with an airline
to platform option and/or weld cable option, the
airline and/or cable must be disconnected from the
platform before the cable track is removed.
3 - 30 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
13 Remove the cable track roller guide mounting If not removing the boom from the machine,
fasteners from the ground controls side of the proceed to step 19.
machine at the platform end.
18 Tag, disconnect and plug the primary extension
14 Remove the roller guide from the cable cylinder hydraulic hoses on the side of the
track guide bracket at the engine side of the number 2 boom tube at the ground controls
machine. side of the machine. Cap the fittings.
15 Tag, disconnect and plug the hydraulic hoses Bodily injury hazard. Spraying
from the bottom of the bulkhead fittings on the hydraulic oil can penetrate and
cable track support at the ground controls side burn skin. Loosen hydraulic
of the machine. connections very slowly to allow
Bodily injury hazard. Spraying
hydraulic oil can penetrate and gradually. Do not allow oil to
burn skin. Loosen hydraulic squirt or spray.
connections very slowly to allow 19 Remove the cable track mounting fasteners
the oil pressure to dissipate from the cable track support at the ground
gradually. Do not allow oil to controls side of the machine.
squirt or spray.
20 Remove the side panels from the boom cable
16 Remove the bulkhead fitting locknuts from the tube located under the cable track at the
bulkhead fittings on the cable track support ground controls side of the machine.
at the ground controls side of the machine.
Remove and cap the fittings. 21 Remove the hose and cable cover mounting
fasteners from the pivot end of the boom at the
17 Tag and disconnect the wiring connectors. ground controls side of the machine. Remove
Note: The wiring connectors that need to be the cover.
disconnected are located next to the hose fittings 22 Remove the hose and cable clamps from the
that were removed in step 16. hoses and cables located below the boom pivot
on the inside of the turntable riser at the ground
controls side of the machine.
23 Tag and disconnect the electrical cables from
the cable track to the ground controls side of
the machine.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 31

boom components
If not removing the boom from the machine, 28 Attach a lifting strap from an overhead crane to
proceed to step 25. each end of the cable track assembly. Carefully
lift the assembly from the boom and set it on a
24 Pull the hydraulic hoses from the boom cable structure capable of supporting it.
tube located under the cable track at the
ground controls side of the machine. Crushing hazard. If the cable
track assemblies are not properly
25 Place blocks between the cable track and the secured together, the cable
cable track tube at the ground controls side of track assemblies may become
the machine. Secure the cable track and the unbalanced and fall when it is
cable track tube together. removed from the machine.
Component damage hazard. Component damage hazard.
Cables, hoses, boom cable tube Cables, hoses, boom cable tube
and cable track can be damaged if and cable track can be damaged if
they are kinked or pinched. they are kinked or pinched.
26 Attach a lifting strap from an overhead crane Component damage hazard. The
to the cable track assembly at the engine side boom cable tube and cable tracks
of the boom. Lift the cable track assembly over can be damaged if they are
the boom and carefully set the assembly on top twisted.
of the longer boom cable tube at the ground
controls side of the machine. How to Repair the Boom
Crushing hazard. If the cable Cable Track
track assemblies are not properly
secured together, the cable track Component damage hazard.
may become unbalanced and The boom cable track can be
fall when it is removed from the damaged if it is twisted.
machine. Note: A cable track repair kit is available through
27 Strap both cable track assemblies together. the Genie Service Parts Department.
Component damage hazard. Before serial number 881 (S-120/125) and

Cables and hoses can be 210 (S-100/105):
damaged if they are kinked or Use part number 62320 which includes a 1-link
pinched. section of cable track. If the cable track has been
replaced using cable track kit, Genie part number
Component damage hazard. 102054, use part number 102214. If unsure which
Cable tracks can be damaged if cable track is on the machine, contact Genie
they are twisted. Industries Service Department.
3 - 32 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
After serial number 880 (S-120/125) and 4-2

209 (S-100/105):
Use part number 102214 which includes a 3-link Boom
section of cable track.
How to Shim the Boom
1 Visually inspect the cable track and determine
which section needs to be replaced. 1 Measure each upper, side and lower wear pad.
1
2 Remove the snap-on cable track spacers. Boom wear pad specifications /2 inch
Minimum thickness 12.7 mm
3 Remove the external snap rings from the pivot
pins at each end of the 3-link section to be
removed. Note: If a wear pad is not less than specification,
perform the following procedure.
4 Lift up the hoses and cables and carefully
remove the damaged 3-link section of cable 2 Remove the retaining fasteners from the
track. appropriate black plastic boom tube cover at
the platform end of the boom. Remove the
Component damage hazard. cover.
Hoses and cables can be
damaged if they are kinked or 3 Extend the boom until the wear pads are
pinched. accessible.
5 Remove the snap-on spacers from the 4 Loosen the wear pad mounting fasteners.
replacement section of cable track.
5 Fit as many shims as can be installed by hand.
6 Lift up the hoses and cables and carefully insert
6 Tighten the mounting fasteners.
the new 3-link section of cable track.
7 Remove the boom end cover retaining
Component damage hazard. fasteners at the pivot end of the boom. Remove
Hoses and cables can be
the boom end cover from the machine.
damaged if they are kinked or
pinched. 8 Remove the boom side inspection cover
retaining fasteners from the boom at the pivot
7 Connect the ends of the replacement cable
end of the boom. Remove the boom inspection
track section to the existing cable track using
cover from the machine to access boom 3 wear
the pivot pins and external snap rings.
pads.
Note: Be sure that the pivot pins are installed from
9 Loosen the wear pad mounting fasteners.
the inside out so the external snap rings are on the
outside of the cable track. 10 Fit as many shims as can be installed by hand.
8 Install the cable track snap-on spacers. 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. 1268494 S-100 • S-105 • S-120 • S-125 3 - 33

boom components
How to Remove the Boom 8 Remove the boom storage area cover retaining
fasteners. Remove the cover from the machine.
Bodily injury hazard. This
procedure requires specific repair 9 Place support blocks under the boom lift
skills, lifting equipment and a cylinder.
suitable workshop. Attempting 10 Remove the pin retaining fastener from the
this procedure without these skills boom lift cylinder rod-end pivot pin. Use a soft
and tools could result in death metal drift to remove the pin.
or serious injury and significant
component damage. Dealer Crushing hazard. The boom lift
service is strongly recommended. cylinder may fall when the rod-end
pivot pin is removed if the boom lift
Note: When removing a hose assembly or fitting, cylinder is not properly supported
the O-ring on the fitting and/or hose end must be by the overhead crane.
installation. Refer to Specifications, Hydraulic Crushing hazard. The boom
Hose and Fitting Torque Specifications. may fall when the rod-end pivot
pin is removed if the boom is
1 Remove the platform. See Repair Procedure, not properly supported by the
How to Remove the Platform. overhead crane.
2 Remove the platform rotator. See Repair 11 Carefully raise the boom with the overhead
Procedure, How to Remove the Platform crane until the rod end of the boom lift cylinder
Rotator. can be removed.
3 S-105 and S-125 models: Remove the Jib 12 Carefully lower the rod end of the boom lift
Boom. See 3-1, How to Remove the Jib Boom. cylinder down onto the support blocks.
4 Remove the cable track. See Repair Procedure, 13 Lower the boom with the overhead crane to a
How to Remove the Boom Cable Track. horizontal position.
5 Raise the boom approximately 4 feet / 1.2 m. 14 Remove the boom end cover retaining fasteners
from the pivot end of the boom. Remove the
6 Attach a lifting strap from an overhead crane to
cover.
the rod end of the boom lift cylinder.
15 Locate the cable break limit switch above the
7 Attach an overhead 10 ton / 10,000 kg crane to
primary boom extension cylinder at the pivot
the platform end of the boom for support. Do
end of the boom.
not lift the boom.
3 - 34 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
16 Tag and disconnect the wiring connector from How to Disassemble the Boom,
the cable break limit switch.
17 Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder. Cap Note: Complete disassembly of the boom is only
the fittings on the cylinder. necessary if the outer or inner boom tubes must
be replaced. The primary boom extension cylinder
Bodily injury hazard. Spraying can be removed without completely disassembling
hydraulic oil can penetrate and the boom. See 4-4, How to Remove the Primary
burn skin. Loosen hydraulic Extension Cylinder.
the oil pressure to dissipate 1 Remove the boom. See 4-2,
gradually. Do not allow oil to How to Remove the Boom.
squirt or spray.
2 Remove the retaining fasteners from the access
18 Attach a second overhead 10 ton / 10,000 kg covers on both sides of the boom at the pivot
crane to the pivot end of the boom for support. end. Remove the access covers.
Do not apply any lifting pressure.
19 Remove the pin retaining fastener from the a
boom pivot pin. Do not remove the pin.
20 Use a soft metal drift to remove the boom pivot
pin.
Component damage hazard. Be
careful not to damage the boom
envelope limit switch(s) located
on the inside of the engine side a side access covers
turntable riser when removing
3 Secure the number 2 and number 3 boom
the boom assembly. The boom
tubes together with a strap or chain to prevent
envelope switch(s) can be
them from moving.
damaged even if the damage is
not visible. 4 Remove the cable clamp from the cable break
limit switch wiring.
21 Carefully remove the boom assembly from the
machine and place it on a structure capable of
supporting it.
Crushing hazard. The boom may
become unbalanced and fall when
it is removed from the machine if
it is not properly supported by the
overhead cranes.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 35

boom components
10 Remove the pulley pivot pins, cable guards and

pulleys.
a
Note: When installing the pulleys, be sure that the
side of the pulley with the taller flange is facing the
center of the boom tube.
11 Locate the number 3 boom tube extension

cable clevis pins on both sides of the number 2
boom tube at the pivot end of the boom.
12 Remove the cotter pin and clevis pin from both
b cables.
Note: When installing a clevis pin, always replace
the cotter pin with a new one.
13 Remove the lower external snap ring and

washer from the cable break limit switch
a cable break limit switch actuator pivot pin.
b cable pulley
14 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.
6 Tag, disconnect and plug the hydraulic hoses 15 Remove the upper plate and actuator pivot pin.
from the primary boom extension cylinder. Cap Do not remove the cable break limit switch from
the fittings on the cylinder. the mounting plate.
Bodily injury hazard. Spraying 16 Push the cable break actuator and cables
hydraulic oil can penetrate and towards the platform end of the boom
burn skin. Loosen hydraulic approximately 18 inches / 46 cm.
the oil pressure to dissipate 17 Remove the red cable adjustment locking
gradually. Do not allow oil to bracket retaining fasteners. Remove the red
squirt or spray. locking bracket from the machine.
7 Remove the fasteners from the inner cable Bodily injury hazard. Failure to
track mounting bracket at the primary boom install the red cable adjustment
extension cylinder. locking bracket will allow the cable
mounting bolts to loosen and fall
8 Lay the inner cable track and hoses down and out which could result in death or
out of the way. serious injury.
9 Remove the pulley pivot pin retaining fasteners
from the number 2 boom tube at the pivot end
of the boom.
3 - 36 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
24 Support and slide the primary boom extension

cylinder out of the boom assembly while
guiding the cables out of the boom and place it
on a structure capable of supporting it.
Crushing hazard. The primary
boom extension cylinder may
it is removed from the boom if
it is not properly supported and
attached to the overhead crane.
Cables can be damaged if they
a
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
a red cable adjustment
locking bracket 25 Remove the retaining fasteners from the limit
switch cover on top of the number 2 boom tube
18 Remove the two cable adjustment bolts. at the platform end of the machine.
19 Remove the cable-end block mounting plate 26 Carefully remove the cover with proximity and
fasteners. Remove the cable-end block limit switches from the top of the number 2
mounting plate from the machine. boom tube at the platform end of the boom.
20 Remove the trunnion pin retaining fasteners. Tip-over hazard. Failure to install
21 Use a slide hammer to remove the trunnion the correct proximity and/or limit
pins from the primary boom extension cylinder. switches in the correct location will
result in the machine tipping over,
22 Remove the primary boom extension cylinder resulting in death or serious injury.
hold down brackets at the pivot end of the
boom. 27 Tag and disconnect the wiring connectors from
the proximity and limit switches at the top of
23 Attach a lifting strap from an overhead crane to the number 2 boom tube at the platform end of
the lifting eye on the primary boom extension the boom. Do not remove the proximity or limit
cylinder. switches.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 37

boom components
28 Remove the retaining fasteners from the limit 34 Attach a lifting strap from an overhead crane to
switch cover on the side of the number 0 boom the number 3 boom tube at the platform end of
tube at the platform end of the boom. the boom.
29 Carefully remove the cover with proximity and 35 Support and slide the number 3 boom tube out
limit switches from the number 0 boom tube at of the number 2 boom tube. When the number
the platform end of the boom. 3 boom tube is approximately halfway removed,
remove the bottom wear pads from the number
Tip-over hazard. Failure to install 2 boom tube at the platform end of the boom.
the correct proximity and/or limit
switches in the correct location will Crushing hazard. The number
result in the machine tipping over, 3 boom tube may become
resulting in death or serious injury. unbalanced and fall when it is
removed from the number 2 boom
30 Tag and disconnect the wiring connectors from
tube if it is not properly supported
the proximity and limit switches at the ground
and attached to the overhead
controls side of the number 0 boom tube at the
crane.
platform end of the boom. Do not remove the
proximity or limit switches. Note: During removal, the overhead crane strap
31 Remove the retaining fasteners from each black
plastic boom tube cover at the platform end of 36 Remove and label the top and side wear pads
the machine. Remove the covers. from the number 2 boom tube at the pivot end
of the boom. Do not remove the bottom wear
32 Remove and label the top and side wear pads
pads.
of the number 3 boom tube at the pivot end
of the boom. Do not remove the bottom wear Note: Pay careful attention to the location and
pads. amount of shims used with each wear pad.
Note: Pay careful attention to the location and 37 Remove and label the top and side wear pads
amount of shims used with each wear pad. from the number 1 boom tube at the platform
end of the boom. Do not remove the bottom
33 Remove and label the top and side wear pads
wear pads.
from the number 2 boom tube at the platform
end of the boom. Do not remove the bottom Note: Pay careful attention to the location and
wear pads. amount of shims used with each wear pad.
Note: Pay careful attention to the location and 38 Attach a lifting strap from an overhead crane to
amount of shims used with each wear pad. the number 2 boom tube at the platform end of
the boom.
3 - 38 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
39 Support and slide the number 2 boom tube out 42 Support the secondary boom extension cylinder
of the number 1 boom tube. When the number with an overhead crane or other suitable lifting
2 boom tube is approximately halfway removed, device.
remove the bottom wear pads from the number
43 Remove the pin retaining fasteners from both
1 boom tube at the platform end of the boom.
the rod-end and barrel-end pivot pins. Do not
Crushing hazard. The number remove the pins.
2 boom tube may become
44 Use a soft metal drift to remove both pivot pins
unbalanced and fall when it is
and remove the secondary boom extension
cylinder from the machine while guiding the
barrel end of the cylinder out of the boom.
crane. Crushing hazard. The secondary
become unbalanced and fall if it is
not properly supported when it is
40 Remove the secondary boom extend cylinder removed from the machine.
cover retaining fasteners. Remove the covers.
Bodily injury hazard. Do not The boom lift cylinder rod can
operate the machine unless the become damaged if the barrel end
secondary extend cylinder covers of the secondary boom extension
are properly installed. Operating cylinder is allowed to come in
the machine with the covers contact with it.
removed could result in death or 45 Remove and label the top and side wear pads
serious injury. from the number 1 boom tube at the pivot end
41 Tag, disconnect and plug the secondary boom of the boom. Do not remove the bottom wear
extension cylinder hydraulic hoses. Cap the pads.
fittings on the cylinder. Note: Pay careful attention to the location and
Bodily injury hazard. Spraying amount of shims used with each wear pad.
squirt or spray.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 39

boom components
46 Remove and label the top and side wear pads How to Disassemble the Boom,
from the number 0 boom tube at the platform
end of the boom. Do not remove the bottom S-100 and S-105 Models
wear pads. Note: Complete disassembly of the boom is only
Note: Pay careful attention to the location and necessary
amount of shims used with each wear pad. if the outer or inner boom tubes must be replaced.
The primary boom extension cylinder can be
47 Attach a lifting strap from an overhead crane to removed without completely disassembling the
the number 1 boom tube at the platform end of boom. See 4-4, How to Remove the Primary
the boom. Extension Cylinder.
48 Support and slide the number 1 boom tube out 1 Remove the boom. See 4-2,
of the number 0 boom tube. When the number How to Remove the Boom.
1 boom tube is approximately halfway removed,
remove the bottom wear pads from the number 2 Remove the retaining fasteners from the access
0 boom tube at the platform end of the boom. covers on both sides of the boom at the pivot
end. Remove the access covers.
Crushing hazard. The number
1 boom tube may become
a
unbalanced and fall when it is
crane.
a side access covers
3 Secure the number 2 and number 3 boom

tubes together with a strap or chain to prevent
them from moving.
4 Remove the cable clamp from the cable break
limit switch wiring.
3 - 40 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components

cables.
a

actuator pivot pin.
12 Remove the cable break actuator mounting
plate retaining fasteners. Remove the lower
b plate from the machine.
13 Remove the upper plate and actuator pivot pin.
Do not remove the cable break limit switch from
the mounting plate.
a cable break limit switch

14 Push the cable break actuator and cables
b cable pulley towards the platform end of the boom
approximately 18 inches / 46 cm.
5 Disconnect the wiring connector from the cable
break limit switch. 15 Remove the red cable adjustment locking
bracket retaining fasteners. Remove the red
6 Tag, disconnect and plug the hydraulic hoses locking bracket from the machine.
from the primary boom extension cylinder. Cap
the fittings on the cylinder. Bodily injury hazard. Failure to
install the red cable adjustment
Bodily injury hazard. Spraying locking bracket will allow the cable
hydraulic oil can penetrate and mounting bolts to loosen and fall
burn skin. Loosen hydraulic out which could result in death or
connections very slowly to allow serious injury.
gradually. Do not allow oil to 16 Remove the two cable adjustment bolts.
squirt or spray. 17 Remove the cable-end block mounting plate
7 Remove the pulley pivot pin retaining fasteners fasteners. Remove the cable-end block
from the number 2 boom tube at the pivot end mounting plate from the machine.
of the boom. 18 Remove the trunnion pin retaining fasteners.
8 Remove the pulley pivot pins, cable guards and 19 Use a slide hammer to remove the trunnion
pulleys. pins from the primary boom extension cylinder.
Note: When installing the pulleys, be sure that the
side of the pulley with the taller flange is facing the
center of the boom tube.

Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 41

boom components
23 Remove the retaining fasteners from the limit

switch cover on top of the number 2 boom tube
at the platform end of the machine.
24 Carefully remove the cover with proximity and
limit switches from the top of the number 2
boom tube at the platform end of the boom.
Tip-over hazard. Failure to install
the correct proximity and/or limit
switches in the correct location will
resulting in death or serious injury.
25 Tag and disconnect the wiring connectors from
the proximity and limit switches at the top of
a
the number 2 boom tube at the platform end of
the boom. Do not remove the proximity or limit
switches.
a red cable adjustment 26 Remove the retaining fasteners from the limit
locking bracket switch cover on the side of the number 1 boom
tube at the platform end of the boom.
20 Remove the primary boom extension cylinder
hold down brackets at the pivot end of the 27 Carefully remove the cover with proximity and
boom. limit switches from the number 1 boom tube at
the platform end of the boom.
21 Attach a lifting strap from an overhead crane to
the lifting eye on the primary boom extension Tip-over hazard. Failure to install
cylinder. the correct proximity and/or limit
switches in the correct location will
22 Support and slide the primary boom extension
cylinder out of the boom assembly while
resulting in death or serious injury.
guiding the cables out of the boom and place it
on a structure capable of supporting it. 28 Tag and disconnect the wiring connectors from
the proximity and limit switches at the ground
Crushing hazard. The primary controls side of the number 1 boom tube at the
platform end of the boom. Do not remove the
proximity or limit switches.
it is removed from the boom if
it is not properly supported and 29 Remove the retaining fasteners from each black
attached to the overhead crane. plastic boom tube cover at the platform end of
the machine. Remove the covers.
3 - 42 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
30 Remove and label the top and side wear pads 34 Remove and label the top and side wear pads
of the number 3 boom tube at the pivot end from the number 2 boom tube at the pivot end
of the boom. Do not remove the bottom wear of the boom. Do not remove the bottom wear
pads. pads.
Note: Pay careful attention to the location and Note: Pay careful attention to the location and
amount of shims used with each wear pad. amount of shims used with each wear pad.
31 Remove and label the top and side wear pads 35 Remove and label the top and side wear pads
from the number 2 boom tube at the platform from the number 1 boom tube at the platform
end of the boom. Do not remove the bottom end of the boom. Do not remove the bottom
wear pads. wear pads.
Note: Pay careful attention to the location and Note: Pay careful attention to the location and
amount of shims used with each wear pad. amount of shims used with each wear pad.
32 Attach a lifting strap from an overhead crane to 36 Attach a lifting strap from an overhead crane to
the number 3 boom tube at the platform end of the number 2 boom tube at the platform end of
the boom. the boom.
33 Support and slide the number 3 boom tube out 37 Support and slide the number 2 boom tube out
of the number 2 boom tube. When the number of the number 1 boom tube. When the number
3 boom tube is approximately halfway removed, 2 boom tube is approximately halfway removed,
remove the bottom wear pads from the number remove the bottom wear pads from the number
2 boom tube at the platform end of the boom. 1 boom tube at the platform end of the boom.
Crushing hazard. The number Crushing hazard. The number
3 boom tube may become 2 boom tube may become
unbalanced and fall when it is unbalanced and fall when it is
removed from the number 2 boom removed from the number 1 boom
tube if it is not properly supported tube if it is not properly supported
and attached to the overhead and attached to the overhead
crane. crane.
Note: During removal, the overhead crane strap Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing. will need to be adjusted for proper balancing.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 43

boom components
4-3 5 Place support blocks under the boom lift

cylinder.
Boom Lift Cylinder
6 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a
How to Remove the Boom soft metal drift to remove the pin. Protect the
Lift Cylinder cylinder rod from damage.
Bodily injury hazard. This Crushing hazard. The boom lift

procedure requires specific repair cylinder may fall when the rod-end
skills, lifting equipment and a pivot pin is removed if the boom lift
suitable workshop. Attempting cylinder is not properly supported
this procedure without these skills by the overhead crane.
and tools could result in death Crushing hazard. The boom
or serious injury and significant may fall when the rod-end pivot
component damage. Dealer pin is removed if the boom is
service is strongly recommended. not properly supported by the
Note: When removing a hose assembly or fitting, overhead crane.
the O-ring on the fitting and/or hose end must be 7 Carefully raise the boom with the overhead
replaced and then torqued to specification during crane until the rod end of the boom lift cylinder
installation. can be removed.
Torque Specifications. 8 Carefully lower the rod end of the boom lift
cylinder down onto the support blocks.
1 Raise the boom until there is approximately
9 Carefully raise the boom with the overhead
4 feet / 1.2 m between the turntable and boom
crane until the barrel end of the boom lift
rest pad.
cylinder is accessible.
2 Attach a lifting strap from an overhead crane or
10 Tag, disconnect and plug the boom lift cylinder
other suitable lifting device to the rod end of the
hydraulic hoses. Cap the fittings on the cylinder.
the boom lift cylinder.
3 Attach an overhead 10 ton / 9071 kg crane to
the platform end of the boom for support. Do
not lift the boom.
4 Remove the boom storage area cover retaining the oil pressure to dissipate
fasteners. Remove the cover from the machine. gradually. Do not allow oil to
squirt or spray.
3 - 44 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
11 Remove the engine pivot plate retaining 17 With the boom lift cylinder being supported by
fastener. Swing the engine pivot plate out away the overhead crane, pull the boom lift cylinder
from the machine. toward the platform until it is out.
Crushing hazard. The boom lift
and fall if it is not properly
supported when it is removed from
the machine.
Be careful not to damage the
a b proximity and/or limit switches
when removing the boom lift
a engine pivot plate anchor hole
b engine pivot plate retaining fastener
cylinder.
12 Locate the engine pivot plate anchor hole at the Component damage hazard. The
cables and hydraulic hoses can be
pivot end of the engine pivot plate.
damaged if the boom lift cylinder
13 Install the bolt that was just removed into the is pulled across them.
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.
14 Remove the pin retaining fastener from the
barrel-end pivot pin. Do not remove the pin.
15 Support the boom lift cylinder with an overhead
crane.
16 Use a slide hammer to remove the boom lift
cylinder barrel-end pivot pin through the access
hole in the engine side turntable riser.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 45

boom components
4-4 3 Remove the access cover retaining fasteners

from both sides of the boom. Remove the
Extension Cylinders access covers.
The primary boom extension cylinder is located 4 Secure the number 2 and number 3 boom
inside the boom assembly and incorporates cables tubes together with a strap or chain to prevent
and pulleys that are responsible for extending the them from moving.
number 2 and 3 boom tubes. The secondary boom 5 Remove the cable clamp from the cable break
extension cylinder (S-120 and S-125 models) is limit switch wiring.
located underneath the number 0 boom tube and
is responsible for extending the number 1 boom
tube. The extension cylinders are equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure. a
How to Remove the Primary

Boom Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death
component damage. Dealer
service is strongly recommended.
a cable break limit switch
6 Disconnect the wiring connector from the cable
break limit switch.
installation. 7 Tag, disconnect and plug the hydraulic hoses
Refer to Specifications, Hydraulic Hose and Fitting from the primary boom extension cylinder. Cap
Torque Specifications. the fittings on the cylinder.
1 Raise the boom to a horizontal position. Bodily injury hazard. Spraying
2 Remove the retaining fasteners from the
boom end cover at the pivot end of the boom.
Remove the cover from the machine.
squirt or spray.
3 - 46 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
8 S-120 and S-125 models: Remove the 17 Push the cable break actuator and cables
fasteners from the inner cable track mounting towards the platform end of the boom
bracket at the primary boom extension cylinder. approximately 18 inches / 46 cm.
9 S-120 and S-125 models: Lay the inner cable 18 Remove the retaining fasteners from the red
track and hoses down and out of the way. cable adjustment locking bracket. Remove the
red locking bracket.
10 Remove the pulley pivot pin retaining fasteners
from the number 2 boom tube at the pivot end Bodily injury hazard. Failure to
of the boom. install the red cable adjustment
locking bracket would allow the
11 Remove the pulley pivot pins, cable guards and
cable mounting bolts to loosen
pulleys.
and fall out which could result in
Note: When installing the pulleys, be sure that the death or serious injury.
side of the pulley with the shorter flange is facing
the inside of the boom tube.

cables.

actuator pivot pin.
15 Remove the cable break actuator mounting a
plate retaining fasteners. Remove the lower
plate.
16 Remove the upper plate and actuator pivot pin. a red cable adjustment
Do not remove the cable break limit switch from locking bracket
the mounting plate.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 47

boom components
19 Remove the two cable adjustment bolts. How to Remove the Secondary
20 Remove the cable-end block mounting plate Boom Extension Cylinder,
fasteners. Remove the cable-end block
mounting plate.
21 Remove the trunnion pin retaining fasteners. Bodily injury hazard. This
procedure requires specific repair
22 Use a slide hammer to remove the trunnion skills, lifting equipment and a
pins from the primary boom extension cylinder. suitable workshop. Attempting
this procedure without these skills
Note: Use a 1/2 -13 bolt thread on each end of the
and tools could result in death
slide hammer.
23 Attach a lifting strap from an overhead crane to component damage. Dealer
the lifting eye on the primary boom extension service is strongly recommended.
cylinder.
24 Support and slide the primary boom extension the O-ring on the fitting and/or hose end must be
cylinder out of the boom assembly while replaced and then torqued to specification during
guiding the cables out of the boom and place it installation.
on a structure capable of supporting it. Refer to Specifications, Hydraulic Hose and Fitting
Crushing hazard. The primary
boom extension cylinder may 1 Raise the boom until the secondary boom
become unbalanced and fall when extension cylinder barrel-end pivot pin is above
it is removed from the boom if the turntable covers.
it is not properly supported and
2 Remove the secondary boom extend cylinder
attached to the overhead crane.
cover retaining fasteners. Remove the covers.
Cables can be damaged if they Bodily injury hazard. Do not
operate the machine unless the
are kinked, pinched or snagged
secondary extend cylinder covers
during removal.
are properly installed. Operating
Note: During removal, the overhead crane strap the machine with the covers
will need to be adjusted for proper balancing. removed could result in death or
serious injury.
3 - 48 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
3 Tag, disconnect and plug the secondary boom

extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
squirt or spray.
4 Support the secondary boom extension cylinder
with an overhead crane or other suitable lifing
device.
5 Remove the pin retaining fasteners from both
the rod-end and barrel-end pivot pins. Do not
remove the pins.
6 Protect the boom lift cylinder rod from damage.
7 Use a soft metal drift to remove both pivot pins.
8 Remove the secondary boom extension
cylinder from the machine while guiding the
barrel end of the cylinder out of the boom.
Crushing hazard. The secondary
become unbalanced and fall if it is
not properly supported when it is
removed from the machine.
The boom lift cylinder rod can
become damaged if the barrel end
of the secondary boom extension
cylinder is allowed to come in
contact with it.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 49

boom components
4-5
Boom Extend/Retract Cables
a
How to Adjust the Boom Extend/ d
Retract Cables
Properly adjusted extend/retract cables are
essential to safe machine operation. Failure to
maintain proper adjustment of the cables could
result in unsafe operating conditions and may
cause component damage. The boom extend and b
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
Note: A flashlight may be necessary to be able to

c
see the extend/retract cables inside of the boom
assembly. a limit switch
b extend cable adjustment bolts
Note: Perform this procedure with the boom fully c red cable adjustment locking bracket
retracted. d boom tube distance
Illustration 1
1 Start the engine from the ground controls.
9 At the pivot end of the boom (illustration 1),
2 Raise the boom to a horizontal position.
turn the cable adjustment bolts (b) clockwise
3 Stop the engine. to obtain 63/4 inches / 17 cm between the end
of the number 3 boom tube and the end of the
4 Remove the boom end cover from the pivot end
number 2 boom tube (d). As a guide (Illustration
of the machine.
2), the end of the extension cable coupling (i)
5 Locate the red locking bracket (c) covering the should be approximately mid-point (k) between
cable adjustment bolts at the pivot end of the the guide plate (l) and the cable retainer
boom (illustration 1). bracket (j). Illustration 2 is visible by removing
the boom side covers.
6 Remove the retaining fastener from the red
locking bracket and remove the bracket from Note: Adjust the cable adjustment bolts evenly so
the machine. the cable break limit switch (a) stays centered in
the limit switch actuator (Illustration 1).
7 Locate the retract cable equalizer bolt under the
number 1 boom tube at the platform end of the Note: If the distance is greater than 63/4 inches /
boom assembly (illustration 3). 17 cm, loosen the extend cable adjustment bolts
and tighten the hex jam nut on the cable tension
8 Loosen the nylock (g) and jam nut (h) on the
equalizer bolt until the distance is less than
cable tension equalizer bracket. Do not remove
63/4 inches / 17 cm. Loosen the jam nut and repeat
the nuts.
step 9.
3 - 50 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
f
l
i
i extension cable coupling
j cable retainer bracket
k equal distance
l guide plate
Illustration 2
e boom tube 1
10 At the platform end of the boom, tighten the f boom tube 2
hex jam nut (h) on the cable tension equalizer g nylock nut
bracket located underneath the number 1 boom h hex jam nut
h g
tube (Illustration 3). Tighten the hex jam nut
until it is snug. Do not overtighten. Illustration 3
11 Hold the hex jam nut with a wrench and tighten 14 Install the red locking bracket over the cable
the nylock nut (g) against the hex jam nut. adjustment bolts. A flat edge of each bolt head (b)
must be on top for the locking bracket to secure
12 Re-check that the cable break limit switch is
the bolts.
centered in the limit switch actuator. Adjust the
extension cable adjustment bolts to center it. Bodily injury hazard. Failure to re-
install the red cable adjustment
13 At the pivot end of the boom, measure the
locking bracket would allow the
distance between the end of the number 3
cable mounting bolts to loosen
boom tube and the end of the number 2 boom
and fall out which could result in
tube.
death or serious injury.
Result: The measurement between the end of
15 Lower the boom to the stowed position.
the number 3 boom tube and the end of the
number 2 boom tube should be 16 Start the engine from the platform controls.
63/4 to 67/8 inches / 17 to 17.5 cm (d).
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 51

boom components
17 Extend the boom approximately 2 feet / 0.6 m. How to Replace the Boom Extend/
18 Retract the boom. While retracting the boom, Retract Cables
visually inspect the number 2 and number 3
boom tubes. Note: The cable pulleys must also be replaced
when replacing the cables.
Result: The number 2 should not move more
than 1/2 inch (13 mm) before the number 3 1 Remove the boom extension cylinder. See 4-4,
boom tube begins to retract. How to Remove the Primary Boom Extension
Cylinder.
Note: If the number 2 boom tube moves more than
1
/2 inch (13 mm) before the number 3 boom tube Boom extend cables:
begins to retract, repeat the procedure until the
number 2 boom moves less than 1/2 inch before 2 Remove the retaining fasteners that secure the
the number 3 boom begins to retract. extension cable retainer to the pulley mount.
Remove the retainer.
o 3 Remove the cables from the lower boom extend
cable bracket that attaches to the number 3
Boom Tube One
boom tube.
Boom Tube Two
Boom Tube Three 4 Remove the front and rear fasteners from the
Boom Tube One
anchor bracket that supports the cable anchors.
Remove the bracket.
n
5 Remove the pulley and boom extend cables

from the extension cylinder assembly. Discard
m
the old cables and pulleys.
6 Route the new boom extend cables through the
boom extend pulley bracket.
m figure 3 platform end
n figure 2, boom tube 3 Note: Be sure before installing the extend cables
o figure 1, pivot end through the boom adjustment coupling that the tall
Illustration 4 end of the cable anchors are facing down.
7 Install the new boom extend cable pulley, pivot

pin and snap rings.
Note: Be sure the boom extend cables are routed
through the grooves of the pulley and the upper
wear pad on the extension cylinder.
8 Install the boom extend cables to the lower

extend cable bracket that mounts to the number
3 boom tube.
3 - 52 S-100 • S-105 • S-120 • S-125 Part No. 1268494

boom components
Boom retract cables: 20 Secure the number 2 and number 3 booms

together at the platform end with a chain or
9 Remove the fasteners from the boom retract strap to prevent them from moving.
cables at the platform end of the boom.
21 Install the boom extension cylinder assembly
10 Attach a rope to one of the boom retract cables into the boom.
at the pivot end of the boom.
Note: Before lowering the extension cylinder into
11 At the platform end of the boom, pull on the the saddles of the number 1 boom tube, wrap the
boom retract cable that has the rope attached boom retract cables around the pulleys.
to it.
22 Remove the chain or strap from the platform
12 Pull the old cable completely out of the boom
end of the number 2 and number 3 boom tubes.
tube. Discard the old boom retract cable.
23 Adjust the boom extend/retract cables.
13 Remove the rope from the old cable and
See, How to Adjust the Boom Extend/Retract
securely attach the rope to the same end of the
Cables.
new boom retract cable.
14 At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
15 Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
the boom tube. Remove the rope.
16 Repeat steps 11 through 16 for the other boom
retract cable.
17 At the platform end of the boom, install the
retract cables and fasteners to the adjustment
plate.
18 Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
19 Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 53

Turntable Covers
5-1 4 Mark the location of the hinges on the bulkhead
to ensure proper cover alignment during
Turntable Covers installation.
In addition to the standard hinged turntable covers, 5 Remove the cover hinge to bulkhead retaining
there are two fixed turntable covers. One fixed fasteners.
cover protects the fuel tank on the engine side of 6 Carefully lift and remove the cover from
the machine and the other protects the turntable the machine.
rotator assembly on the ground controls side of the
machine. Crushing hazard. The turntable
cover could become unbalanced
How to Remove a Hinged and fall when it is removed from
Turntable Cover supported and secured to a
1 Raise the turntable cover. Support and secure appropriate lifting device.
the open cover to an overhead crane or forklift.
Bodily injury hazard. Safety
Do not lift it.
decals are essential to safe
Crushing hazard. Due to its heavy machine operation. Failure to
weight, do not attempt to support replace all safety and instructional
the cover by hand. decals could result in death
or serious injury. If a turntable
Component damage hazard. cover must be replaced, be sure
Protect the cover from damage that all appropriate safety and
by using carpet or padding on the instructional decals are applied to
crane or forklift forks. the new cover.
2 Remove the upper and lower retaining clips Note: Alignment adjustments may be necessary
from the gas strut. when a new cover is installed.
3 Gently pry the strut pivot sockets off of the ball
studs and remove the strut. Protect the strut
cylinder rod from damage.
Crushing hazard. The turntable
cover will fall when the gas struts
are removed if it is not properly
supported.
3 - 54 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Turntable components
How to Remove a Fixed

Turntable Cover
1 Ground controls side: Remove the top
retaining fasteners from the power to platform
plug panel and loosen the bottom retaining
fasteners. Do not disconnect the wiring.
2 Support the cover with a suitable lifting device.
Protect the cover from damage.
3 Remove the cover mounting fasteners.
4 Carefully remove the cover from the machine.
Crushing hazard. The turntable
cover may become unbalanced
supported.
Bodily injury hazard. Safety
decals are essential to safe
machine operation. Failure to
replace all safety and instructional
decals could result in death
or serious injury. If a turntable
cover must be replaced, be sure
that all appropriate safety and
instructional decals are applied to
the new cover.
Note: Alignment adjustments may be necessary
when a new cover is installed.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 55

Engines
6-1 How to Remove the Flex Plate
RPM Adjustment 1 Disconnect the wiring plug at the electronic
proportional controller located on the drive
Refer to Maintenance Procedure, pump.
Check and Adjust the Engine RPM.
2 Remove the hose clamp from the air cleaner
6-2 hose at the air cleaner. Carefully disconnect
the hose from the air cleaner.
Flex Plate
3 Remove the air cleaner mounting fasteners.
The flex plate couples the engine to the pump. The Remove the air cleaner from the machine.
flex plate is bolted to the engine flywheel and has
a cut-out in the center for the pump coupler. 4 Remove the fuel filter/water separator retaining
fasteners from the pump mounting plate. Do
not disconnect the fuel hoses.
a b c d e
5 Remove the fuel filter/water separator and lay it
to the side.
6 Support the drive pump assembly with an
appropriate lifting device. Then remove all of
the pump mounting plate to engine bell housing
bolts.
7 Carefully pull the pump away from the engine
f
and secure it from moving.
a pump
b pump shaft Component damage hazard.
c coupler Hoses can be damaged if they are
d flex plate
e flywheel
kinked or pinched.
f Deutz models- .245 inch / 6.2 mm gap
8 Remove the flex plate mounting fasteners,
Cummins or Perkins models-
.255 inch / 6.5 mm gap then remove the flex plate from the flywheel.
3 - 56 S-100 • S-105 • S-120 • S-125 Part No. 1268494

engines
How to Install the Flex Plate 1
8 3
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Apply Loctite® removable thread sealant to the
mounting fasteners. Then torque the flex plate 6 5
mounting bolts in sequence to:
Cummins engines: 23 ft-lbs / 31.2 Nm.
Deutz and Perkins engines: 28 ft-lbs / 38 Nm.
4 7
3 Install the pump coupler onto the pump shaft
2
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump Perkins Engines
end plate for your engine. Cummins Engines
Before Serial Number 1029
4 Apply Loctite® removable thread sealant to the Deutz 913 Engines
pump coupler set screw.
Perkins and Cummins engines before serial 1
number 1029 and Deutz 913 engines:
Torque the set screw to 20 ft-lbs / 27 Nm. 8 3
Perkins and Cummins engines after serial
number 1028 and Deutz 2011 engines:
Torque the set screw to 61 ft-lbs / 83 Nm.
5 Install the bell housing/mounting plate 6 5
assembly. Apply Loctite® removable thread
sealant to the mounting fasteners. Then torque
the pump retaining fasteners to:
Cummins, Perkins and Deutz 913 engines: 4 7
28 ft-lbs / 38 Nm.
Deutz 2011 engines: 47 ft-lbs / 63 Nm. 2
Component damage hazard. Do Perkins Engines

Cummins Engines
not force the drive pump during
After Serial Number 1028
installation or the flex plate teeth
may become damaged.
1
When installing the pump, do not
6 3
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.
4 5
Deutz 2011 Engines
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 57

engines
6-3 6-4
Oil Pressure and Coolant Oil Pressure and Temperature
Temperature Sending Units - Sending Units - Deutz Models
Cummins and Perkins Models
The engine oil temperature sending unit is an
The coolant temperature sending unit is an electrical device. If the engine oil temperature
electrical device. If the coolant temperature reaches 275° F / 135° C, the ECM will shut the
reaches 210° F / 99° C, the ECM will shut the engine off to prevent damage and will not start
engine off to prevent damage and will not start until the engine oil temperature drops below
until the coolant temperature drops below 275° F / 135° C. The engine temperature will be
210° F / 99° C. The engine temperature will be shown on the display screen at the ground controls
shown on the display screen at the ground controls when the key is on and the Emergency Stop
when the key is on and the Emergency Stop Button is pulled out to the on position. Use the
Button is pulled out to the on position. Use the scroll buttons and scroll to the Engine Temperature
scroll buttons and scroll to the Engine Temperature screen.
screen. Component damage hazard.
Do not crank the engine with
Do not crank the engine with a oil temperature fault shown on
a water temperature fault shown the display at the ground controls.
on the display at the ground The oil pressure sending unit is an electrical
controls. device. If the oil pressure drops below
The oil pressure sending unit is an electrical 12 psi / 0.8 bar, the ECM will shut the engine off
device. If the oil pressure drops below to prevent damage. The engine oil pressure will
12 psi / 0.8 bar, the ECM will shut the engine off be indicated on the display screen at the ground
to prevent damage. The engine oil pressure will controls while the engine is running. Use the scroll
be indicated on the display screen at the ground buttons and scroll to the Engine Oil Pressure
controls while the engine is running. Use the scroll screen.
buttons and scroll to the Engine Oil Pressure Component damage hazard.
screen. Do not crank the engine with a low
oil pressure fault shown on the
Do not crank the engine with a low display at the ground controls.
oil pressure fault shown on the
display at the ground controls.
3 - 58 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Ground Controls
The ground control box (TCON) is the 7-1
communication and operations center for the
machine. The ground control box contains two Circuit Boards
key switches. The key switch towards the top
of the control box is for selection of ground or How to Remove the LCD Display
platform controls. The key switch at the bottom Screen Circuit Board
of the control box is the Service Bypass key
switch. It is used to allow the boom to be raised 1 Push in the Emergency Stop button to the
above 10° with the axles retracted and to correct off position at both the ground and platform
an out-of-level platform. If the machine trips an controls.
envelope safety switch, the operator at the ground
controls can turn and hold the Service Bypass key 2 Remove the platform control box mounting
switch in the recover position and the machine fasteners. Remove the platform control box
will automatically lower the boom to the stowed from the machine.
position in sequence. Component damage hazard.
The ground control box contains a replaceable
membrane decal with touch sensitive buttons for
various machine functions. The ground control box 3 Locate the cables that connect to the bottom
also contains two printed circuit boards: of the control box. Number each cable and its
location at the control box.
The LCD (Liquid Crystal Display) circuit board
is mounted to the inside of the control box lid which 4 Disconnect the cables from the bottom of the
controls the LCD display screen. platform control box.
The ECM circuit board is the main circuit board 5 Remove the control cable plug retaining
for the machine. There are relays on the ECM fasteners from the bottom of the platform
circuit board that can be replaced. All operating control box.
parameters and configuration of options for the 6 Remove the platform control box lid fasteners.
machine are stored in the ECM memory. Open the control box lid.
Note: The ECM circuit board inside the ground
control box (TCON) cannot be replaced by itself.
If the ECM circuit board is faulty and needs to be
replaced, contact the Genie Industries Service
Department.
Note: When an ECM circuit board is replaced, the

proportional valves will need to be calibrated. See
1-3, How to Calibrate a Joystick.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 59

Ground Controls
7 Locate the ECM circuit board mounted to the 7-2

inside of the platform control box.
Membrane Decal
with electrically charged circuits The membrane decal is a special decal that
could result in death or serious consists of a decal with an electronic membrane
injury. Remove all rings, watches on the backside. The membrane contains touch
and other jewelry. sensitive areas that, when pushed, activates the
machine functions. The membrane buttons activate
Electrostatic discharge (ESD) machine functions similar to toggle switches, but
can damage printed circuit board do not have any moving parts.
components. Maintain firm contact
with a metal part of the machine How to Replace the Membrane
that is grounded at all times when Decal
handling printed circuit boards OR
use a grounded wrist strap. 1 Turn the key switch at the ground controls to
the off position.
8 Remove the ECM circuit board mounting
fasteners. 2 Push in the Emergency Stop button to the
off position at both the ground and platform
9 Carefully remove the ECM circuit board from controls.
the platform control box.
3 Remove the ground control box lid fasteners.
Open the control box lid.
4 Carefully disconnect the two ribbon cables from
the membrane decal at the ECM circuit board.
and other jewelry.
Electrostatic discharge (ESD)
that is grounded at all times when
use a grounded wrist strap.
3 - 60 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Ground Controls
5 Carefully remove the membrane decal from the 7-3

control box lid while guiding the ribbon cables
out of the control box lid. Control Relays
6 Remove any decal adhesive from the control Relays used for single function switching are single
box lid with a mild solvent. pole double throw (SPDT) relays.
Note: Do not allow any solvent to come in contact
with the LCD display screen. How to Test a Single Pole Double
Throw Relay
7 Install the new membrane decal (Genie part
number 50811) while guiding the ribbon cables Electrocution/burn hazard. Contact
through the control box lid. with electrically charged circuits
8 Connect the ribbon cables to the ECM circuit
board.
and other jewelry.
9 Close the control box lid and install the retaining
fasteners.
Electrostatic discharge (ESD)
that is grounded at all times when
use a grounded wrist strap.
2 Open the ground control box and remove the
relay to be tested from the ECM circuit board.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 61

Ground Controls
3 Connect the leads from an ohmmeter or

continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test Desired result
terminal 85 to 86 85 to 95 Ω
terminal 87 to 87a & 30 no continuity
(infinite Ω)
terminal 87a to 30 continuity
(zero Ω)
87
87a
86 85
30
4 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
terminal combinations.
Test Desired result
terminal 87 to 87a no continuity
(infinite Ω)
terminal 87a to 30 no continuity
(infinite Ω)
terminal 87 to 30 continuity
(zero Ω)
85 87 87a
86 30
Control Relay Schematic
3 - 62 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Limit Switches
120 ft / 36.6 m

68 65
100 ft / 30.5 m
LSB2RO
102 ft
90 ft / 27.4 m (31.1 m)
LSB4EO LSB2RS
100 ft 101 ft
(30.5 m) (30.8 m)
80 ft / 24.4 m
LSB8AS LSB13AO LSB13AO LSB8AS

50 53 70 ft / 21.3 m 53 50
LSB4ES LSB3EO 60 ft / 18.3 m LSB3EO LSB4ES

75.5 ft 75 ft 75 ft 75.5 ft
(23 m) (22.9 m) (22.9 m) (23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS LSB7DS
11 LSB1DO 20 ft / 6.1 m LSB1DO 11
10 10
10 ft / 3 m
LSB3RS LSB3RO LSB3RO LSB3RS

3.5 ft (1.1 m) 3 ft (0.9 m) 3 ft (0.9 m) 3.5 ft (1.1 m)
0 ft / 0 m
S-100 and S-105 Models S-120 and S-125 Models
LSAX1RO LSAX2RO
LSAX1EO LST10 LSAX2ES LSAX2EO
LSAX1ES
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 63

Limit Switches
8-1 3 Activate the limit switch. Connect the leads from

an ohmmeter or continuity tester to the deutsch
Limit Switches connector terminals in the combination listed
below and check for continuity.
How to Test the Limit Switches
terminal 1 to 2 no continuity
There are 2 types of limit switches: Mechanical (roller (infinite Ω)
arm) and proximity. Mechanical limit switches terminal 3 to 4 continuity
are activated by a part of the machine physically (zero Ω)
moving the roller arm of the switch. Proximity terminal 1 to 3 and 4 no continuity
switches are a magnetic type of switch and are (infinite Ω)
activated by the close presence of a ferrous metal. terminal 2 to 3 and 4 no continuity
(infinite Ω)
Mechanical Operational Limit Switch:
1 Manually activate the limit switch. Mechanical Safety Limit Switch:
Result: The limit switch arm should move freely 1 Connect the leads from an ohmmeter or
and spring return to center. A distinct click continuity tester to the deutsch connector
should be felt and heard. terminals in the combination listed below and
check for continuity.
2 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector terminal 1 to 2 continuity
terminals in the combination listed below and (zero Ω)
check for continuity. terminal 3 to 4 continuity
(zero Ω)
terminal 1 to 2 continuity terminal 1 to 3 and 4 no continuity
(zero Ω) (infinite Ω)
terminal 3 to 4 no continuity terminal 2 to 3 and 4 no continuity
(infinite Ω) (infinite Ω)
terminal 1 to 3 and 4 no continuity terminal 5 to 6 no continuity
(infinite Ω) (infinite Ω)
terminal 2 to 3 and 4 no continuity
(infinite Ω)
Numbering Legend Circuit number
D Down
AX Axle A Angle
B Boom L Load moment
T Turntable E Extend
LS Limit switch O Operational
R Retract
S Safety
LS AX 1 R O
3 - 64 S-100 • S-105 • S-120 • S-125 Part No. 1268494
Limit Switches
2 Activate the limit switch. Connect the leads from 3 Place a piece of ferrous metal (steel, iron, etc.)
an ohmmeter or continuity tester to the deutsch in front of the target area so it is no more than
1
connector terminals in the combination listed /2 inch / 12.7 mm away from the target area of
below and check for continuity. the proximity switch.
terminal 1 to 2 no continuity 4 Connect the leads from an ohmmeter or
(infinite Ω) continuity tester to the deutsch connector
terminal 3 to 4 no continuity terminals in the combination listed below and
(infinite Ω) check for continuity.
(infinite Ω)
(zero Ω)
(infinite Ω)
5 Move the piece of ferrous metal (steel, iron,
etc.) so it is more than 1/2 inch / 12.7 mm away
(zero Ω)
from the target area of the proximity switch.
Proximity Switch: 6 Connect the leads from an ohmmeter or
continuity tester to the deutsch connector
1 Connect the leads from an ohmmeter or terminals in the combination listed below and
continuity tester to the deutsch connector check for continuity.
terminals in the combination listed below and
check for continuity. terminal 3 to 4 no continuity
(infinite Ω)
terminal 3 to 4 no continuity
(infinite Ω)
How to Adjust the Limit Switches
2 Locate the target area of the proximity switch. Note: Perform this procedure on a flat and level
area and free from obstructions.
1 Fully retract the boom.
a 2 Place a digital protractor or digital level on top

of the boom tube.

Proximity switch
a target area
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 65

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). degree proximity switch (LSB13AO).
5 Disconnect the deutsch connector from the 16 Disconnect the deutsch connector from the
68 degree proximity switch (LSB14AO) and 53 degree proximity switch (LSB13AO) and
connect an ohmmeter or continuity tester to connect an ohmmeter or continuity tester to
terminals 3 and 4 of the deutsch connector. terminals 3 and 4 of the deutsch connector.
6 Adjust LSB14AO until the switch contacts just 17 Adjust LSB13AO until the switch contacts just
open. While observing the digital protractor, open. While observing the digital protractor,
raise the boom until the switch contacts close, raise the boom until the switch contacts close,
then lower the boom until the switch contacts then lower the boom until the switch contacts
open. Repeat the process until the switch open. Repeat the process until the switch
contacts open between 67.5 and 68 degrees. contacts open between 52.5 and 53 degrees.
7 Tighten the 68 degree proximity switch 18 Tighten the 53 degree limit switch mounting
(LSB14AO) mounting fasteners. fasteners.
8 Lower the boom to 65.3 degrees. 19 Lower the boom to 50.3 degrees.
9 Loosen the mounting fasteners from the 65 20 Loosen the mounting fasteners from the 50
degree safety switch (LSB9AS). degree safety switch (LSB8AS).
10 Disconnect the deutsch connector from the 65 21 Disconnect the deutsch connector from the 50
degree safety switch (LSB9AS) and connect degree safety switch (LSB8AS) and connect an
an ohmmeter or continuity tester to terminals 1 ohmmeter or continuity tester to terminals 1 and 2,
and 2, and to terminals 3 and 4 of the deutsch and to 3 and 4 of the deutsch connector.
connector.
22 Adjust LSB8AS until the switch contacts just
11 Adjust LSB9AS until the switch contacts just open. While observing the digital protractor,
open. While observing the digital protractor, raise the boom until the switch contacts close,
raise the boom until the switch contacts close, then lower the boom until the switch contacts
then lower the boom until the switch contacts open. Repeat the process until the switch
open. Repeat the process until the switch contacts open between 50 and 50.5 degrees.
contacts open between 65 and 65.5 degrees.
12 Tighten the 65 degree safety switch mounting
fasteners.
13 Lower the boom to 52.5 degrees.
3 - 66 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Limit Switches
8-2
Limit Switch and Level Sensor
Locations
LSB3RO
LSB3EO
LSB4EO
LSB3RS
LSB9AS
LSB4ES
LSB8AS
LSB7DS LSB1DO
LSB14AO LSB13AO
LSB19LO
LSB6S
LSB2RO
LSB19LO LSB2RS
LSAX2ES PLATFORM
LSAX1EO TURNTABLE LEVEL
LSAX1ES LEVEL LSAX2RO SENSOR
LSAX1RO SENSOR
LSAX2EO
LST1O
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 67

Limit switches
Located under the drive chassis end cover at 8-3

the center of the square end (blue): LSAX1RO,
LSAX1EO, LSAX1ES Limit Switch Functions
Located under the drive chassis end cover at
the center of the round end (yellow): LSAX2RO, LSAX1RO: Operational Limit Switch, Front Axle,
LSAX2EO, LSAX2ES Retract. This switch activates when the axle is
fully retracted, activating axle retracted LED and
Located in the center of the swing chassis: LS- shutting off power to axle retract coils after two
T1O seconds.
Located on the hydraulic tank tray: LSAX2RO: Operational Limit Switch, Rear Axle,
Turntable Level Sensor Retract. This switch activates when the axle is
Located on the inside of the swing chassis bulk- fully retracted, activating axle retracted LED and
head at the counterweight end: LSB9AS, LS- shutting off power to axle retract coils after two
B8AS seconds.
Located at the base of the swing chassis near the LSAX1EO: Operational Limit Switch, Front Axle,
counterweight: LSB1LO Extend. This switch is activated when the axle is
fully extended. If this switch is not activated, boom
Located at the counterweight end of Boom tube 0: functions are restricted to the stowed range. If unit
LSB6S is out of stowed, all boom functions are disabled.
Located on the counterweight side of the lift Axle can be extended while driving to recover.
cylinder support assembly: LSB1DO, LSB7DS, LSAX2EO: Operational Limit Switch, Rear Axle,
LSB13AO, LSB14AO Extend. This switch is activated when the axle is
Located on the outside of the platform end of fully extended. If this switch is not activated, boom
Boom tube 0: functions are restricted to the stowed range. If unit
LSB2RO, LSB2RS is out of stowed, all boom functions are disabled.
Axle can be extended while driving to recover.
Located on the top of the platform end of Boom
tube 2: LSAX1ES: Safety Limit Switch, Front Axle, Ex-
LSB3EO, LSB3RS, LSB3RO, LSB2RO, LSB4ES tend. If this switch is tripped, then the axle is not
fully extended. In this condition, if unit is out of
Located on the platform rotator: Platform Level stowed, power is cut to boom up, boom extend
Sensor and axle retract.
LSAX2ES: Safety Limit Switch, Rear Axle, Ex-
tend. 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.
3 - 68 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Limit Switches
LSB6S: Safety Limit Switch, Cable Tension. Cuts LSB3RO: Operational Limit Switch, 3’ Extend.
power to the extend directional valve if extend This switch activates anytime the boom is extend-
cables are out of adjustment or one breaks. ed beyond 3 feet. If axles are not extended, boom
extend is disabled and the extend axle LED and
LSB1DO: Operational Limit Switch, 10O Angle.
icon will flash as long as boom extend is operat-
This switch activates anytime the boom is raised
ed. If axles are extended at this point, the motors
above 10O. If axles are not extended, boom up is
are shifted to low and drive speed is limited to
disabled and the extend axle LED and icon will
0.7 mph. The boom up/down speed and turntable
flash as long as boom up is operated. At this point,
rotate speed are limited to 60% of maximum.
if axles are extended, the motors are shifted to low
and drive speed is limited to 0.7 mph. LSB3RS: Safety Limit Switch, 3.5’ Extend. If axles
are not extended, this switch is activated when the
LSB7DS: Safety Limit Switch, 11O Angle. If axles
boom is extended beyond 3.5 feet, cutting power
are not extended, this switch is activated when
to boom extend and axle retract.
boom is raised to 11O, cutting power to boom up
and axle retract. LSB3EO: Operational Limit Switch, 75’ Extend.
O This switch activates anytime the boom is extend-
LSB13AO: Operational Limit Switch, 53 Angle.
ed to 75 feet or beyond. At this point drive speed is
This switch activates at 53O boom angle, allowing
reduced to 0.4 mph, boom up/down is reduced to
the boom to be extended beyond 75 feet. If the
29% of maximum and turntable rotate is reduced
boom is lowered past this switch when the boom
to 40% of maximum. If boom angle is less than
is beyond 75 feet, boom extend and boom down
53O, then boom extend is disabled and the raise
are disabled. The retract boom LED and icon and
boom LED and icon and alarm will flash as long as
alarm will flash as long as boom down is operated.
boom extend is operated.
LSB8AS: Safety Limit Switch, 50O Angle. This
LSB4ES: Safety Limit Switch, 75.5’ Extend. This
switch cuts power to boom extend, boom down
and the engine fuel solenoid when it is mechan-
and engine fuel solenoid when it is mechanically
ically activated at 50O if the boom length is more
activated at 75.5 feet, if boom angle is less than
than 75.5 feet.
50O.
LSB14AO: Operational Limit Switch, 68O Angle.
LSB4EO: Operational Limit Switch, 100’ Extend.
This switch is activated at 68O boom angle and al-
This switch activates anytime the boom is extend-
lows the boom to be extended beyond 100 feet. If
ed to 100 feet or beyond. The boom up/down is
the boom is lowered past this switch when extend-
reduced to 20% of maximum. If boom angle is less
ed beyond 100 feet, boom extend and boom down
than 68O, then boom extend is disabled and the
are disabled. The boom retract LED and icon and
raise boom LED and icon and alarm will flash as
alarm will flash as long as boom down is operated.
long as boom extend is operated. If boom angle is
LSB9AS: Safety Limit Switch, 65O Angle. This greater than 65O, the BO lockout valve will activate
switch cuts power to boom extend, boom down allowing hydraulic flow to the external cylinder to
and the engine fuel solenoid when it is mechan- continue to extend to 120 feet.
ically activated at 65O if the boom length is more
than 101 feet.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 69

Limit switches
LSB2RS: Safety Limit Switch, 101’ Extend. This

and engine fuel solenoid when it is mechanically
activated at 101 feet, if boom angle is less than
65O.
LSB2RO: Operational Limit Switch, 100’ Retract.
This switch is activated anytime boom length is
100’ or less. Anytime the boom is being retracted
while this switch is activated, the BN lockout valve
is activated allowing hydraulic flow out of the inner
cylinder.
LSB19LO: Operational Limit Switch, Down
Overload. This switch disables all functions except
boom retract and boom up and activates a medi-
um frequency alarm and the boom down overload
diagnostic code.
LST1O: Operational Limit Switch, Drive Enable.
This switch is activated when the turntable is rotat-
ed in the standard drive zone.
Turntable Level Sensor: Measures the X axis
and Y axis of the turntable. The alarm sounds at
4.5O.
Platform Level Sensor: Measures the angle of
the platform. The range of measurement is +/- 20O.
The safety cutout is set at +/- 10O from gravity and
will disable the primary and secondary boom up/
down functions and the platform level up/down
functions.
3 - 70 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Hydraulic Pumps
9-1 2 Tag, disconnect and plug the hydraulic hoses
from the function pumps. Cap the fittings on the
Function Pumps pumps.
There are three hydraulic pumps connected to Bodily injury hazard. Spraying
the engine. There is one variable displacement hydraulic oil can penetrate and
pump that is used for drive functions and two fixed burn skin. Loosen hydraulic
displacement pumps attached to the drive pump connections very slowly to allow
that are used for all other machine functions. the oil pressure to dissipate
How to Remove the squirt or spray.
Function Pumps 3 Support the function pumps with an overhead
crane or other suitable lifing device.
the O-ring on the fitting and/or hose end must be 4 Remove the pump mounting bolts. Carefully
replaced and then torqued to specification during remove the pumps.
Crushing hazard. The function
pumps may become unbalanced
1 Close the two hydraulic tank valves located at and fall when the mounting
the hydraulic tank. bolts are removed if they are not
properly supported.
Be sure to open the two hydraulic
tank valves and prime the pumps
after installing the pumps.
See 9-2, How to Prime the Pumps.
open closed

engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur.
If the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 71

Hydraulic Pumps
9-2 3 Close the two hydraulic tank valves located at

the hydraulic tank.
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral
or null adjustment. Any internal service to the
pump should only be performed at an authorized open closed
Sundstrand-Sauer service center. Call the Genie
Industries Service Department to locate your local
engine must not be started with
authorized service center.
the hydraulic tank shutoff valves in
How to Remove the Drive Pump damage will occur. If the tank
Component damage hazard. The valves are closed, remove the key
work area and surfaces where this from the key switch and tag the
procedure will be performed must machine to inform personnel of
be clean and free of debris that the condition.
could get into the hydraulic system
and cause severe component
from the drive pump. Cap the fittings on the
damage. Dealer service is
pump.
recommended.
1 Remove the function pumps. See How to squirt or spray.
Remove the Function Pumps. 5 Support the drive pump with a suitable lifting
2 Disconnect the electrical connection at the device and remove the two drive pump
electronic displacement controller (EDC) mounting fasteners.
located on the drive pump. 6 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
3 - 72 S-100 • S-105 • S-120 • S-125 Part No. 1268494

hydraulic pumps
7 Remove the drive pump from the machine. Cummins and Perkins models:
Component damage hazard. 2 Remove the engine pivot plate retaining
Be sure to open the two hydraulic fastener. Swing the engine pivot plate out away
tank valves and prime the pump from the machine to access the fuel injection
after installing the pump. pump.
Note: Before installing the pump, verify proper
pump coupler spacing. Refer to the appropriate
flex plate installation instructions for your engine.
How to Prime the Pumps

sure that the hydraulic tank shutoff
valves are in the open position a b
before priming the pump. The
engine must not be started with a engine pivot plate anchor hole
the hydraulic tank shutoff valves in b engine pivot plate retaining fastener
damage will occur. 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
anchor hole to secure it from
open closed moving could result in death or
serious injury.
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. 1268494 S-100 • S-105 • S-120 • S-125 3 - 73

hydraulic pumps
5 Deutz models: Disconnect the engine wiring

harness from the fuel shutoff solenoid at the
injector pump.

a
Perkins models
a fuel shutoff solenoid
6 Have another person crank the engine with the

starter motor for 15 seconds, wait 15 seconds,
Deutz models then crank the engine an additional 15 seconds
or until the pressure reaches 250 psi / 17.2 bar.
Cummins and Perkins models: Disconnect
Bodily injury hazard. Keep hands,
the wire from the fuel shutoff solenoid at the
loose clothing and hair clear of
injector pump.
all moving engine parts while the
engine is cranking.
7 Deutz models: Connect the engine wiring
harness to the fuel shutoff solenoid at the
injector pump.
Cummins and Perkins models: Connect the
wire to the fuel shutoff solenoid at the injector
a
pump.
8 Start the engine and check for hydraulic leaks.
Cummins models
3 - 74 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Hydraulic Pumps
9-3 4 Activate any function using auxiliary power.
Auxiliary Pump Result: If the pressure gauge reads 2500 psi /

172 bar, immediately stop. The pump is good.
How to Test the Auxiliary Pump Result: If pressure fails to reach 2500 psi
/ 172 bar, the internal relief valve setting is
The auxiliary pump is a 2-section, gear-type pump.
incorrect or the pump is bad and will need to be
Pump number 1 is the pump section closest to
serviced or replaced.
the pump motor and pump number 2 is the pump
section that is farther from the pump motor. Each 5 Turn the key switch to the off position.
section of the pump has its own relief valve located
6 Remove the pressure gauge and reconnect the
within the pump body.
hydraulic hose.
Note: When removing a hose assembly or fitting, 7 Disconnect the hydraulic hose from the high
the O-ring on the fitting and/or hose end must be pressure port from pump number 2.
installation. Refer to Specifications, Hydraulic 8 Connect a 0 to 5000 psi / 0 to 345 bar pressure
Hose and Fitting Torque Specifications. gauge to the high pressure port on pump
number 2.
1 Disconnect and plug the high pressure
hydraulic hose from pump number 1. 9 Turn the key switch to ground control and
pull out the Emergency Stop button to the on
Bodily injury hazard. Spraying position.
burn skin. Loosen hydraulic 10 Activate any function using auxiliary power.
connections very slowly to allow Result: If the pressure gauge reads 3000 psi /
the oil pressure to dissipate 207 bar, immediately stop. The pump is good.
gradually. Do not allow oil to squirt
or spray. Result: If pressure fails to reach 3000 psi
/ 207 bar, the internal relief valve setting is
2 Connect a 0 to 5000 psi / 0 to 345 bar pressure incorrect or the pump is bad and will need to be
gauge to the high pressure port on pump serviced or replaced.
number 1.
11 Remove the pressure gauge and reconnect the
3 Turn the key switch to ground control and hydraulic hose.
pull out the Emergency Stop button to the on
position.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 75

hydraulic pumps
How to Remove the Auxiliary

Pump
1 Open the ground controls side turntable cover.
from the pumps.
3 Remove the pump mounting fasteners and
remove the pump from the pump motor.
3 - 76 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-1
Function Manifold Components, S-100 and S-105 Models
(to serial number 136)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No. Description Item Function Torque
1 Relief valve, 1800 psi / 124.1 bar........ FA........... Boom extend pressure limit.......................18-20 ft-lbs / 24-27 Nm
2 Proportional solenoid valve................. FB.......... Boom extend/retract
proportional speed control.............33-37 ft-lbs / 44.9-50.3 Nm
3 Solenoid valve, 3 position 4 way......... FC.......... Turntable rotate left/right..................25-27 ft-lbs / 34-36.7 Nm
4 DO3 valve, 3 position 4 way................ FD.......... Boom up/down....................................... 30-35 in-lbs / 3-4 Nm
5 Priority flow regulator valve,
0.1 gpm / 0.38 L/min........................... FE.......... Bleeds off differential
sensing valves to tank........................18-20 ft-lbs / 24-27 Nm
6 Proportional solenoid valve................. FF.......... Boom up/down proportional
speed control.................................33-37 ft-lbs / 44.9-50.3 Nm
7 Proportional solenoid valve................. FG.......... Turntable rotate proportional
speed control......................................18-20 ft-lbs / 24-27 Nm
8 Counterbalance valve,
3200 psi / 220.6 bar FH Boom down circuit...............................30-35 ft-lbs / 38-41 Nm
9 Relief valve, 2600 psi / 179.3 bar........ FI............ Turntable rotate, boom lift and
boom retract pressure limit...............25-27 ft-lbs / 34-36.7 Nm
10 Check valve......................................... FJ........... Load sensing circuit,
boom up/down.....................................12-14 ft-lbs / 16-19 Nm
This list continues. Please turn the page.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 77

manifolds
1 2 3 4
FA FB FC FD
FE
FR 5
17
FQ
16
FF
6
FG
FP 7
15
FH
8
FI
9
FJ
10
FK
11
FM FL
12
14
TP
13
3 - 78 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
Function Manifold Components, S-100 and S-105 Models, continued

Index Schematic
11 Orifice - plug,
0.040 inch / 1.02 mm............................FK.......... Differential sensing dampening
12 Check valve......................................... FL........... Load sensing circuit,
turntable rotate....................................12-14 ft-lbs / 16-19 Nm
13 Diagnostic Nipple............................................... Testing
14 Check valve......................................... FM.......... Load sensing circuit,
boom extend/retract.............................12-14 ft-lbs / 16-19 Nm
15 Differential sensing valve.................... FP.......... Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
16 Solenoid valve, 2 position 3 way......... FQ.......... Boom retract control..................................25-27 ft-lbs / 34-37 Nm
17 Solenoid valve, 2 position 3 way......... FR.......... Boom extend control..................................52-60 ft-lbs / 71-82 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 79

Manifolds
1 2 3 4
FA FB FC FD
FE
FR 5
17
FQ
16
FF
6
FG
FP 7
15
FH
8
FI
9
FJ
10
FK
11
FM FL
12
14
TP
13
3 - 80 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-2
(from serial number 137)
Index Schematic
1 Solenoid Valve Assembly,

3 position 4 way, DO3, 12V DC........... FD.......... Boom up/down..............................................30-35 in-lbs / 3-4 Nm
2 Solenoid Valve, 3 position 4 way......... FC.......... Turntable rotate control, left/right...............25-27 ft-lbs / 34-37 Nm
3 Proportional Solenoid Valve................ FG.......... Turntable rotate,
proportional speed control.................. 18-20 ft-lbs / 25-27 Nm
4 Solenoid Valve, 2 position 3 way......... AA.......... Auxiliary drive/steer selector......................25-27 ft-lbs / 34-37 Nm
5 Relief Valve, 3000 psi / 206.8 bar........ AC.......... Platform manifold pressure limit................18-20 ft-lbs / 24-27 Nm
6 Flow Regulator Valve,
3 gpm / 11.36 L/min............................ AD.......... Priority flow to platform..............................25-27 ft-lbs / 34-37 Nm
7 Check Valve, 5 psi / 0.34 bar............... AE.......... Blocks flow from pump 2
to auxiliary pump............................. 12-14 ft-lbs / 16.3-19 Nm
8 Proportional Solenoid Valve, N.C........ FF.......... Primary lift, proportional
valve speed control..............................33-37 ft-lbs / 45-50 Nm
9 Check Valve, 10 psi / 0.69 bar............. AB.......... Blocks flow from pump 1 and 2
to auxiliary pump.......................... 18-20 ft-lbs / 24.5-27.2 Nm
10 Check Valve......................................... AG.......... Blocks flow from auxiliary pump,
port 2A to pump 1............................... 33-37 ft-lbs / 45-50 Nm
11 Check Valve, 5 psi / 0.34 bar............... AF.......... Blocks flow from auxiliary pump,
ports 2A and 3A to pump 2................. 25-27 ft-lbs / 34-37 Nm
This list continues on the next page.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 81

manifolds
1
FD
FC
2
FA
24
FG
3
FR
23 AA
4
AC
5
FQ AD
22 6
AE
7
FF
8
FE
21
FL
20
FP
19 AB
FJ 9
18
FM
17
AG
10
AF
FB 11
16
FI
12
FH
13
FK
14
TP
15
3 - 82 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds

Index Schematic
12 Relief Valve, 2600 psi / 179.3 bar........ FI............ Turntable, primary lift and
boom retract pressure limit................. 25-27 ft-lbs / 34-37 Nm
13 Counterbalance Valve,
3200 psi / 220.6 bar............................ FH.......... Primary lift, load holding............................30-35 ft-lbs / 38-41 Nm
14 Orifice Plug, 0.040 inch / 1.016 mm.... FK.......... Differential sensing damping
15 Diagnostic Nipple................................ TP.......... Testing
16 Proportional Valve............................... FB.......... Boom extend/retract solenoid
valve proportional speed control..........33-37 ft-lbs / 45-50 Nm
17 Check Valve, 5 psi / 0.34 bar............... FM.......... Extension cylinder
load sense check............................. 12-14 ft-lbs / 16.3-19 Nm
18 Check Valve, 5 psi / 0.34 bar............... FJ........... Primary lift load sense check...........12-14 ft-lbs / 16.3-19 Nm
19 Differential Sensing Valve,
110 psi / 7.58 bar................................ FP.......... Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
20 Check Valve, 5 psi / 0.34 bar............... FL........... Extension cylinder
0.1 gpm / 0.38 L/min........................... FE.......... Bleeds off differential
sensing valve to tank.................... 18-20 ft-lbs / 24.5-27.2 Nm
22 Solenoid Valve, 2 position 3 way......... FQ.......... Boom retract control..................................52-60 ft-lbs / 71-82 Nm
23 Solenoid Valve, 2 position 3 way......... FR.......... Boom extend control..................................52-60 ft-lbs / 71-82 Nm
24 Relief Valve, 1800 psi / 124.1 bar........ FA........... Boom extend pressure limit........................................... 18-20ft-lbs/
24.5-27.2 Nm.....................................................
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 83

manifolds
1
FD
FC
2
FA
24
FG
3
FR
23 AA
4
AC
5
FQ AD
22 6
AE
7
FF
8
FE
21
FL
20
FP
19 AB
FJ 9
18
FM
17
AG
10
AF
FB 11
16
FI
12
FH
13
FK
14
TP
15
3 - 84 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-3 How to Adjust the Boom Extend

Valve Adjustments - Function Relief Valve
Manifold, S-100 and S-105 Models Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 3000 psi / 0 to 207 bar pressure
Manifold Relief Valve gauge to the test port on the function manifold.
stowed position.
3 Fully raise and extend the boom.
gauge to the test port on the function manifold. 4 Simultaneously push and hold the function
enable/high speed button and the boom
2 Start the engine from the ground controls. extend button with the boom fully extended.
3 Simultaneously push and hold the function Observe the pressure reading on the pressure
enable/high speed button and the boom gauge. Refer to Specifications, Hydraulic
retract button with the boom fully retracted. Specifications.
Observe the pressure reading on the pressure 5 Turn the engine off. Use a wrench to hold the
gauge. Refer to Specifications, Hydraulic Oil relief valve and remove the cap (item FA).
Specifications.
6 Adjust the internal hex socket. Turn it clockwise
4 Turn the engine off. Use a wrench to hold the to increase the pressure or counterclockwise to
relief valve and remove the cap (item FI). decrease the pressure. Install the relief valve
5 Adjust the internal hex socket. Turn it clockwise cap.
to increase the pressure or counterclockwise to
Tip-over hazard. Do not adjust
decrease the pressure. Install the relief valve the relief valve higher than
cap. specified.
Tip-over hazard. Do not adjust 7 Repeat steps 2 through 6 to confirm the relief
the relief valve higher than valve pressure.
specified.
6 Repeat steps 2 through 5 to confirm the relief
valve pressure.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 85

Manifolds
10-4
Proportional Valves -
Function Manifold
Note: When a proportional valve cartridge or coil is
replaced or moved to a different valve cartridge or
cavity, the proportional valve cartridge or coil will
need to be calibrated. See Repair Procedure, How
to Calibrate a Joystick.
3 - 86 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-5
Index Schematic
1 Relief valve, 1800 psi / 124.1 bar........ BA.......... Boom extend pressure limit................18-20 ft-lbs / 24-27 Nm
2 Proportional solenoid valve................. BB.......... Boom extend/retract
proportional speed control..................33-37 ft-lbs / 45-50 Nm
3 Solenoid valve, 3 position 4 way......... BC.......... Turntable rotate left/right.....................25-27 ft-lbs / 34-37 Nm
4 DO3 valve, 3 position 4 way................ BD.......... Boom up/down....................................... 30-35 in-lbs / 3-4 Nm
5 Priority flow regulator valve,
0.1 gpm / 0.38 L/min........................... BE.......... Bleeds off differential
sensing valves to tank........................18-20 ft-lbs / 24-27 Nm
6 Proportional solenoid valve................. BF.......... Boom up/down proportional
7 Proportional solenoid valve................. BG.......... Turntable rotate proportional
8 Counterbalance valve,
3200 psi / 220.6 bar............................ BH.......... Boom down circuit..............................30-35 ft-lbs / 38-41 Nm
9 Relief valve, 2600 psi / 179.3 bar........ BI........... Turntable rotate, boom lift and
boom retract pressure limit.................25-27 ft-lbs / 34-37 Nm
10 Check valve......................................... BJ........... Load sensing circuit,
boom up/down....................................12-14 ft-lbs / 16-19 Nm
11 Orifice - plug,
0.040 inch / 1.02 mm........................... BK.......... Differential sensing dampening
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 87

manifolds
1 2 3 4
BA BB BC BD
BE
5
BR
19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
8
BI
9
BJ
10
BK
11
BN BM BL TP
15 14 13 12
3 - 88 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds

Index Schematic
12 Diagnostic nipple................................................ Testing

13 Check valve......................................... BL.......... Load sensing circuit,
turntable rotate...................................12-14 ft-lbs / 16-19 Nm
14 Check valve......................................... BM......... Load sensing circuit,
boom extend/retract............................12-14 ft-lbs / 16-19 Nm
15 Solenoid valve, N.C. Poppet................ BN.......... Boom retract sequence control..................33-37 ft-lbs / 45-50 Nm
16 Solenoid valve, N.C. Poppet................ BO.......... Boom extend sequence control.................33-37 ft-lbs / 45-50 Nm
17 Differential sensing valve.................... BP.......... Directs flow to functions.............................25-27 ft-lbs / 34-37 Nm
18 Solenoid valve, 2 position 3 way......... BQ.......... Boom retract control..................................52-60 ft-lbs / 71-82 Nm
19 Solenoid valve, 2 position 3 way......... BR.......... Boom extend control..................................52-60 ft-lbs / 71-82 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 89

Manifolds
1 2 3 4
BA BB BC BD
BE
5
BR
19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
8
BI
9
BJ
10
BK
11
BN BM BL TP
15 14 13 12
3 - 90 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-6
(from serial number 431 to 574)
Index Schematic
1 DO3 Valve, 3 position 4 way,............... BD.......... Boom up/down........................................ 30-35 in-lbs / 3-4 Nm
2 Solenoid Valve, 3 position 4 way......... BC.......... Turntable rotate left/right......................25-27 ft-lbs / 34-37 Nm
3 Proportional Solenoid Valve................ BG.......... Turntable rotate, proportional
speed control...................................... 18-20 ft-lbs / 25-27 Nm
4 Solenoid Valve, 2 position 3 way......... AA.......... Auxiliary drive/steer selector................25-27 ft-lbs / 34-37 Nm
5 Relief Valve, 3000 psi / 206.8 bar........ AC.......... Platform manifold pressure limit..........18-20 ft-lbs / 25-27 Nm
3 gpm / 11.36 L/min............................ AD.......... Priority flow to platform........................25-27 ft-lbs / 34-37 Nm
to auxiliary pump......................... 12-14 ft-lbs / 16.2-18.9 Nm
8 Proportional Solenoid Valve, N.C........ BF.......... Primary lift,
9 Check Valve......................................... AB.......... Blocks flow from pump 1 and 2
to auxiliary pump................................ 18-20 ft-lbs / 25-27 Nm
11 Check Valve......................................... AF.......... Blocks flow from auxiliary pump,
12 Relief Valve, 2600 psi / 179.3 bar........ BI........... Turntable, primary lift and boom
retract pressure limit........................... 25-27 ft-lbs / 34-37 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 91

Manifolds
1
BD
BC
2
BA
26
BG
3
BR
25
AA
4
AC
5
BQ AD
24 6
AE
7
BF
8
BO
23
BE
22
BL
21
BP
20
AB
BJ 9
19
BM
18
BN
17
AG 10
AF
11
BI
12
BH
13
BK
14
BB TP
16 15
3 - 92 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds

(from serial number 431 to 574)
Index Schematic
3200 psi / 220.6 bar............................ BH.......... Primary lift, load holding..................... 30-35 ft-lbs / 41-47 Nm
14 Orifice Plug, 0.040 inch / 1.016 mm.... BK.......... Differential sensing damping
16 Proportional Solenoid Valve, N.C........ BB.......... Boom extend/retract proportional
speed control...................................... 33-37 ft-lbs / 45-50 Nm
17 Solenoid Valve,
2 position 2 way, N.C........................... BN.......... Boom retract sequence control.......... 33-37 ft-lbs / 45-50 Nm
18 Check Valve, 5 psi / 0.34 bar............... BM......... Extension cylinder
19 Check Valve, 5 psi / 0.34 bar............... BJ........... Primary lift load sense check........... 12-14 ft-lbs / 16.3-19 Nm
110 psi / 7.58 bar................................ BP.......... Directs flow to functions...................... 25-27 ft-lbs / 34-37 Nm
21 Check Valve, 5 psi / 0.34 bar............... BL.......... Turntable rotate
0.1 gpm / 0.38 L/min........................... BE.......... Bleeds off differential
sensing valve to tank.......................... 18-20 ft-lbs / 25-27 Nm
23 Solenoid Valve,
2 position 2 way, N.C........................... BO.......... Boom extend sequence control......... 33-37 ft-lbs / 45-50 Nm
24 Solenoid Valve, 2 position 3 way......... BQ.......... Boom retract control.......................... 52-60 ft-lbs / 71-82 Nm
25 Solenoid Valve, 2 position 3 way......... BR.......... Boom extend control.......................... 52-60 ft-lbs / 71-82 Nm
26 Relief Valve, 1800 psi / 124.1 bar........ BA.......... Boom extend pressure limit................ 18-20 ft-lbs / 25-27 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 93

Manifolds
1
BD
BC
2
BA
26
BG
3
BR
25
AA
4
AC
5
BQ AD
24 6
AE
7
BF
8
BO
23
BE
22
BL
21
BP
20
AB
BJ 9
19
BM
18
BN
17
AG 10
AF
11
BI
12
BH
13
BK
14
BB TP
16 15
3 - 94 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-7
Index Schematic
1 Solenoid Valve Assembly,

3 position 4 way, DO3, 12V DC........... BD.......... Boom up/down........................................ 30-35 in-lbs / 3-4 Nm
2 Solenoid Valve, 2 position 3 way......... AA.......... Auxiliary drive/steer selector................25-27 ft-lbs / 34-37 Nm
to auxiliary pump............................. 12-14 ft-lbs / 16.3-19 Nm
3 gpm / 11.36 L/min............................ AD.......... Priority flow to platform..................23-25 ft-lbs / 31.2-33.9 Nm
5 Check Valve, 10 psi / 0.69 bar............. AB.......... Blocks flow from pump 1 and 2
to auxiliary pump................................ 18-20 ft-lbs / 25-27 Nm
6 Solenoid Valve, 3 position 4 way ........ BC.......... Turntable rotate control,
left/right............................................... 25-27 ft-lbs / 34-37 Nm
7 Proportional Solenoid Valve................ BG.......... Turntable rotate,
230 psi / 15.9 bar................................ BP.......... Directs flow to functions.......................33-37 ft-lbs / 45-50 Nm
9 Check Valve......................................... BL.......... Turntable rotate
10 Proportional Solenoid Valve................ BB.......... Boom extend/retract
11 Check Valve, 5 psi / 0.34 bar............... AF.......... Blocks flow from auxiliary pump,
13 Relief Valve, 3000 psi / 206.8 bar........ AC.......... Platform manifold
pressure limit..................................... 18-20 ft-lbs / 25-27 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 95

Manifolds
1 2 3 4 5
BD AA AE AD AB
BC
6
BR
27
BG
7
BP
8
BQ
26
BL
BN 9
25
BO
24
BF
23
BS
22 BB
10
BK
21 AF
BJ 11
20
BM
19
TP
BE 12
18
AC
13
BI
14
AG
15
BH
16
BA
17
3 - 96 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds

Index Schematic
14 Relief Valve, 2600 psi / 179.3 bar........ BI........... Turntable, primary lift and
boom retract pressure limit.............. 12-14 ft-lbs / 16.3-19 Nm
3200 psi / 220.6 bar............................ BH.......... Primary lift, load holding......................30-35 ft-lbs / 41-47 Nm
17 Relief Valve, 1800 psi / 124.1 bar........ BA.......... Boom extend pressure limit.................18-20 ft-lbs / 25-27 Nm
0.1 gpm / 0.38 L/min........................... BE.......... Leads off differential
sensing valve to tank.......................... 18-20 ft-lbs / 25-27 Nm
19 Check Valve, 5 psi / 0.34 bar............... BM......... Extension cylinder
20 Check Valve, 5 psi / 0.34 bar............... BJ........... Primary lift load sense check............12-14 ft-lbs / 16.3-19 Nm
21 Orifice Plug, 0.040 inch / 1.016 mm.... BK.......... Differential sensing damping
22 Check Valve, 30 psi / 2.06 bar............. BS.......... Back pressure check,
boom extend....................................... 33-37 ft-lbs / 45-50 Nm
23 Proportional Solenoid Valve................ BF.......... Primary lift,
24 Solenoid Valve,
2 position 2 way, N.C........................... BO.......... Boom extend sequence control...........33-37 ft-lbs / 45-50 Nm
25 Solenoid Valve,
2 position 2 way, N.C........................... BN.......... Boom retract sequence control............33-37 ft-lbs / 45-50 Nm
26 Solenoid Valve, 2 position 3 way......... BQ.......... Boom retract control............................52-60 ft-lbs / 71-82 Nm
27 Solenoid Valve, 2 position 3 way......... BR.......... Boom extend control............................52-60 ft-lbs / 71-82 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 97

Manifolds
1 2 3 4 5
BD AA AE AD AB
BC
6
BR
27
BG
7
BP
8
BQ
26
BL
BN 9
25
BO
24
BF
23
BS
22 BB
10
BK
21 AF
BJ 11
20
BM
19
TP
BE 12
18
AC
13
BI
14
AG
15
BH
16
BA
17
3 - 98 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-8 How to Adjust the Boom Extend

Valve Adjustments - Function Relief Valve
Manifold, S-120 and S-125 Models Perform this procedure with the boom in the
stowed position.
Manifold Relief Valve gauge to the test port on the function manifold.
stowed position.
3 Fully raise and extend the boom.
gauge to the test port on the function manifold. 4 Simultaneously push and hold the function
enable/high speed button and the boom
2 Start the engine from the ground controls. extend button with the boom fully extended.
3 Simultaneously push and hold the function Observe the pressure reading on the pressure
enable/high speed button and the boom gauge. Refer to Specifications, Hydraulic
retract button with the boom fully retracted. Specifications.
Observe the pressure reading on the pressure 5 Turn the engine off. Use a wrench to hold the
gauge. Refer to Specifications, Hydraulic relief valve and remove the cap (item BA).
Specifications.
4 Turn the engine off. Use a wrench to hold the to increase the pressure or counterclockwise to
relief valve and remove the cap (item BI). decrease the pressure. Install the relief valve
5 Adjust the internal hex socket. Turn it clockwise cap.
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve the relief valve higher than
cap. specified.
Tip-over hazard. Do not adjust 7 Repeat steps 2 through 6 to confirm the relief
the relief valve higher than valve pressure.
specified.
valve pressure.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 99

Manifolds
10-9
Function Manifold
need to be calibrated. See 1-3, How to Calibrate a
Joystick Controller.
3 - 100 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-10
Platform Manifold Components, S-100 and S-120 Models
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
1 Proportional solenoid valve,

3 position 4 way.................................. GH......... Platform level up/down..............................18-20 ft-lbs / 24-27 Nm
2 Check valve......................................... GF.......... Platform rotate circuit
3 Check valve......................................... GJ.......... Platform level circuit
4 Accumulator, 500 psi / 34.5 bar........... GM......... Hydraulic dampening...........................................23 ft-lbs / 31 Nm
5 Differential sensing valve, N.O............ GI........... Platform level differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
6 Differential sensing valve, N.O............ GE.......... Platform rotate differential
sensing circuit......................................23-25 ft-lbs / 31-34 Nm
7 Orifice - plug, 0.030 inch / 0.762 mm.. GB.......... Platform rotate left circuit
8 Orifice - plug, 0.030 inch / 0.762 mm.. GC......... Platform rotate right circuit
9 Shuttle valve........................................ GG......... Platform level load sense circuit..........7.4-9 ft-lbs / 10-12 Nm
10 Shuttle valve........................................ GA.......... Platform rotate load sense circuit.........7.4-9 ft-lbs / 10-12 Nm
11 Differential sensing valve, N.C............. GC......... Directs flow to functions.............................23-25 ft-lbs / 31-34 Nm
3 position 4 way.................................. GD......... Platform rotate left/right.............................18-20 ft-lbs / 24-27 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 101

Manifolds
1 2 3 4
GH GF GJ GQ
GD
12
GO
11
GI
5
GE
6
GA GG GC GB
10 9 8 7
3 - 102 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-11
Platform Manifold Components, S-105 and S-125 Models
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
1 Differential sensing valve, N.C............. CB.......... Directs flow to functions.............................19-21 ft-lbs / 16-19 Nm
2 Flow control valve................................ CD.......... Bleeds off differential valve to tank............19-21 ft-lbs / 26-29 Nm
3 Solenoid valve, 3 position 5 way......... CE.......... Function enable valve................................19-21 ft-lbs / 26-29 Nm
3 position 5 way.................................. CF.......... Jib up/down circuit.....................................19-21 ft-lbs / 26-29 Nm
5 Check valve, 10 psi............................. CG......... Avoid the effect of system
back pressure............................................19-21 ft-lbs / 26-29 Nm
6 Flow control valve,
0.3 GPM / 1.14 LPM............................ CH.......... Platform rotate circuit.................................33-37 ft-lbs / 45-50 Nm
7 Pressure compensation valve............. CI........... Platform level diff. sensing circuit...............33-37 ft-lbs / 45-50 Nm
8 Pressure compensation valve............. CJ.......... Jib boom diff. sensing circuit......................19-21 ft-lbs / 26-29 Nm
9 Check valve, 5 psi............................... CA.......... Platform load sense/level circuit................12-14 ft-lbs / 16-19 Nm
10 Check valve, 5 psi............................... CC.......... Jib boom load sense/up/down circuit.........12-14 ft-lbs / 16-19 Nm
3 position 5 way.................................. CK.......... Platform rotate left/right circuit...................19-21 ft-lbs / 26-29 Nm
3 position 5 way.................................. CL.......... Platform rotate left/right circuit...................19-21 ft-lbs / 26-29 Nm
13 Check Valve DISC............................... CM......... Platform load sense/rotate circuit..............19-21 ft-lbs / 26-29 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 103

manifolds
1
CB
CD
2
CE 3
CL CM
12 13
CF 4
CK
11
CC
10
CA
9
CG
5
CJ CI CH
8 7 6
3 - 104 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-12
Platform Manifold
need to be calibrated. See 1-3, How to Calibrate a
Joystick.
10-13
Platform Rotate Counterbalance Valve Manifold Components
Index Schematic
1 Counterbalance valve.......................... A............ Platform rotate left.....................................37-44 ft-lbs / 50-60 Nm

2 Counterbalance valve.......................... B............ Platform rotate right...................................37-44 ft-lbs / 50-60 Nm
A
1
B B
2
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 105

manifolds
10-14
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
1 Counterbalance valve.......................... A............ Turntable rotate left....................................37-44 ft-lbs / 50-60 Nm

2 Counterbalance valve.......................... B............ Turntable rotate right..................................37-44 ft-lbs / 50-60 Nm
3 Shuttle valve, 2 position 3 way............ C............ Turntable rotation brake release................10-12 ft-lbs / 14-16 Nm
A
1
B B
C
2
C
3
3 - 106 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-15
Steer and Axle Extend/Retract Manifold Components - View 1
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end
of the machine.
Index Schematic
1 Solenoid Valve, 3 position 4 way......... EA.......... Steering cylinder control,

square end, right side..........................18-20 ft-lbs / 24-27 Nm
2 Solenoid Valve, 3 position 4 way......... EB.......... Steering cylinder control,
square end, left side............................18-20 ft-lbs / 24-27 Nm
3 Solenoid Valve, 3 position 4 way......... EC.......... Steering cylinder control,
round end, right side............................18-20 ft-lbs / 24-27 Nm
4 Solenoid Valve, 3 position 4 way......... ED.......... Steering cylinder control,
round end, left side..............................18-20 ft-lbs / 24-27 Nm
1.4 gpm / 5.3 L/min............................. ET.......... Steering cylinder speed,
round end, right side, retract................18-20 ft-lbs / 24-27 Nm
2 gpm / 7.6 L/min................................ EU.......... Steering cylinder speed,
round end, left side, extend.................18-20 ft-lbs / 24-27 Nm
2 gpm / 7.6 L/min................................ EV.......... Steering cylinder speed,
square end, right side, extend.............18-20 ft-lbs / 24-27 Nm
0.1 gpm / 0.38 L/min........................... EO.......... Bleeds off differential valve to tank............18-20 ft-lbs / 24-27 Nm
9 Differential Sensing Valve, 110 psi...... EP.......... Meters flow to functions sensing ..............25-27 ft-lbs / 34-37 Nm
1.4 gpm / 5.3 L/min............................. EW......... Steering cylinder speed,
square end, left side, retract................18-20 ft-lbs / 24-27 Nm
11 Solenoid Valve,
3 position 4 way.................................. ES.......... Axle extend contrrol...................................25-27 ft-lbs / 34-37 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 107

manifolds
1 2 3
EA EB EC
ES
11
ED
4
EW
10
EP
9
EO
8
EV EU ET
7 6 5
3 - 108 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-16
Steer and Axle Extend/Retract Manifold Components - View 2
of the machine.
Index Schematic

2 gpm / 7.6 L/min................................ EE.......... Steering cylinder speed.............................18-20 ft-lbs / 25-27 Nm
1.4 gpm / 5.3 L/min............................. EJ........... Steering cylinder speed, circle end,
left side, retract....................................18-20 ft-lbs / 25-27 Nm
1.4 gpm / 5.3 L/min............................. EQ.......... Steering cylinder speed,
square end, right side, retract..............18-20 ft-lbs / 25-27 Nm
2 gpm / 7.6 L/min................................ ER.......... Steering cylinder speed,
square end, left side, extend................18-20 ft-lbs / 25-27 Nm
5 Check Valve, 5 psi / 0.34 bar............... EX.......... Axle extend load sense,
both ends..........................................12-14 ft-lbs / 16.3-19 Nm
6 Relief Valve, 1800 psi / 124 bar........... EQQ....... Axle extend................................................18-20 ft-lbs / 25-27 Nm
7 Relief Valve, 3000 psi / 207 bar........... EZ.......... Steering pressure limit...............................18-20 ft-lbs / 25-27 Nm
(Removed from S-120/125 at serial number 522, S-100/105 at serial number 148)
8 Check Valve, 5 psi / 0.34 bar............... EY.......... Axle retract load sense,
both ends..........................................12-14 ft-lbs / 16.3-19 Nm
9 Check Valve, 5 psi / 0.34 bar............... EKK........ Steering load sense, square end,
right side, extend..............................12-14 ft-lbs / 16.3-19 Nm
10 Check Valve, 5 psi / 0.34 bar............... EII.......... Steering load sense, square end,
right side, retract...............................12-14 ft-lbs / 16.3-19 Nm
11 Check Valve......................................... EM......... Steering cylinder lock, square end,
right side, extend/retract......................18-20 ft-lbs / 25-27 Nm
12 Check Valve, 5 psi / 0.34 bar............... ENN....... Steering load sense, square end,
left side, retract.................................12-14 ft-lbs / 16.3-19 Nm
13 Check Valve, 5 psi / 0.34 bar............... EJJ......... Steering load sense, square end,
left side, extend.................................12-14 ft-lbs / 16.3-19 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 109

manifolds
1 2 3 4 5
EE EJ EQ ER EX
TP
21
EQQ
6
EZ
7
EY
8
EKK
9
EOO EPP EMM EG ELL EH EK EJJ ENN EM EII

20 19 18 17 16 15 14 13 12 11 10
3 - 110 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
Steer and Axle Extend/Retract Manifold Components - View 2, continued

of the machine.
Index Schematic
14 Check Valve......................................... EK.......... Steering cylinder lock, square end,

left side, extend/retract........................18-20 ft-lbs / 25-27 Nm
15 Check Valve......................................... EH.......... Steering cylinder lock, circle end,
right side, extend/retract......................18-20 ft-lbs / 25-27 Nm
16 Check Valve, 5 psi / 0.34 bar............... ELL........ Steering load sense, circle end,
right side, retract...............................12-14 ft-lbs / 16.3-19 Nm
17 Check Valve......................................... EG.......... Steering cylinder lock, circle end,
left side, extend/retract.....................12-14 ft-lbs / 16.3-19 Nm
18 Check Valve, 5 psi / 0.34 bar............... EMM...... Steering load sense, circle end,
right side, extend..............................12-14 ft-lbs / 16.3-19 Nm
19 Check Valve, 5 psi / 0.34 bar............... EPP........ Steering load sense, circle end,
left side, extend.................................12-14 ft-lbs / 16.3-19 Nm
20 Check Valve, 5 psi / 0.34 bar............... EOO....... Steering cylinder lock, circle end,
left side, retract.................................12-14 ft-lbs / 16.3-19 Nm
21 Diagnostic Nipple Cap......................... TP.......... Testing
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 111

manifolds
1 2 3 4 5
EE EJ EQ ER EX
TP
21
EQQ
6
EZ
7
EY
8
EKK
9
EOO EPP EMM EG ELL EH EK EJJ ENN EM EII

20 19 18 17 16 15 14 13 12 11 10
3 - 112 S-100 • S-105 • S-120 • S-125 Part No. 1268494

manifolds
10-17 How to Adjust the Axle Extend

Valve Adjustments - Steer and Relief Valve
Axle Extend/Retract Manifold Note: Perform this procedure with the axles
retracted, the boom in the stowed position and the
How to Adjust the Steer and Axle machine on a paved surface.
Retract Relief Valve 1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
Note: Perform this procedure with the axles gauge to the test port on the steer and axle
retracted and the boom in the stowed position. extend/retract manifold.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure 2 Start the engine from the platform controls.
gauge to the test port on the steer and axle 3 Press down the foot switch and push the axle
extend/retract manifold. extend button. Observe the pressure reading
2 Start the engine from the platform controls. on the pressure gauge. Refer to Specifications,
Hydraulic Specifications.
3 Position the machine so that the left front wheel
is against an immoveable object such as a 4 Turn the engine off. Use a wrench to hold the
curb. relief valve and remove the cap (item EQQ).
4 Press down the foot switch and activate the 5 Adjust the internal hex socket. Turn it clockwise
steer function. Steer the wheel into the curb to increase the pressure or counterclockwise to
and hold. Observe the pressure reading on decrease the pressure. Install the relief valve
the pressure gauge. Refer to Specifications, cap.
Hydraulic Component Specifications.
5 Turn the engine off. Use a wrench to hold the the relief valve higher than
relief valve and remove the cap (item EZ). specified.
6 Adjust the internal hex socket. Turn it clockwise 6 Repeat steps 2 through 5 to confirm relief valve
to increase the pressure or counterclockwise to pressure.
decrease the pressure. Install the relief valve
cap.
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm relief valve
pressure.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 113

manifolds
3 - 114 S-100 • S-105 • S-120 • S-125 Part No. 1268494

manifolds
10-18
Traction Manifold Components
(S-100/105- to serial number 290)
(S-120/125- to serial number 1194)
The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index Schematic
1 Solenoid valve, 2 position 3 way......... DA.......... 2 speed control..........................................25-30 ft-lbs / 38-41 Nm
2 Flow regulator valve,
2 gpm / 7.57 L/min.............................. DB.......... Drive slip limit, rear....................................35-40 ft-lbs / 47-54 Nm
3 Flow divider/combiner valve................ DC.......... Controls flow to rear drive
motors in forward and reverse.....130-140 ft-lbs / 176-190 Nm
2 gpm / 7.57 L/min.............................. DD.......... Drive slip limit, front...................................35-40 ft-lbs / 47-54 Nm
5 Flow divider/combiner valve................ DE.......... Controls flow to front drive
motors in forward and reverse.....130-140 ft-lbs / 176-190 Nm
6 Flow divider/combiner valve................ DF.......... Controls flow to front and
rear flow divider combiner valves
(items DC and DE)......................130-140 ft-lbs / 176-190 Nm
7 Check valve......................................... DG......... Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
8 Check valve......................................... DH.......... Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
2.7 gpm / 10.22 L/min......................... DI........... Drive slip limit, front and rear.....................35-40 ft-lbs / 47-54 Nm
10 Check valve......................................... DJ.......... Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
11 Check valve......................................... DK.......... Anti-cavitation............................................35-40 ft-lbs / 47-54 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 115

manifolds
1 2 3
DA DB DC
DO
17
DD
4
DN
16
DM
15 DE
5
DP
14
DF
6
DL
13
TP
12
DG
7
DH
8
DK DJ DI
11 10 9
3 - 116 S-100 • S-105 • S-120 • S-125 Part No. 1268494

manifolds
Traction Manifold Components, continued

(S-100/105- to serial number 290), (S-120/125- to serial number 1194)
Index Schematic
12 Diagnostic fitting.................................. TP.......... Testing
13 Shuttle valve,
3 position 3 way.................................. DL.......... Charge pressure circuit that
gets hot oil out of low presure
side of the drive pump.........................35-40 ft-lbs / 47-54 Nm
14 Check valve, 50 psi / 3.45 bar............. DP.......... 2 speed/brake charge
pressure circuit....................................25-30 ft-lbs / 38-41 Nm
15 Relief valve, 250 psi / 17.2 bar............ DM......... Charge pressure circuit.............................35-40 ft-lbs / 47-54 Nm
16 Orifice - plug,
0.030 inch / 0.762 mm......................... DN.......... Brake release and
2 speed shift control
17 Solenoid valve, 2 position 3 way......... DO......... Brake control.............................................25-30 ft-lbs / 38-41 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 117

manifolds
1 2 3
DA DB DC
DO
17
DD
4
DN
16
DM
15 DE
5
DP
14
DF
6
DL
13
TP
12
DG
7
DH
8
DK DJ DI
11 10 9
3 - 118 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-19
Traction Manifold Components
(S-100/105- from serial number 291)
(S-120/125- from serial number 1195)
Index Schematic
1 Check Valve......................................... HA.......... Anti-cavitation...............................30-35 ft-lbs / 40.7-47.5 Nm
2 Solenoid Valve, 2 position 3 way......... HB.......... Two-speed drive motor shift..........26-30 ft-lbs / 35.3-40.7 Nm
3 Solenoid Valve, 2 position 3 way......... HC.......... Brake release................................26-30 ft-lbs / 35.3-40.7 Nm
4 Check Valve......................................... HD.......... Keeps brakes released if temporary
loss of charge pressure.................20-25 ft-lbs / 27.1-33.9 Nm
5 Shuttle Valve, 3 position 3 way............ HE.......... Charge pressure circuit that directs
hot oil out of low pressure side
of drive pump.................................50-55 ft-lbs / 67.8-74.6 Nm
6 Relief Valve, 250 psi / 17.23 bar.......... HF.......... Charge pressure circuit.................20-25 ft-lbs / 27.1-33.9 Nm
7 Orifice Plug, 0.030 inch / 0.762 mm.... HG......... Brake and two-speed circuit..........20-25 ft-lbs / 27.1-33.9 Nm
8 Check Valve......................................... HH.......... Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
9 Check Valve......................................... HI........... Anti-cavitation................................30-35 ft-lbs / 40.7-47.5 Nm
10 Flow Divider/Combiner Valve.............. HJ.......... Controls flow to
square end drive motors
in forward and reverse................90-100 ft-lbs / 122-135.6 Nm
11 Check Valve......................................... HK.......... Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
12 Bi-directional/Flow Control Valve,
2 gpm / 7.6 L/min................................ HL.......... Equalizes pressure on both sides of
divider/combiner valve FJ .............30-35 ft-lbs / 40.7-47.5 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 119

manifolds
1 2 3 4 5
HA HB HC HD HE
HR
18
HQ
17
HF
6
HP
16
HO
15
HG
HN 7
14
HM
13 HH
8
HI
9
HJ
10
HL HK
12 11
3 - 120 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
Traction Manifold Components, continued

(S-100/105- from serial number 291), (S-120/125- from serial number 1195)
Index Schematic
2 gpm / 7.6 L/min................................ HM......... Equalizes pressure on both sides
of divider/combiner valve FQ.........30-35 ft-lbs / 40.7-47.5 Nm
2 gpm / 7.6 L/min................................ HN.......... Equalizes pressure on both sides
of divider/combiner valve FQ.........30-35 ft-lbs / 40.7-47.5 Nm
15 Check Valve......................................... HO......... Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
16 Flow Divider/Combiner Valve.............. HP.......... Controls flow to
circle end drive motors
in forward and reverse................90-100 ft-lbs / 122-135.6 Nm
17 Flow Divider/Combiner Valve.............. HQ......... Controls flow to divider/combiner
valves FJ and FP........................90-100 ft-lbs / 122-135.6 Nm
18 Check Valve......................................... HR.......... Anti-cavitation................................20-25 ft-lbs / 27.1-33.9 Nm
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 121

manifolds
1 2 3 4 5
HA HB HC HD HE
HR
18
HQ
17
HF
6
HP
16
HO
15
HG
HN 7
14
HM
13 HH
8
HI
9
HJ
10
HL HK
12 11
3 - 122 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
10-20 10-21
Valve Adjustments - Valve Coils
Traction Manifold How to Test a Coil
How to Adjust the Charge A properly functioning coil provides an
Pressure Relief Valve electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
1 Connect a 0 to 600 psi / 0 to 41 bar pressure within the coil. Zero resistance or infinite
gauge to the test port located on the drive resistance indicates the coil has failed.
manifold.
Since coil resistance is sensitive to temperature,
2 Start the engine from the platform controls. resistance values outside specification can
3 Drive the machine slowly in either direction and produce erratic operation. When coil resistance
observe the pressure reading on the pressure decreases below specification, amperage
gauge. Refer to Specifications, Hydraulic increases. As resistance rises above specification,
Specifications. voltage increases.
4 Turn the engine off. Use a wrench to hold the While valves may operate when coil resistance
charge pressure relief valve and remove the is outside specification, maintaining coils within
cap (item DM or FF). specification will help ensure proper valve function
over a wide range of operating temperatures.
to increase the pressure or counterclockwise Electrocution/burn hazard. Contact
to decrease the pressure. Install the relief valve with electrically charged circuits
cap. could result in death or serious
and other jewelry.
valve pressure.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to

be tested.
2 Test the coil resistance using a multimeter
set to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 123

Manifolds
Valve Coil Resistance How to Test a Coil Diode

Specification Genie incorporates spike suppressing diodes in
Note: The following coil resistance specifications all of its directional valve coils except proportional
are at an ambient temperature of 68°F / 20°C. As valves and those coils with a metal case. Properly
valve coil resistance is sensitive to changes in functioning coil diodes protect the electrical circuit
air temperature, the coil resistance will typically by suppressing voltage spikes. Voltage spikes
increase or decrease by 4% for each 18°F / 20°C naturally occur within a function circuit following
that your air temperature increases or decreases the interruption of electrical current to a coil. Faulty
from 68°F / 20°C. diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
Description Specification damage.
Solenoid valve, 2 position 3 way, 12V DC 9Ω
(schematic item DA, DO, FB, FC)
Solenoid valve, 3 position 4 way, 12V DC 9.8 Ω could result in death or serious
(schematic item EA, EB, EC, ED)
(before serial number 292)
and other jewelry.
Solenoid valve, 3 position 4 way, 12V DC 8.8 Ω
(schematic item EA, EB, EC, ED) 1 Test the coil for resistance. Refer to, How to
(after serial number 291) Test a Coil.
Proportional solenoid valve, 12V DC 5.4 Ω 2 Connect a 10Ω resistor to the negative terminal
(schematic item FG, BG, GD, GH)
of a known good 9V DC battery. Connect the
Proportional solenoid valve, 12V DC 5Ω other end of the resistor to a terminal on the
(schematic item FB, FF, BB, BF) coil.
3 position 4 way D03 valve, 12V DC 4.6 Ω
(schematic item FD, BD) Note: The battery should read 9V DC or more
when measured across the terminals.
Solenoid Valve, 2 position 3 way, 12V DC 4.6 Ω
(schematic item FQ, FR, BQ, BR)
Solenoid Valve, 2 position 2 way, 12V DC 7.2 Ω a
(schematic item BN, BO) COIL AMMETER
Solenoid valve, 3 position 4 way 12V 7.2 Ω d

(schematic items ES, FC, BC)
(before serial number 292)
c - b
Solenoid valve, 3 position 4 way 12V 7.1 Ω
(schematic items ES)
+
(after serial number 291) 10 9V

RESISTOR BATTERY
Solenoid valve, 2 position 3 way 12V 7.2 Ω
c
(schematic items AA)
+
b
-
a multimeter
b 9V DC battery
c 10Ω resistor
d coil
Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6
3 - 124 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Manifolds
3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.
4 Connect the negative lead to the other terminal

on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
5 Momentarily connect the positive lead from

the multimeter to the positive terminal on the
9V DC battery. Note and record the current
reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 125

Fuel and Hydraulic Tanks

11-1 5 Remove the fuel tank hold down strap retaining
fasteners. Remove the straps from the fuel
Fuel Tank tank.
6 Support and secure the fuel tank to an
How to Remove the Fuel Tank appropriate lifting device.
Explosion and fire hazard. 7 Remove the fuel tank from the machine.
Engine fuels are combustible.
Remove the fuel tank in an open, Crushing hazard. The fuel tank
well-ventilated area away from may become unbalanced and fall
heaters, sparks, flames and if it is not properly supported and
lighted tobacco. Always have an secured to the lifting device.
approved fire extinguisher within
easy reach. Component damage hazard.
The fuel tank is plastic and may
Explosion and fire hazard. Never become damaged if it is allowed to
drain or store fuel in an open fall.
container due to the possibility of
Note: Clean the fuel tank and inspect
fire.
for cracks and other damage before installing.
1 Remove the fixed engine side turntable cover.
See 5-1, How to Remove a Fixed Turntable
Cover.
2 Tag, disconnect and plug the fuel supply and
return hoses. Cap the fittings on the fuel tank.
3 Remove the fuel filler cap from the tank.
4 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. See
capacity specifications.
Explosion and fire hazard.
When transferring fuel, connect
a grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand operated pump
suitable for use with diesel fuel.
3 - 126 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Fuel and hydraulic tanks
11-2 2 Close the two hydraulic shutoff valves located

at the hydraulic tank.
Hydraulic Tank
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainers for
the pump supply lines and has an external return
line filter with a filter condition indicator.
How to Remove the open closed

Hydraulic Tank
Component damage hazard. The sure that the hydraulic tank shutoff
work area and surfaces where valves are in the open position
this procedure will be performed before priming the pump. The
must be clean and free of debris engine must not be started with
that could get into the hydraulic the hydraulic tank shutoff valves in
system. the closed position or component
damage will occur. If the hydraulic
tank shutoff valves are closed,
remove the key from the key
switch and tag the machine to
installation.
inform personnel of the condition.
Torque Specifications. 3 Remove the drain plug from the hydraulic
tank and allow all of the oil from the tank to
1 Remove the ground controls side turntable drain into a suitable container. See capacity
cover. See 5-1, How to Remove a Hinged specifications.
Turntable Cover.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 127

Fuel and hydraulic Tanks
4 Remove the ground controls support bracket 12 Remove the hydraulic tank from the machine.
retaining fasteners. Remove the ground
controls assembly from the machine. Crushing hazard. The hydraulic
tank could become unbalanced
Component damage hazard. and fall if it is not properly
Be sure to properly support the supported and secured to the
ground control box. Do not allow overhead crane.
the ground controls to hang by the
wiring. Component damage hazard. Be
sure to open the two hydraulic
Component damage hazard. tank valves and prime the pump
The ground control box wiring after installing the hydraulic tank.
can be damaged if it is kinked or See 9-2, How to Prime the Pumps.
pinched.
Note: Always use pipe thread sealant when
5 Tag and disconnect the wiring from the horn. installing the drain plug and strainers.
6 Remove the horn retaining fasteners. Remove Note: Refer to Specifications, Machine
the horn from the machine. Specifications for hydraulic oil requirements.
7 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank shutoff
valves.
8 Tag, disconnect and plug the supply hose for
the auxiliary power unit. Cap the fitting on the
hydraulic tank.
9 Disconnect and plug the T-fitting located at the
return filter with the 2 hoses connected to it.
Cap the fitting on the return filter housing.
10 Remove the hydraulic tank retaining fasteners.
11 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.
3 - 128 S-100 • S-105 • S-120 • S-125 Part No. 1268494


12-1 3 Tag, disconnect and plug the hydraulic hoses
from the manifold that is mounted to the motor.
Turntable Rotation Hydraulic
Motor and Drive Hub hydraulic oil can penetrate and
How to Remove the Turntable connections very slowly to allow
Rotation Hydraulic Motor the oil pressure to dissipate
Note: When removing a hose assembly or fitting, or spray.
replaced and then torqued to specification during 4 Remove the motor/brake mounting fasteners.
installation. Refer to Specifications, Hydraulic Remove the motor from the brake.
a
1 Secure the turntable from rotating with the
turntable rotation lock pin. b
unlocked locked
2 Remove the ground controls side fixed turntable

cover. See 5-1, How to Remove a Fixed
Turntable Cover. e d
a motor
b motor/brake mounting bolts
c brake
d drive hub mounting bolts
e drive hub
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 129

Turntable Rotation components
How to Remove the Turntable 4 Attach a lifting strap from an overhead crane or
other suitable lifting device to the drive hub.
Rotation Drive Hub
5 Remove the drive hub mounting bolts and
1 Secure the turntable from rotating with the remove the drive hub from the machine.
turntable rotation lock pin.
Tip-over hazard. If the turntable
rotation lock pin is not properly
installed, machine stability is
compromised and the machine
could tip over when the drive hub
is removed from the machine,
which could result in death or
serious injury.
unlocked locked
Crushing hazard. The drive hub
may become unbalanced and
2 Remove the turntable rotation motor. See How
fall if it is not properly supported
to Remove the Turntable Rotation Hydraulic
by the overhead crane or lifting
Motor.
device.
3 Remove the brake from the drive hub and set it
6 Remove the plug from the side of the drive hub.
off to the side.
Drain the oil from the hub.
a
Installing the Drive Hub:
b 7 Install the drive hub. Use blue thread locking

seal on all bolts. Torque the drive hub mounting
c
bolts to 280 ft-lbs / 380 Nm.
8 Install the brake onto the drive hub and torque
the mounting fasteners to 20 ft-lbs / 27 Nm.
9 Install the motor onto the brake and torque the
mounting fasteners to 93 ft-lbs / 126 Nm.
9 Fill the drive hub with oil from the side hole
until the oil level is even with the bottom of the
hole. Apply pipe thread sealant to the plugs
and install the plugs. Refer to Specifications,
e d Specifications.
a motor 10 Adjust turntable rotation gear backlash.

b motor/brake mounting bolts
c brake
d drive hub mounting bolts
e drive hub
3 - 130 S-100 • S-105 • S-120 • S-125 Part No. 1268494

How to Adjust the

Turntable Rotation Gear Backlash
The turntable rotation drive hub is adjustable to
control the gap between the rotation motor gear
and the turntable bearing.
Note: Be sure to check the backlash with the

machine on a flat level surface.
1 Secure the turntable from rotating with the

turntable rotation lock pin.
a b
a adjustment bolt with lock nut

b pivot plate mounting bolts
unlocked locked
4 Loosen the lock nut on the turntable drive hub
adjustment bolt.
2 Remove the ground controls side fixed turntable 5 Tighten the turntable drive hub adjustment
cover. See 5-1, How to Remove a Fixed bolt until the turntable drive hub gear is fully
Turntable Cover. engaged and tight into the turntable rotate gear.
3 Loosen the turntable rotate drive hub mounting 6 Turn the adjustment bolt 3/4 turn
bolts. Do not remove them. counterclockwise. Tighten the lock nut on the
Note: It may be necessary to raise the boom adjustment bolt.
slightly to access all the turntable rotate drive hub 7 Rotate the drive hub away from the turntable
mounting bolts. rotate gear until it contacts the adjustment bolt.
Torque the turntable rotate drive hub mounting
bolts. Refer to Specifications, Machine Torque
Specifications.
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 131

3 - 132 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Axle Components
13-1 Measure the circle-end tires:
Steer Sensors 3 Press the square-end steer mode button.

4 Measure the distance between the inside of
The steer sensor measures steer angle and
one circle-end tire and the chassis side plate on
communicates that information to the ground
both sides of the axle.
controls ECM. The steer sensor on the ground
controls side of the machine at the square end acts Measure here
as the lead sensor. The other three sensors follow
the position, or steer angle, of the lead sensor.
There is a steer sensor mounted to the top of each
upper yoke pivot pin.
Note: If the square-end steering function becomes Square-end Circle-end
inoperative, switch to circle-end steer mode and

the ground controls side circle-end steer sensor
will become the lead sensor.
Note: This procedure will require a minimum of two

people.
Result: Both measurements should be the
Note: Perform this procedure with the axles same to indicate that the tires are parallel with
extended. the chassis.
How to Measure the Tire Note: If the measurements are different or if a tire
is not parallel with the chassis, the steer sensor
Alignment of that tire will need to be adjusted. See How to
1 Start the engine from the platform controls. Adjust a Steer Sensor.
2 Press down the foot switch and push the engine 5 Repeat step 4 for the other circle-end tire.
idle select button until the engine switches to
high rpm.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 133

axle components
Measure the square-end tires: How to Adjust a Steer Sensor

6 Press the circle-end steer mode button. Square-end steer sensors:
7 Measure the distance between the inside of 1 At the platform controls, press the circle-end
one square-end tire and the chassis side plate steer mode button.
on both sides of the axle.
2 Locate the steer sensor on top of the yoke pivot
Measure here
pin.
3 Loosen the steer sensor cover retaining
fasteners. Do not remove them.
4 Rotate the steer sensor cover either clockwise
Square-end Circle-end or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
Measure here
Result: Both measurements should be the

same to indicate that the tires are parallel with
the chassis. Square-end Circle-end
Note: If the measurements are different or if a tire

is not parallel with the chassis, the steer sensor
of that tire will need to be adjusted. See How to
Adjust a Steer Sensor.
8 Repeat step 4 for the other square-end tire.

5 Repeat step 4 until the tire is parallel with the
chassis.
6 Tighten the steer sensor cover fasteners.
7 Repeat steps 2 through 6 for the other square-
end steer sensor.
3 - 134 S-100 • S-105 • S-120 • S-125 Part No. 1268494

axle components
Circle-end steer sensors: 13-2

8 At the platform controls, press the square-end Yoke and Hub
steer mode button.
9 Locate the steer sensor on top of the yoke pivot How to Remove the Yoke
pin. and Hub
10 Loosen the steer sensor cover retaining The yoke installation utilizes bushings and a thrust
fasteners. Do not remove them. washer that may require periodic replacement.
11 Rotate the steer sensor cover either clockwise There is a steer sensor mounted to the upper yoke
or counterclockwise. Measure the distance pivot pin.
between the inside of tire and the chassis side
plate on both sides of the axle.
Measure here
1 Remove the hose hanger bracket retaining

fasteners mounted to the top of the yoke.
Square-end Circle-end Remove the hose hanger bracket from the
machine.
from the drive motor and brake assembly. Cap
the fittings on the drive motor and brake.
12 Repeat step 4 until the tire is parallel with the hydraulic oil can penetrate and
chassis. burn skin. Loosen hydraulic
13 Tighten the steer sensor cover fasteners. connections very slowly to allow
14 Repeat steps 9 through 13 for the other circle- gradually. Do not allow oil to squirt
end steer sensor. or spray.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 135

axle components
3 Mark the mounting position of the steer sensor 7 Remove the steer sensor activator pin retaining
cover on the yoke. fasteners. Remove the steer sensor activator
pin from the machine.
Note: It is very important that the steer sensor
is installed in the exact position it was in prior Note: It is very important that the steer sensor
to removal. If the steer sensor is not installed activator pin is installed in the exact position it was
correctly, the steer function may operate in prior to removal. If the steer sensor activator pin
improperly. If any steer functions operate is not installed correctly, the steer function may
improperly after removing and installing a steer operate improperly. If any steer functions operate
sensor, see 13-1, How to Adjust a Steer Sensor. improperly after removing and installing a steer
sensor activator pin, see 13-1, How to Adjust a
4 Remove the steer sensor cover retaining Steer Sensor.
fasteners. Carefully remove the steer sensor
cover and lay it out of the way. 8 Loosen the wheel lug nuts. Do not remove
them.
steer sensor is a very sensitive 9 Center a lifting jack of ample capacity under the
instrument. It can be damaged axle of the yoke and drive hub to be removed.
internally if it is dropped or Do not raise the machine.
sustains any physical shock, even
10 Block the wheels at the opposite end of the
if the damage is not visible.
machine.
5 Lay the hoses and steer sensor cable out of the
11 Raise the machine approximately 6 inches
way.
(15 cm) and place blocks under the chassis for
Component damage hazard. support.
Cables and hoses can be
12 Remove the lug nuts and remove the tire and
damaged if they are kinked or
wheel assembly.
pinched.
13 Remove the drive motor mounting fasteners.
6 Mark the mounting position of the steer sensor
activator pin mounted to the top of the yoke 14 Slide the drive motor shaft out of the drive hub
pivot pin. and remove the drive motor from the machine.
steering cylinder rod-end pivot pins. Remove
the pins.
upper and lower yoke pivot pins.
3 - 136 S-100 • S-105 • S-120 • S-125 Part No. 1268494

axle components
17 Support the yoke/drive hub assembly with a 13-3

lifting jack. Secure the yoke/drive hub assembly
to the lifting jack. Drive Motor
18 Use a soft metal drift to remove both yoke pivot
pins.
How to Remove a Drive Motor
19 Remove the yoke/drive hub assembly from the Component damage hazard.
Repairs to the motor should only
machine.
be performed by an authorized
Crushing hazard. The yoke/ dealer.
hub assembly may become
unbalanced and fall when the yoke Component damage hazard. The
work area and surfaces where this
pivot pins are removed if it is not
procedure will be performed must
properly supported and secured to
be clean and free of debris that
the lifting jack.
could get into the hydraulic system
20 Place the yoke/drive hub assembly on a flat and cause severe component
surface with the drive hub facing down. damage. Dealer service is
recommended.
21 Remove the drive hub mounting fasteners that
attach the yoke to the drive hub. Remove the Note: When removing a hose assembly or fitting,
yoke weldment from the drive hub. the O-ring on the fitting and/or hose end must be
Note: Replace the thrust washer with a new one
when installing the yoke/drive hub assembly onto
the axle. Refer to Specifications, Machine Torque
Specifications. 1 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
drive motor.
or spray.
2 Remove the drive motor mounting fasteners.
3 Slide the drive motor shaft out of the brake and
drive hub. Remove the drive motor from the
machine.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 137

axle components
13-4 8 Place a second lifting jack under the drive hub

for support and secure the drive hub to the
Drive Hub lifting jack.
9 Remove the drive hub mounting bolts that
How to Remove a Drive Hub attach the drive hub to the yoke. Remove the
Note: When removing a hose assembly or fitting, drive hub from the machine.
Crushing hazard. The drive
hub may become unbalanced and
installation.
fall if it is not properly supported
and secured to the lifting jack.
Refer to Specifications, Machine
1 Remove the drive motor. See 13-3, How to Torque Specifications.
Remove a Drive Motor.
2 Tag, disconnect and plug the hydraulic hose
from the brake. Cap the fittting on the brake.
or spray.
3 Loosen the wheel lug nuts. Do not remove
them.
4 Center a lifting jack of ample capacity under
the axle of the drive hub to be removed. Do not
raise the machine.
machine.
6 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
7 Remove the wheel lug nuts. Remove the tire
and wheel assembly.
3 - 138 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Axle Components
13-5 7 Place a rod through each steer cylinder pivot

pin and twist to remove the pins.
Steering Cylinders
How to Remove a
Steering Cylinder
8 Remove the steering cylinder from the machine.
1 Locate the hose bracket mounted to the steer
cylinder. Crushing hazard. The steer
2 Remove the hose bracket cover retaining and fall if it is not properly
fasteners. Remove the hose bracket cover. supported by the lifting device.
3 Remove the hose bracket retaining fasteners
from the steering cylinder.
from the steering cylinder. Cap the fittings on
the cylinder.
or spray.
steer cylinder pivot pins.
6 Support the steer cylinder with a suitable lifting
device.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 139

axle components
13-6 Top and bottom wear pads:
Extendable Axles 3 Center a lifting jack of ample capacity under the

axle that needs to be shimmed. Do not raise
The extendable axles are used to widen the foot the machine.
print of the drive chassis for stability.
machine.
How to Shim an Extendable Axle
5 Raise the machine just until the weight of the
Note: Measure each wear pad. Replace the wear
machine is relieved off of the axle. Do not raise
pad if it is less than 7/16 inch / 11 mm thick.
the wheels off of the ground.
If the wear pad is 7/16 inch / 11 mm thick or more,
perform the following procedure. 6 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
1 Fully extend the axle.
7 Use a round punch through the wear pad
2 Remove the wear pad retaining fasteners. mounting holes to align the shims with the wear
Side wear pads: pad. Install the wear pad retaining fasteners.
3 Install the new shims under the wear pad to 8 Extend and retract the axle through an entire
obtain zero clearance and zero drag. cycle. Check for tight spots that could cause
binding or scraping of the axle tubes.
4 Use a round punch through the wear pad
mounting holes to align the shims with the wear Note: Always maintain squareness between the
pad. Install the wear pad retaining fasteners. inner and outer axle tubes.
5 Extend and retract the axle through an entire

cycle. Check for tight spots that could cause
binding or scraping of the axle tubes.
Note: Always maintain squareness between the
inner and outer axle tubes.
3 - 140 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Axle Components
How to Remove an Inner Axle 8 Remove the pin retaining fasteners from the
axle stop pin. Use a slide hammer to remove
Note: When removing a hose assembly or fitting, the pin.
replaced and then torqued to specification during 9 Remove the access cover fasteners from
installation. the end of the inner axle to access the axle
Refer to Specifications, Hydraulic Hose and Fitting extension cylinder clevis pin. Remove the
Torque Specifications. cover.
10 Place support blocks under the end of the axle
Note: Perform this procedure with the tires parallel
extension cylinder for support.
to the chassis and the axles fully extended.
11 Remove the cotter pin from the axle extension
1 Remove the top drive chassis cover. cylinder clevis pin.
2 Remove the yoke and hub assembly. See 13-2, Note: Alwayse use a new cotter pin when installing
How to Remove the Yoke and Hub. a clevis pin.
3 Remove the steering cylinder. See 13-5, How
12 Use a soft metal drift to remove the axle
to Remove a Steering Cylinder.
extension cylinder clevis pin.
4 Remove the axle cover retaining fasteners
13 Carefully support and slide the inner axle out
located above the axle. Remove the chassis
of the chassis. Remove the axle from the
cover from the machine.
machine.
5 Remove the upper wear pad retainer plate
Crushing hazard. The inner
retaining fasteners. Remove the plate from the
axle may become unbalanced
machine.
6 Attach a lifting strap from an overhead crane of the machine if it is not properly
ample capacity to the inner axle for support. Do supported by the overhead crane.
not lift it.
7 Remove the retaining fasteners from the upper aluminum limit switch track and
and lower wear pads at the outer axle. Do not the axle extension cylinder may
remove the side wear pads. become damaged if the axle is
allowed to fall when it is removed
Note: Pay careful attention to the location and from the machine.
amount of shims used with each wear pad.
will need to be carefully adjusted for proper
balancing.
Note: When installing an inner axle, there needs to

be a minimum of 1/8 inch / 3.1 mm gap between the
proximity switches and the aluminum limit switch
track. Measure the gap with the axles in both
the retracted and extended positions. Adjust the
proximity switches as necesary to obtain a
1
/8 inch / 3.1 mm gap.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 3 - 141

axle components
How to Remove the Axle 7 Attach a lifting strap from an overhead crane to
the end of the axle extension cylinder.
Extension Cylinder
Note: Attach the lifting strap to the end of the
1 Remove a yoke and hub assembly. See 13-2, cylinder that has the inner axle removed.
How to Remove the Yoke and Hub.
8 Remove the cotter pin from the axle extension
2 Remove the axle. See How to Remove an Inner cylinder clevis pin on the remaining inner axle.
Axle.
Note: Alwayse use a new cotter pin when installing
3 Remove the access covers from the end of the a clevis pin.
remaining axle.
9 Use a soft metal drift to remove the pin.
4 Tag, disconnect and plug the axle extension
cylinder hydraulic hoses. Cap the fittings on the Crushing hazard. The axle
cylinder. extension cylinder may fall if it is
not properly supported.
hydraulic oil can penetrate and Component damage hazard. The
burn skin. Loosen hydraulic axle extension cylinder and limit
connections very slowly to allow switches can become damaged
the oil pressure to dissipate if the axle extension cylinder is
gradually. Do not allow oil to squirt allowed to fall.
or spray.
10 Carefully support and slide the axle extension
5 Tag and disconnect the wiring connectors from cylinder out of the axle.
the proximity switches and limit switch. Do not
remove the switches.
will need to be carefully adjusted for proper
Note: The wiring connectors for the switches can balancing.
be accessed through the access holes on either
side of the chassis end plate.
6 Place blocks under the axle extension cylinder

for support.
3 - 142 S-100 • S-105 • S-120 • S-125 Part No. 1268494

January 2019 Section 4 • Diagnostic Codes
Diagnostic Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-100, S-105, S-120, S-125 Operator’s
Manual.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropiate fault code thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing
before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
• Machine parked on a firm, level surface Electrocution/burn hazard. Contact
• Boom in stowed position could result in death or serious
• Turntable rotated with the boom between injury. Remove all rings, watches
the non-steer wheels and other jewelry.
• Turntable secured with the turntable Bodily injury hazard. Spraying
rotation lock hydraulic oil can penetrate and
• Key switch in the off position with the burn skin. Loosen hydraulic
key removed connections very slowly to allow
• Wheels chocked
• All external AC power disconnected squirt or spray.
from the machine
Note: Perform all troubleshooting on a firm, level
surface.
Note: Two persons will be required to safely

perform some troubleshooting procedures.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4-1

Section 4 • Diagnostic Codes January 2019
Diagnostic codes
Fault Diagnostics -
Control System
How to Read Control System

Fault Codes
Note: Initial fault testing occurs at power-up.
Faults are abnormal conditions that exist due

to component failure or System misuse. CPU,
memory, LCD, LED, limited joystick and limited
operator switch testing is done on power-up. If
an operator switch is depressed on power-up,
the display should show and error and not allow
any machine functions.
Releasing the switch will clear the error and
allow all machine functions. The joystick
operates similarly.
All other fault testing is done continuously.
1 When a fault is diagnosed, the PCON fault
indicator will flash and a fault message will be
displayed on the TCON LCD. The message will
contain the fault source and type.
2 Additional information, including the occurrence
counter and a time-stamp is available with a
PC, connected to one of the RS232 ports. Up
to 16 unique fault messages can be saved.
Each fault is saved with the device identity,
fault type, engine hour time-stamp and an 8-bit
occurrence counter.
3 The fault code table on the following pages lists
the functions or components monitored by the
system.
4 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Diagnostic codes
Error Source Error Type Effects Recovery Actions

Normal function except threshold for
Not calibrated one or the other direction is zero, Dis- Calibrate Thresholds
play message on LCD
Just calibrated Initiate one second beep of audible Self-clearing

warning device (transient)
Primary Boom Ext/Ret Flow Valve
Value at 5.0 V
Power up controller with
Value Too High Limited Speed and Direction frozen at problem
zero and neutral, Alarm sounds corrected
Value Too Low
Value at 0 V
play message on LCD

Primary Boom Up/Down Flow Valve
Value at 5.0 V
Limited Speed and Direction frozen at Power up controller with
Value Too High
zero and neutral, Alarm sounds problem
Value Too Low corrected
Value at 0 V
Primary Boom Extend Valve
Primary Boom Retract Valve Power up controller with

Fault Check Limited Speed and Direction frozen at problem
Primary Boom Up Valve zero and neutral, Alarm sounds corrected
Primary Boom Down Valve
Range Check
Engine Speed
(underspeed)
Range Check Power up controller with
Oil Pressure Display message on LCD problem
(low oil pressure)
corrected
Range Check
Water/Oil Temp
(high temperature)
Water/Oil Temp Sensor Power up controller with
Fault Check Display message on LCD problem
Oil Pressure Sensor corrected

Fault Check (both Axle Extend/Retract disabled, display
Axle Extend/Retract Buttons problem
buttons pressed) message on LCD corrected

Axle Valves Fault Check Limited Speed and Direction frozen at problem
zero and neutral, Alarm sounds corrected
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4-3

Diagnostic codes

Value at 5.0 V
Value Too High Limited Speed and Direction frozen at
problem
zero and neutral, Alarm sounds
Value at 0 V
Primary Ext/Ret Joystick
Joystick Speed and Direction frozen

Not calibrated Calibrate Joystick
at zero and neutral
Initiate one second beep of audible Self-clearing

Just calibrated warning device (transient)
Value at 5.0 V
Value Too High Limited Speed and Direction frozen at Power up controller with
Value at 0 V
Primary Up/Down Joystick
Joystick Speed and Direction frozen Calibrate Joystick
Not calibrated
at zero and neutral

Just calibrated
Value at 5.0 V
Value at 0 V
Steer Joystick Joystick Speed and Direction frozen

at zero and neutral


Primary Boom Up/Down switches on Fault Check (both Primary Boom Up/Down disabled, dis-
problem
TCON buttons pressed) play message on LCD
corrected
Primary Boom Ext/Ret switches on Fault Check (both Primary Boom Ext/Retract disabled,
problem
TCON buttons pressed) display message on LCD
corrected
Stop all boom functions, allow only Power up controller with
Primary Boom Length Fault Check boom retract, once fully retracted allow problem
(unknown length) boom down. Display message on LCD corrected
Stop all boom functions, allow only Power up controller with
Primary Boom Angle Fault Check boom retract. Display message on LCD problem
(unknown angle) corrected
4 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Diagnostic codes
Display message on LCD and allow Perform auto calibrate

Primary Up/Down Speed Not calibrated operation at default speed precedure
Not calibrated Display message on LCD and allow Perform auto calibrate
Primary Extend/Retract Speed
operation at default speed precedure
SAFETY SWITCH P3 Display message on LCD

P3 SAFETY SWITCH FAULT
Display message on LCD
SAFETY SWITCH P6R1 P6R1 SAFETY SWITCH FAULT
SAFETY SWITCH P6R2 Display message on LCD

P6R2 SAFETY SWITCH FAULT

SAFETY SWITCH P7

SAFETY SWITCH P7R
P7R SAFETY SWITCH FAULT

SAFETY SWITCH P9A
P9A SAFETY SWITCH FAULT
SAFETY SWITCH P9B Display message on LCD

P9B SAFETY SWITCH FAULT Power up controller with
Fault Check problem
Display message on LCD corrected
SAFETY SWITCH P10 P10 SAFETY SWITCH FAULT



SAFETY SWITCH P14

SAFETY SWITCH P18

SAFETY SWITCH P22R Display message on LCD

P22R SAFETY SWITCH FAULT

CAN Bus Fault Check Display message on LCD problem
corrected
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4-5

Diagnostic codes

Primary Boom Lock-Out Valve #1 Power up controller with
Fault Check Limited Speed and Direction frozen at
zero and neutral, Alarm sounds problem corrected
Primary Boom Lock-Out Valve #2
Platform Overload
Fault Check Display message on LCD Power up controller with
(if active) problem corrected
Shut Down Mode
Value at 5.0 V
Value Too High Limited Speed and Direction frozen at

Value Too Low problem corrected
Value at 0 V
Turntable Rotate Joystick
Not calibrated Joystick Speed and Direction frozen Calibrate Joystick

at zero and neutral

Fault Check (both TT rotate disabled, display message on Power up controller with
Turntable Rotate Buttons buttons pressed) LCD problem corrected
Not calibrated Display message on LCD and allow Perform auto calibrate
Turntable Rotate Speed
operation at default speed procedure

one or the other directions is zero,dis- Calibrate Thresholds
Not calibrated
play message on LCD

Turntable Rotate Flow Valve Just calibrated
Value at 5.0 V
zero and neutral, Alarm sounds problem corrected
Value Too Low
Value at 0 V
Turntable Rotate CW Valves Limited Speed and Direction frozen at Power up controller with
Fault Check
Turntable Rotate CCW Valves zero and neutral, Alarm sounds problem corrected
Turntable Level Sensor X-Direction

Display message on LCD and sound
Turntable Level Sensor Y-Direction Fault Check audible alarm Correct problem
Platform Level Sensor Y-Direction
4 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Diagnostic codes

Value at 5.0 V
Limited Speed and Direction frozen Power up controller with
Value Too High
at zero and neutral, Alarm sounds problem
Value at 0 V
Propel Joystick
Not calibrated Joystick Speed and Direction frozen Calibrate Joystick

at zero and neutral

play message on LCD
Value at 5.0 V
Propel Valves (High Current)
Value Too High Power up controller with
Shut down engine, Limited Speed and
problem
Value Too Low Direction frozen at zero and neutral,
corrected
Alarm sounds
Value at 0 V
Motor Speed Valve Shut down engine, Limited Speed and Power up controller with
Fault Check Direction frozen at zero and neutral, problem corrected
Brake Valve Alarm sounds
Platform Level Up Valve
Platform Level Down Valve
Platform Rotate CW Valve
Fault Check Limited Speed and Direction frozen at problem
Platform Rotate CCW Valve zero and neutral, Alarm sounds corrected
Jib Up Valve
Jib Down Valve
Jib Switches
Platform Rotate Switches Fault Check (both Affected functions disabled, display problem
buttons pressed) message on LCD corrected
Platform Level Switches
Footswitch Timeout Display message on LCD Recycle power

Hydraulic Generator/Welder - Bypass Fault Check Disable Generator, Display message problem
Valve on LCD Display corrected
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4-7

Diagnostic codes

Value at 5.0 V
Value Too High Limited Speed and Direction frozen Power up controller with
at zero and neutral, Alarm sounds problem
SteeringJoystick Value at 0 V
Joystick Speed and Direction frozen
at zero and neutral

Value at 5.0 V

LF Steer Angle Sensor Limited Speed and Direction frozen at
problem
Value Too Low zero and neutral, Alarm sounds
corrected
Value at 0 V
Value at 5.0 V

RF Steer Angle Sensor Limited Speed and Direction frozen at problem
Value Too Low zero and neutral, Alarm sounds corrected
Value at 0 V
Value at 5.0 V

Limited Speed and Direction frozen at
LR Steer Angle Sensor zero and neutral, Alarm sounds problem
Value Too Low
corrected
Value at 0 V
Value at 5.0 V
RR Steer Angle Sensor problem
Value at 0 V
LF Steer Valves
RF Steer Valves Limited Speed and Direction frozen at Power up controller with
Fault Check problem
LR Steer Valves corrected
RR Steer Valves
Hydraulic Generator/Welder - Bypass Fault Check Display message on LCD problem
Valve corrected
4 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494

CONTROL SYSTEM fault codes

P_38-Propel P_39-Turntable P_10-Primary P_11-Primary P_9A-Primary P_9B-
(P13-17 TCON) Rotate (P13-19 Boom Extend Up (P12-09 Down (P12-06 Ignition/Fuel
TCON) (P12-08 TCON) TCON) TCON) (P12-07 TCON)
P_22-Jib Jib P_22R - Primary P_12 - Axle
Lvl Pwr Up/Down FC Retract (P121-08
SCON)
P_38 P_39 P_10 P_11 P_9A P_9B P_22 P_22R P_12

Turntable tilt axis (+5°, secondary OFF OFF OFF
boom not stowed)
Primary Boom Angle (crosscheck) OFF OFF OFF OFF OFF*
Primary Boom Length (crosscheck) OFF OFF OFF OFF OFF*
Primary 2 Cylinder (crosscheck) OFF OFF OFF*
Boom Envelope Safety Interlock OFF OFF OFF
Axle Safety Not Stowed OFF OFF
Axles crosscheck Angle sensor vs. OFF OFF OFF OFF
safety switch(es)
Axle (not fully extended) and TT OFF OFF
Rotate (stowed and in drive disable
zone)
Turntable Tilt Angle (crosscheck OFF OFF OFF OFF OFF
SCON internal sensor 3 in a delta
configuration)
Loss of CAN OFF OFF OFF OFF OFF* OFF
Platform Overload (SCON pin #1) OFF
Platform Out of Level (>10°) OFF
Jib Bellcrank Out of Level (>10°) OFF
Boom Safety (max angle) OFF OFF OFF OFF
Boom Safety (max length) OFF OFF OFF OFF OFF OFF
Axle Retract Safety OFF
Cable Tension (#1 or #2) OFF
* P-9A and P-10 energized if boom is fully retracted as indicated by LSB3RS
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4-9

Fault Source and Type will display as: Fault Source

Source Type ID Description
" ID XXX_xx FAULT " 3 SCON Controller Area Network
Where XXX is the one to three digit Fault Source and xx is 4 Primary Boom Angle Zone
the two digit Fault Type. 5 Primary Boom Length Switches Cross-Check
8 PCON Controller Area Network
TCON - Turntable Controller 9 Engine
18 DCON Controller Area Network
PCON - Platform Controller
20 Boom Extend/Retract Joystick
SCON - Safety Controller 21 Boom Up/Down Joystick
DCON - Drive Controller 26 Boom Extend/Retract Buttons
27 Boom Up/Down Buttons
Fault Type
28 Boom Angle Sensors Cross-Check (SCON)
ID Description
29 LSB2RS/LSB4ES Cross-Check (SCON)
11 Value at 5V
30 Propel Joystick
12 Value too High
35 Propel Valve
13 No Response
40 Turntable Rotate Joystick
15 Value too Low
43 Footswitch Timeout
16 Value at 0V
44 Jib Up/Down Joystick
17 Not Calibrated
48 PBMAS Safety Envelope (SCON)
21 Fault
49 Jib Up/Down Buttons
26 Timeout
50 Jib Up/Down Flow Valve
31 Invalid Setup
52 Steer Joystick
32 Min Cal Too Low
53 Left Front Steer Sensor
33 Min Cal Too High
54 Right Front Steer Sensor
55 Left Rear Steer Sensor
56 Right Rear Steer Sensor
59 Rocker Steer Joystick
61 PBMLS Safety Envelope (SCON)
63 Front Axle Sensor
64 Rear Axle Sensor
4 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Fault Source Fault Source

ID Description ID Description
65 Turntable Level Sensor X-Direction 124 Enable Output Power P7R
66 Turntable Level Sensor Y-Direction 125 Primary Down Power P9A
67 Boom Length Sensor Cross-Check (SCON) 126 IGN/Fuel Power P9B
68 Boom Safety Envelope (SCON) 127 Primary Extend Power P10
70 Turntable Controller - Platform Controller 128 Primary Up Power P11
Software Version 129 Axle Retract Power P12
73 Engine Pressure Sensor 132 Platform Level Power P22
74 Engine Temperature Sensor 133 Primary Up/Down Valve Power P22R
75 LSB2RO/LSB4EO Cross-Check 134 DCON Valve Power P7R
80 TCON/SCON Calibration Inconsistent 142 Turntable Rotate CW Valve
81 Boom Up/Down Flow Valve (Fine) 143 Turntable Rotate CCW Valve
82 Boom Extend/Retract Flow Valve 144 Axle Safety Not Stowed (SCON)
83 Boom Extend/Retract Speed 145 Boom Up Valve
85 Boom Up/Down Speed 146 Boom Down Valve
86 Boom Angle Sensor 147 Platform Overload Switches Inconsistent
90 Jib Rotate Flow Valve (SCON)
91 Turntable Rotate Buttons 148 Boom Extend Valve
92 Turntable Rotate Flow Valve 149 Boom Retract Valve
93 Turntable Rotate Speed 152 Boom Up/Down Flow Valve (Gross)
94 Boom Length Sensor 153 Primary Lockout P1 Valve
95 Jib Rotate Joystick 154 Primary Lockout P2 Valve
98 Platform Level Sensor 157 Axles Fully Extended Cross-Check (SCON)
99 Platform Level Buttons 158 Drive Disable Zone and Axles Not Fully
110 Platform Rotate Buttons Extended (SCON)
113 Jib Rotate Buttons 160 Left Front Steer Valve
117 Propel Power P38 161 Right Front Steer Valve
118 Turntable Rotate Power P39 162 Left Rear Steer Valve
121 Valve Power P6R1 163 Right Rear Steer Valve
122 Engine Power P6R2 164 Axle Valve
123 Enable Input Power P7 165 Boom Not Retracted and Chassis Tilted (SCON)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 11

Fault Source
ID Description
166 Brake Valve
167 Motor Shift Valve
168 Chassis Tilt Sensors Cross-Check (SCON)
170 Jib Bellcrank Level Sensor
171 Jib Bellcrank Level Flow Valve
172 AUX Relay
173 Platform Level Toggle Switch
174 Platform Rotate Toggle Switch
175 Platform Level Flow Valve
176 Platform Rotate Valve
180 Boom Length Sensor
195 Safety Platform Overload (SCON)
220 RSB1AO Active Cross-Check
221 LTB1LO Active Cross-Check
222 Axle Extend/Retract Toggle Switch
235 RSB1AO/LSB1DO Cross-Check
236 LTB1LO/LSB3RO Cross-Check
237 LTB1LO/LSB4EO Cross-Check
238 Pressure Comp Enable #1 Valve
239 Pressure Comp Enable #2/Generator Valve
245 Check Machine Software Type at TCON
246 Check Machine Software Type at SCON
247 TCON/SCON Software Inconsistent
4 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Deutz td 2.9 l4 engine fault codes
SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 51 6 1022 Actuator error EGR-Valve; signal
KWP = Keyword Protocol range check high
SPN FMI KWP Description 51 6 1224 Actuator EGR-Valve; over
51 3 1019 EGR-Valve, short circuit to current
battery 51 6 1230 Actuator error EGR-Valve;
51 3 1024 Position sensor error of actuator Overload by short-circuit
EGR-Valve; signal range check 51 7 1016 Actuator position for EGR-Valve
high not plausible
51 3 1226 EGR-Valve; short circuit to 51 11 1231 Actuator error EGR-Valve; Power
battery (A02) stage over temp due to high
51 3 1227 EGR-Valve; short circuit to current
battery (A67) 51 12 1018 Actuator EGR-Valve; powerstage
51 4 1020 EGR-Valve; short circuit to over temperature
ground 51 12 1021 Mechanical actuator defect
51 4 1025 Position sensor error of actuator EGR-Valve
EGR-Valve; signal range check 51 12 1225 Actuator EGR-Valve;
low over temperature
51 4 1228 EGR-Valve; short circuit to 94 1 474 Low fuel pressure; warning
ground (A02) threshold exceeded
51 4 1229 EGR-Valve; short circuit to 94 1 475 Low fuel pressure; shut off
ground (A67) threshold exceeded
51 4 1232 Actuator error EGR-Valve; 94 3 472 Sensor error low fuel pressure;
Voltage below threshold signal range check high
51 5 1015 Actuator error EGR-Valve; signal 94 4 473 Sensor error low fuel pressure;
range check low signal range check low
51 5 1017 Actuator EGR-Valve; open load 97 3 464 Sensor error water fuel; signal
51 5 1023 Actuator error EGR-Valve; signal range check high
range check low 97 4 465 Sensor error water fuel; signal
51 5 1223 Actuator EGR-Valve; open load range check low
51 6 1014 Actuator error EGR-Valve; signal 97 12 1157 Water in fuel level prefilter;
range check high maximum value exceeded
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 13


FMI = Failure Mode Identifier 108 3 412 Sensor error ambient air press;
KWP = Keyword Protocol signal range check high
SPN FMI KWP Description 108 4 413 Sensor error ambient air press;
100 0 734 High oil pressure; warning signal range check low
threshold exceeded 110 0 98 High coolant temperature;
100 0 735 High oil pressure; shut off warning threshold exceeded
threshold exceeded 110 0 99 High coolant temperature; shut
100 1 736 Low oil pressure; warning off threshold exceeded
threshold exceeded 110 3 96 Sensor error coolant temp;
100 1 737 Low oil pressure; shut off signal range check high
threshold exceeded 110 4 97 Sensor error coolant temp;
100 3 732 Sensor error oil pressure; signal signal range check low
range check high 111 1 101 Coolant level too low
100 4 733 Sensor error oil pressure; signal 132 11 1 Air flow sensor load correction
range check low factor exceeding the maximum
102 2 88 Charged air pressure above drift limit; plausibility error
warning threshold 132 11 2 Air flow sensor load correction
102 2 89 Charged air pressure above shut factor exceeding drift limit;
off threshold plausibility error
102 4 777 Sensor error charged air press; 132 11 3 Air flow sensor low idle correction
signal range check low factor exceeding the maximum
105 0 996 High charged air cooler drift limit
temperature; warning threshold 132 11 4 Air flow sensor load correction
exceeded factor exceeding the maximum
105 0 997 High charged air cooler drift limit
temperature; shut off threshold 157 3 877 Sensor error rail pressure; signal
exceeded range check high
105 3 994 Sensor error charged air 157 4 878 Sensor error rail pressure; signal
temperature; signal range check range check low
high
105 4 995 Sensor error charged air
temperature; signal range check
low
4 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494


FMI = Failure Mode Identifier 174 0 481 High low fuel temperature;
KWP = Keyword Protocol warning threshold exceeded
SPN FMI KWP Description 174 0 482 High low fuel temperature; shut
168 0 1180 Physical range check high for off threshold exceeded
battery voltage 175 0 740 Physical range check high for oil
168 1 1181 Physical range check low for temperature
battery voltage 175 0 745 High oil temperature; warning
168 2 47 High battery voltage; warning threshold exceeded
threshold exceeded 175 0 746 High oil temperature; shut off
168 2 48 Low battery voltage; warning threshold exceeded
threshold exceeded 175 1 741 Physical range check low for oil
168 3 45 Sensor error battery voltage; temperature
signal range check high 175 2 738 Sensor oil temperature;
168 4 46 Sensor error battery voltage; plausibility error
signal range check low 175 2 739 Sensor oil temperature;
171 3 417 Sensor error environment plausibility error oil temperature
temperature; signal range check too high
high 175 3 743 Sensor error oil temperature;
171 4 418 Sensor error environment signal range check high
temperature; signal range check 175 4 744 Sensor error oil temperature;
low signal range check low
172 0 1182 Physical range check high for 190 0 389 Engine speed above warning
intake air temperature threshold (FOC-Lewel 1)
172 1 1183 Physical range check low for 190 2 421 Offset angle between crank and
intake air temperature camshaft sensor is too large
172 2 9 Sensor ambient air temperature; 190 8 419 Sensor camshaft speed;
plausibility error disturbed signal
172 2 983 Intake air sensor; plausibility
error
172 3 981 Sensor error intake air; signal
range check high
172 4 982 Sensor error intake air; signal
range check low
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 15


FMI = Failure Mode Identifier 412 3 1007 Sensor error EGR cooler
KWP = Keyword Protocol downstream temperature; signal
SPN FMI KWP Description range check high
190 8 422 Sensor crankshaft speed; 412 4 1008 Sensor error EGR cooler
disturbed signal downstream temperature; signal
190 11 390 Engine speed above warning range check low
threshold (FOC-Lewel 2) 520 9 306 Timeout Error of
190 12 420 Sensor camshaft speed; no CAN-Receive-Frame TSC1TR;
signal Setpoint
190 12 423 Sensor crankshaft speed; no 597 2 49 Break lever mainswitch and
signal break lever redundancy switch
status not plausible
190 14 391 Engine speed above warning
threshold (Overrun Mode) 624 3 971 SVS lamp; short circuit to batt
190 14 1222 Camshaft and Crankshaft speed 624 4 972 SVS lamp; short circuit to grd
sensor signal not available on 624 5 969 SVS lamp; open load
CAN 624 12 970 SVS lamp; powerstage over
411 0 791 Physical range check high for temperature
differential pressure Venturiunit 630 12 376 Access error EEPROM memory
(EGR) (delete)
411 1 792 Physical range check low for 630 12 377 Access error EEPROM memory
differential pressure Venturiunit (read)
(EGR)
630 12 378 Access error EEPROM memory
411 3 795 Sensor error differential pressure (write)
Venturiunit (EGR); signal range
check high 639 14 84 CAN-Bus 0 "BusOff-Status"
411 4 381 Physical range check low for 651 3 580 Injector 1 (in firing order); short
(EGR) differential pressure circuit
411 4 796 Sensor error differential pressure 651 4 586 High side to low side short circuit
Venturiunit (EGR); signal range in the injector 1 (in firing order)
check low
4 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494


FMI = Failure Mode Identifier 677 3 956 Starter relay high side; short
KWP = Keyword Protocol circuit to battery
SPN FMI KWP Description 677 3 960 Starter relay low side; short
651 5 568 Injector 1 (in firing order); circuit to battery
interruption of electric connection 677 4 957 Starter relay high side; short
652 3 581 Injector 2 (in firing order); short circuit to ground
circuit 677 4 961 Starter relay low side; short
652 4 587 High side to low side short circuit circuit to ground
in the injector 2 (in firing order) 677 5 958 Starter relay; no load error
652 5 569 Injector 2 (in firing order); 677 12 959 Starter relay; powerstage over
interruption of electric connection temperature
653 3 582 Injector 3 (in firing order); short 703 3 426 Engine running lamp; short circuit
circuit to battery
653 4 588 High side to low side short circuit 703 4 427 Engine running lamp; short circuit
in the injector 3 (in firing order) to ground
653 5 570 Injector 3 (in firing order); 703 5 424 Engine running lamp; open load
interruption of electric connection
703 12 425 Engine running lamp;
654 3 583 Injector 4 (in firing order); short powerstage over temperature
circuit
729 5 545 Cold start aid relay open load
654 4 589 High side to low side short circuit
in the injector 4 (in firing order) 729 12 547 Cold start aid relay; over
temperature error
654 5 571 Injector 4 (in firing order);
interruption of electric connection 898 9 305 Timeout Error of
CAN-Receive-Frame TSC1TE;
676 11 543 Cold start aid relay error Setpoint
676 11 544 Cold start aid relay open load 1079 13 946 Sensor supply voltage monitor
1 error (ECU)
1080 13 947 Sensor supply voltage monitor
2 error (ECU)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 17


FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature
KWP = Keyword Protocol upstream turbine; shut off
SPN FMI KWP Description threshold exceeded
1109 2 121 Engine shut off demand ignored 1180 3 1067 Sensor error exhaust gas
1136 0 1398 Physikal range check high for temperature upstream turbine;
ECU temperature signal range check high
1136 1 1399 Physikal range check low for 1180 11 1066 Sensor exhaust gas temperature
ECU temperature upstream turbine; plausibility
error
1136 3 1400 Sensor error ECU temperature;
signal range check high 1188 2 1414 Wastegate; status message from
ECU missing
1136 4 1401 Sensor error ECU temperature;
signal range check low 1188 7 1415 Wastegate actuator; blocked
1176 3 849 Sensor error pressure sensor 1188 11 1411 Wastegate actuator; internal
upstream turbine; signal range error
check high 1188 11 1412 Wastegate actuator; ELO
1176 4 850 Sensor error pressure sensor calibration not performed
downstream turbine; signal range correctly
check high 1188 11 1416 Wastegate actuator; over
1180 0 1193 Physical range check high for temperature (> 145°C )
exhaust gas temperature 1188 11 1417 Wastegate actuator; over
upstream turbine temperature (> 135°C )
1180 0 1460 Turbocharger Wastegate CAN 1188 11 1418 Wastegate actuator; operating
feedback; warning threshold voltage error
exceeded 1188 11 1413 Wastegate actuator calibration
1180 0 1462 Exhaust gas temperature deviation too large, recalibration
upstream turbine; warning required
threshold exceeded 1231 14 85 CAN-Bus 1 "BusOff-Status"
1180 1 1194 Physical range check low for 1231 14 86 CAN-Bus 2 "BusOff-Status"
exhaust gas temperature
upstream turbine
1180 1 1461 Turbocharger Wastegate CAN
feedback; shut off threshold
exceeded
4 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494


FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error
KWP = Keyword Protocol of short circuit to ground
SPN FMI KWP Description measurement cyl. Bank 1
1237 2 747 Override switch; plausibility error 2798 4 1339 Injector diagnostics; short circuit
1322 12 610 Too many recognized misfires in to ground monitoring Test in Cyl.
more than one cylinder Bank 0
1323 12 604 Too many recognized misfires in 2798 4 1340 Injector diagnostics; short circuit
cylinder 1 (in firing order) to ground monitoring Test in Cyl.
Bank 1
1324 12 605 Too many recognized misfires in
cylinder 2 (in firing order) 3224 2 127 DLC Error of
CAN-Receive-Frame AT1IG1
1325 12 606 Too many recognized misfires in NOX Sensor (SCR-system
cylinder 3 (in firing order) upstream cat; DPF-system
1326 12 607 Too many recognized misfires in downstream cat); length of frame
cylinder 4 (in firing order) incorrect
2659 0 1524 Physical range check high for 3224 9 128 Timeout Error of
EGR exhaust gas mass flow CAN-Receive-Frame AT1IG1;
2659 1 1525 Physical range check low for NOX Sensor upstream
EGR exhaust gas mass flow 3248 4 1047 Sensor error particle filter
2659 2 1523 Exhaust gas recirculation AGS downstream temperature; signal
sensor; plausibility error range check low
2659 2 1527 AGS sensor temperature exhaust 3699 2 1616 DPF differential pressure sensor
gas mass flow; plausibility error and a further sensor or actuator
CRT system defective
2659 12 1526 Exhaust gas recirculation; AGS
sensor has "burn off" not 3699 2 1617 Temperature sensor us. and ds.
performed DOC simultaneously defect
2797 4 1337 Injector diagnostics; timeout error 3699 14 1615 Maximum stand-still-duration
of short circuit to ground reached; oil exchange required
measurement cyl. Bank 0 4765 0 1039 Physical range check high for
upstream (DOC)
4765 1 1042 Physical range check low for
upstream (DOC)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 19


FMI = Failure Mode Identifier 523008 2 649 Timeout error in Manipulation
KWP = Keyword Protocol control
SPN FMI KWP Description 523009 9 825 Pressure Relief Valve (PRV)
4766 0 1029 Physical range check high for reached maximum allowed
exhaust gas temperature opening count
downstream (DOC) 523009 10 833 Pressure Relief Valve (PRV)
4766 1 1032 Physical range check low for reached maximum allowed
exhaust gas temperature open time
downstream (DOC) 523212 9 171 Timeout Error of
4768 2 1036 Sensor exhaust gas temperature CAN-Receive-Frame
upstream (DOC); plausibility ComEngPrt; Engine Protection
error 523216 9 198 Timeout Error of
4768 3 1044 Sensor error exhaust gas CAN-Receive-Frame
temperature upstream (DOC); PrHtEnCmd; pre-heat command,
signal range check high engine command
4768 4 1045 Sensor error exhaust gas 523240 9 179 Timeout CAN-message
temperature upstream (DOC); FunModCtl; Function Mode
signal range check low Control
4769 2 1026 Sensor exhaust gas temperature 523350 4 565 Injector cylinder-bank 1; short
downstream (DOC); plausibility circuit
error 523352 4 566 Injector cylinder-bank 2; short
4769 3 1034 Sensor error exhaust gas circuit
temperature downstream (DOC); 523354 12 567 Injector powerstage output defect
signal range check high
523470 2 826 Pressure Relief Valve (PRV)
4769 4 1035 Sensor error exhaust gas forced to open; performed by
temperature downstream (DOC); pressure increase
signal range check low
523470 2 827 Pressure Relief Valve (PRV)
523006 3 34 Controller mode switch; short forced to open; performed by
circuit to battery pressure shock
523006 4 35 Controller mode switch; short
circuit to ground
523008 1 648 Manipulation control was
triggered
4 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494


FMI = Failure Mode Identifier 523612 12 613 Internal ECU monitoring
KWP = Keyword Protocol detection reported error
SPN FMI KWP Description 523612 12 614 Internal ECU monitoring
523470 7 876 Maximum rail pressure in limp detection reported error
home mode exceeded (PRV) 523612 12 615 Internal ECU monitoring
523470 11 831 The PRV can not be opened at detection reported error
this operating point with a 523612 12 616 Internal ECU monitoring
pressure shock detection reported error
523470 11 832 Rail pressure out of tolerance 523612 12 617 Internal ECU monitoring
range detection reported error
523470 12 828 Open Pressure Relief Valve 523612 12 618 Internal ECU monitoring
(PRV); shut off condition detection reported error
523470 12 829 Open Pressure Relief Valve 523612 12 619 Internal ECU monitoring
(PRV); warning condition detection reported error
523470 14 830 Pressure Relief Valve (PRV) is 523612 12 620 Internal ECU monitoring
open detection reported error
523550 12 980 T50 start switch active for too 523612 12 621 Internal ECU monitoring
long detection reported error
523601 13 948 Sensor supply voltage monitor 523612 12 623 Internal ECU monitoring
3 error (ECU) detection reported error
523603 9 126 Timeout Error of 523612 12 624 Internal ECU monitoring
CAN-Receive-Frame AMB; detection reported error
Ambient Temperature Sensor
523612 12 625 Internal ECU monitoring
523605 9 300 Timeout Error of detection reported error
CAN-Receive-Frame TSC1AR;
Traction Control 523612 12 627 Internal ECU monitoring
detection reported error
523606 9 301 Timeout Error of
CAN-Receive-Frame TSC1AR; 523612 12 628 Internal ECU monitoring
Retarder detection reported error
523612 12 387 Internal software error ECU;

injection cut off
523612 12 612 Internal ECU monitoring
detection reported error
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 21


FMI = Failure Mode Identifier 523615 3 596 Metering unit (Fuel-System);
KWP = Keyword Protocol short circuit to battery low side
SPN FMI KWP Description 523615 4 595 Metering unit (Fuel-System);
523612 12 637 Internal ECU monitoring short circuit to ground high side
detection reported error 523615 4 597 Metering unit (Fuel-System);
523612 12 1170 Internal software error ECU short circuit to ground low side
523612 14 973 Softwarereset CPU SWReset_0 523615 5 592 Metering unit (Fuel-System);
523612 14 974 Softwarereset CPU SWReset_1 open load
523612 14 975 Softwarereset CPU SWReset_2 523615 12 593 Metering unit (Fuel-System);
powerstage over temperature
523613 0 856 Maximum positive deviation of
rail pressure exceeded 523619 2 488 Physical range check high for
(RailMeUn0) exhaust gas temperature
upstream (SCR-CAT)
rail pressure in meeting unit 523698 11 122 Shut off request from supervisory
exceeded (RailMeUn1) monitoring function
523613 0 858 Railsystem leakage detected 523717 12 125 Timeout Error of

(RailMeUn10) CAN-Transmit-Frame AmbCon;
Weather environments
rail pressure in meeting unit 523718 3 1488 SCR mainrelay; short circuit to
exceeded (RailMeUn2) battery (only CV56B)
523613 0 860 Negative deviation of rail 523718 4 1489 SCR mainrelay; short circuit to
pressure second stage ground (only CV56B)
(RailMeUn22) 523718 5 1486 SCR mainrelay; open load (only
523613 0 862 Maximum rail pressure exceeded CV56B)
(RailMeUn4) 523718 12 1487 SCR mainrelay; powerstage over
523613 1 861 Maximum rail pressure exceeded temperature (only CV56B)
(RailMeUn3) 523766 9 281 Timeout Error of
523613 2 864 Setpoint of metering unit in CAN-Receive-Frame Active
overrun mode not plausible TSC1AE
523613 3 594 Metering unit (Fuel-System); 523767 9 282 Timeout Error of

short circuit to battery high side CAN-Receive-Frame Passive
TSC1AE
4 - 22 S-100 • S-105 • S-120 • S-125 Part No. 1268494


FMI = Failure Mode Identifier 523897 13 561 Check of missing injector
KWP = Keyword Protocol adjustment value programming
SPN FMI KWP Description (IMA) injector 3 (in firing order)
523768 9 283 Timeout Error of 523898 13 562 Check of missing injector
CAN-Receive-Frame Active adjustment value programming
TSC1AR (IMA) injector 4 (in firing order)
523769 9 284 Timeout Error of 523910 6 1261 Air Pump; over current
CAN-Receive-Frame Passive 523913 3 74 Sensor error glow plug control
TSC1AR diagnostic line voltage; signal
523770 9 285 Timeout Error of range check high
CAN-Receive-Frame Passive 523913 4 75 Sensor error glow plug control
TSC1DE diagnostic line voltage; signal
523776 9 291 Timeout Error of range check low
CAN-Receive-Frame TSC1TE 523914 3 78 Glow plug control; short circuit to
active battery
523777 9 292 Passive Timeout Error of 523914 4 79 Glow plug control; short circuit to
CAN-Receive-Frame TSC1TE; ground
Setpoint
523914 5 76 Glow plug control; open load
523778 9 293 Active Timeout Error of
CAN-Receive-Frame TSC1TR 523914 5 1216 Glow plug control release line;
short circuit error
523779 9 294 Passive Timeout Error of
CAN-Receive-Frame TSC1TR 523914 11 1217 Glow plug control; internal error
523788 12 299 Timeout Error of 523914 12 77 Glow plug control; powerstage

CAN-Transmit-Frame TrbCH; over temperature
Status Wastegate 523919 2 1378 Sensor air pump airpressure;
523793 9 202 Timeout Error of plausibility error
CAN-Receive-Frame UAA10; 523920 2 1379 Sensor exhaust gas back
AGS sensor service message pressure burner; plausibility error
CAN-Receive-Frame UAA11;
AGS sensor data
523895 13 559 Check of missing injector
adjustment value programming
(IMA) injector 1 (in firing order)
523896 13 560 Check of missing injector
adjustment value programming
(IMA) injector 2 (in firing order)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 23


FMI = Failure Mode Identifier 523936 12 169 Timeout Error of
KWP = Keyword Protocol CAN-Transmit-Frame
SPN FMI KWP Description EEC3VOL2; Engine send
523922 7 1262 Burner Shut Off Valve; blocked messages
closed 523946 0 1158 Zerofuel calibration injector 1 (in
523922 7 1264 Burner Shut Off Valve; blocked firing order); maximum value
closed exceeded
523929 0 109 Fuel Balance Control integrator 523946 1 1164 Zerofuel calibration injector 1 (in
injector 1 (in firing order); firing order); minimum value
maximum value exceeded exceeded
injector 1 (in firing order); firing order); maximum value
minimum value exceeded exceeded
523932 1 118 Fuel Balance Control integrator 523960 0 1011 Physical range check high for
injector 4 (in firing order); EGR cooler downstream temp.
minimum value exceeded
CAN-Transmit-Frame
EEC3VOL1; Engine send
messages
4 - 24 S-100 • S-105 • S-120 • S-125 Part No. 1268494


FMI = Failure Mode Identifier 524016 2 1259 Amount of air is not plausible to
KWP = Keyword Protocol pumb speed
SPN FMI KWP Description 524016 2 1260 Calculated amount of air is not
523960 0 1458 High exhaust gas temperature plausible to HFM reading
EGR cooler downstream; 524016 11 1258 HFM sensor; electrical fault
warning threshold exceeded
524021 11 1263 Burner fuel line pipe leak behind
523960 1 1012 Physical range check low for Shut Off Valve
EGR cooler downstream temp.
524024 11 1302 Deviation of the exhaust gas
523960 1 1459 High exhaust gas temperature temp. setpoint to actual value
EGR cooler downstream; shut off downstream (DOC) too high
threshold exceeded
524028 2 1431 CAN message PROEGRActr;
523980 14 1187 Bad quality of reduction agent plausible error
detected
523981 11 918 Urea-tank without heating CAN-Receive-Frame
function (heating phase) ComEGRActr - exhaust gas
523982 0 360 Powerstage diagnosis disabled; recirculation positioner
high battery voltage 524030 7 1440 EGR actuator; internal error
523982 1 361 Powerstage diagnosis disabled; 524031 13 1441 EGR actuator; calibration error
low battery voltage
524032 2 1442 EGR actuator; status message
523988 3 1245 Charging lamp; short circuit to EGRCust is missing
battery
524033 7 1443 EGR actuator; due to overload in
523988 4 1246 Charging lamp; short circuit to Save Mode
ground
524034 3 1438 Disc separator; short circuit to
523988 5 1243 Charging lamp; open load battery
523988 12 1244 Charging lamp; open temp. 524034 4 1439 Disc separator; short circuit to
523998 4 1327 Injector cylinder bank 2 slave; ground
short circuit 524034 5 1436 Disc separator; open load
523999 12 1328 Injector powerstage output Slave 524034 12 1437 Disc separator; powerstage over
defect temperature
524014 1 1254 Air pressure glow plug flush line;
below limit
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 25


FMI = Failure Mode Identifier 524108 9 1669 Timeout Error of
KWP = Keyword Protocol CAN-Transmit-Frame
SPN FMI KWP Description ComEGRTVActr
524035 12 1341 Injector diagnostics; time out 524109 9 1679 Timeout Error of
error in the SPI communication CAN-Receive-Frame
524057 2 1505 Electric fuel pump; fuel pressure ComRxEGRTVActr
build up error 524110 9 1670 Timeout Error of
524097 9 1663 Timeout Error of CAN-Transmit-Frame
CAN-Transmit-Frame ComETVActr
DPFBrnAirPmpCtl 524111 9 1680 Timeout Error of
524098 9 1664 Timeout Error of CAN-Receive-Frame
CAN-Transmit-Frame ComRxETVActr
ComDPFBrnPT 524112 9 1671 Timeout ComlTVActr
524099 9 1665 Timeout Error of 524113 9 1681 Timeout Error of
CAN-Transmit-Frame CAN-Receive-Frame
ComDPFC1 ComRxlTVActr
CAN-Transmit-Frame CAN-Transmit-Frame A1DOC
ComDPFHisDat 524115 9 1660 Timeout Error of
524101 9 1667 Timeout Error of CAN-Transmit-Frame AT1S
CAN-Transmit-Frame 524116 9 1661 Timeout Error of
ComDPFTstMon CAN-Transmit-Frame SCR2
CAN-Receive-Frame CAN-Transmit-Frame SCR3
ComRxDPFBrnAirPmpCtl
CAN-Receive-Frame ComRxCM1
ComRxDPFBrnAirPmp
CAN-Receive-Frame ComRxCustSCR3
ComRxDPFCtl
CAN-Transmit-Frame
ComEGRMsFlw
CAN-Receive-Frame
ComRxEGRMsFlw1
CAN-Receive-Frame
ComRxEGRMsFlw2
4 - 26 S-100 • S-105 • S-120 • S-125 Part No. 1268494

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP Description
CAN-Receive-Frame
ComRxSCRHtDiag
CAN-Receive-Frame
ComRxTrbChActr
CAN-Receive-Frame
ComRxUQSens
CAN-Receive-Frame
ComSCRHtCtl
CAN-Receive-Frame
ComTxAT1IMG
CAN-Receive-Frame
ComTxTrbChActr
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 27

PERKINS 854F-34T ENGINE FAULT CODE

SPN FMI Description Refer to Engine Manual
27 3 Engine Exhaust Gas Recirculation Valve Position: Voltage Value Position Sensor- Test
Above Normal
27 4 Engine Exhaust Gas Recirculation Valve Position: Voltage Value Position Sensor- Test
Be- low Normal
29 3 Accelerator Pedal Position 2: Voltage Above Normal Analog Throttle Position Sensor Circuit
Test
Test
51 3 Engine Throttle Valve 1 Position: Voltage Above Normal Value Position Sensor- Test
51 4 Engine Throttle Valve 1 Position: Voltage Below Normal Value Position Sensor- Test
Test
91 4 Accelerator Pedal Position 1: Voltage Below Normal Analog Throttle Position Sensor Circuit
Test
97 4 Water In Fuel Indicator: High - least severe Fuel Contains Water
100 2 Engine Oil Pressure: Erratic, Intermittent, or Incorrect Switch Circuits - Test
100 17 Engine Oil Pressure: Low - least severe (1) Oil Pressure Is Low
102 3 Engine Intake Manifold #1 Pressure: Voltage Above Normal Engine Pressure Sensor Open or Short
Circuit - Test
102 4 Engine Intake Manifold #1 Pressure: Voltage Below Normal Engine Pressure Sensor Open or Short
Circuit - Test
102 20 Engine Intake Manifold #1 Pressure: Data Drifted High Engine Pressure Sensor Open or Short
Circuit - Test
102 21 Engine Intake Manifold #1 Pressure: Data Drifted Low Engine Pressure Sensor Open or Short
Circuit - Test
105 3 Engine Intake Manifold #1 Temperature: Voltage Above Engine Temperature Sensor Open or
Normal Short Circuit - Test
105 4 Engine Intake Manifold #1 Temperature: Voltage Below Engine Temperature Sensor Open or
107 2 Engine Air Filter 1 Differential Pressure: Switch Circuits - Test
Erratic, Intermittent, or Incorrect
107 15 Engine Air Filter 1 Differential Pressure: High - least severe Inlet Air Is Restricted
(1)
107 16 Engine Air Filter 1 Differential Pressure: High - moderate Inlet Air Is Restricted
severity (2)
4 - 28 S-100 • S-105 • S-120 • S-125 Part No. 1268494


108 3 Barometric Pressure: Voltage Above Normal Engine Pressure Sensor Open or
Short Circuit - Test
108 4 Barometric Pressure: Voltage Below Normal Engine Pressure Sensor Open or
110 3 Engine Coolant Temperature: Voltage Above Normal Engine Temperature Sensor Open or
110 4 Engine Coolant Temperature: Voltage Below Normal Engine Temperature Sensor Open or
110 15 Engine Coolant Temperature: High - least severe (1) Coolant Temperature Is High
110 16 Engine Coolant Temperature: High - moderate severity (2) Coolant Temperature Is High
152 2 Number Of ECU Resets: Erratic, Intermittent, or Incorrect ECM Memory - Test
157 0 Engine Injector Metering Rail#1 Pressure: High - most severe Fuel Rail Pressure Problem
(3)
157 2 Engine Injector Metering Rail#1 Pressure: Erratic, Intermittent, Fuel Rail Pressure Problem
or Incorrect
157 3 Engine Injector Metering Rail#1 Pressure: Voltage Above Engine Temperature Sensor Open or
157 4 Engine Injector Metering Rail#1 Pressure: Voltage Below Engine Temperature Sensor Open or
157 10 Engine Injector Metering Rail#1 Pressure: Abnormal Rate of Engine Temperature Sensor Open or
Change Short Circuit - Test
157 16 Engine Injector Metering Rail#1 Pressure: High - moderate Fuel Rail Pressure Problem
severity (2)
157 17 Engine Injector Metering Rail#1 Pressure: Low - least severe (1) Fuel Rail Pressure Problem
157 18 Engine Injector Metering Rail#1 Pressure: Low - moderate Fuel Rail Pressure Problem
severity (2)
168 3 Battery Potential/ Power Input 1: Voltage Above Normal Ignition Keyswitch Circuit and Battery
Supply Circuit - Test
166 2 Engine Rated Power: Erratic, Intermittent, or Incorrect ECM Memory - Test
166 14 Engine Rated Power: Special Instruction ECM Memory - Test
168 4 Battery Potential/ Power Input 1: Voltage Below Normal Ignition Keyswitch Circuit and Battery
Supply Circuit - Test
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 29


172 3 Engine Air Inlet Temperature Sensor: Voltage Above Engine Temperature Sensor Open or Short
Normal Circuit - Test
172 3 Engine Air Inlet Temperature Sensor: Voltage Below Engine Temperature Sensor Open or Short
173 3 Engine Exhaust Gas Temperature: Voltage Above Engine Temperature Sensor Open or Short
173 4 Engine Exhaust Gas Temperature: Voltage Below Engine Temperature Sensor Open or Short
174 3 Engine Fuel Temperature 1: Voltage Above Normal Engine Temperature Sensor Open or Short
Circuit - Test
174 4 Engine Fuel Temperature 1: Voltage Below Normal Engine Temperature Sensor Open or Short
Circuit - Test
190 8 Engine Speed: Abnormal Frequency, Pulse Width, or Engine Speed/Timing Sensor Circuit - Test
Period
190 15 Engine Speed: High - least severe (1) Engine Over speeds
558 2 Accelerator Pedal1Low Idle Switch: Erratic, Idle Validation Switch Circuits - Test
Intermittent, or Incorrect
593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle
shutdown is about to occur. This code does
not represent a fault. If equipped, the warning
lamp will come on.
594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut
down has occurred. This code does not
represent a fault. If equipped, the warning lamp
will flash and the shutdown lamp will come on.
623 6 Red Stop Lamp: Current Above Normal Indicator Lamp Circuit- Test
624 6 Amber Warning Lamp: Current Above Normal Indicator Lamp Circuit- Test
630 2 Calibration Memory: Erratic, Intermittent, or Incorrect Injector Data Incorrect- Test
637 11 Engine Timing Sensor: Other Failure Mode Engine Speed/Timing Sensor Circuit - Test
639 9 J1939 Network #1: Abnormal Update Rate CAN Data Link Circuit - Test
639 14 J1939 Network #1: Special Instruction CAN Data Link Circuit - Test
651 5 Engine Injector Cylinder #01: Current Below Normal Injector Solenoid Circuit - Test
651 6 Engine Injector Cylinder #01: Current Above Normal Injector Solenoid Circuit - Test
651 20 Engine Injector Cylinder #01: Data Drifted High Injector Data Incorrect- Test
651 21 Engine Injector Cylinder #01: Data Drifted Low Injector Data Incorrect- Test
4 - 30 S-100 • S-105 • S-120 • S-125 Part No. 1268494


676 5 Engine Glow Plug Relay: Current Below Normal Glow Plug Starting Aid - Test
676 6 Engine Glow Plug Relay: Current Above Normal Glow Plug Starting Aid - Test
676 19 Engine Glow Plug Relay: Data Error Glow Plug Starting Aid - Test
677 3 Engine Starter Motor Relay: Voltage Above Normal Start Relay Circuit - Test
677 5 Engine Starter Motor Relay: Current Below Normal Start Relay Circuit - Test
677 6 Engine Starter Motor Relay: Current Above Normal Start Relay Circuit - Test
723 8 Engine Speed Sensor #2: Abnormal Frequency, Pulse Engine Speed/Timing Sensor Circuit - Test
Width, or Period
976 2 PTO Governor State: Erratic, Intermittent, or Incorrect PTO Switch Circuit - Test
1041 2 Start Signal Indicator: Erratic, Intermittent, or Incorrect Start Relay Circuit - Test
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 31


1076 2 Engine Fuel Injection Pump Fuel Control Value: Solenoid Value - Test
Current Below Normal
Current Above Normal
1081 5 Engine Wait to Start Lamp: Current Below Normal Indicator Lamp Circuit - Test
1081 6 Engine Wait to Start Lamp: Current Above Normal Indicator Lamp Circuit - Test
1127 16 Engine Turbocharger 1 Boost Pressure: High - moderate Intake Manifold Air Pressure Is High
severity (2)
1127 18 Engine Turbocharger 1 Boost Pressure: Low - moderate Intake Manifold Air Pressure Is Low
severity (2)
1188 5 Engine Turbocharger Wastegate Actuator 1 Solenoid Value - Test
Position: Current Below Normal
1188 6 Engine Turbocharger Wastegate Actuator 1 Solenoid Value - Test
Position: Current Above Normal
1209 3 Engine Exhaust Gas Pressure: Voltage Above Normal Engine Pressure Sensor Open or Short
Circuit - Test
1209 4 Engine Exhaust Gas Pressure: Voltage Below Normal Engine Pressure Sensor Open or Short
Circuit - Test
1221 2 Continuously Monitored Systems ECM Memory - Test
Support/Status: Erratic, Intermittent, or Incorrect
1221 14 Continuously Monitored Systems Support/Status: Another diagnostic code has requested
Special Instruction engine speed limitation. The warning lamp
will flash. The engine speed is limited to
1200rpm. Troubleshoot all other diagnostic
codes. No troubleshooting is required for
this diagnostic code.
1239 0 Engine Fuel Leakage 1: High- most severe (3) Fuel Rail Pressure Problem
1485 7 ECM Main Relay: Not Responding Properly Electrical Power Supply - Test
1485 14 ECM Main Relay: Special Instruction Electrical Power Supply - Test
4 - 32 S-100 • S-105 • S-120 • S-125 Part No. 1268494


2791 5 Engine Exhuast Gas Recirculation (EGR) Value Motorized Value - Test
Control: Current Below Normal
2791 6 Engine Exhuast Gas Recirculation (EGR) Value Motorized Value - Test
Control: Current Above Normal
2791 7 Engine Exhuast Gas Recirculation (EGR) Value Control: Motorized Value - Test
Not Responding Properly
2797 6 Engine Injector Group 1: Current Above Normal Injector Solenoid Circuit - Test
2797 7 Engine Injector Group 1: Not Responding Property Injector Solenoid Circuit - Test
2798 6 Engine Injector Group 2: Current Above Normal Injector Solenoid Circuit - Test
2840 12 ECU Instance: Failure ECM Memory - Test
2840 14 ECU Instance: Special Instruction Electrical Power Supply - Test
2880 2 Engine Operator Primary Intermediate Speed Select: Throttle Switch Circuit - Test
Voltage Above Normal
Voltage Below Normal
2970 2 Accelerator Pedal 2 Low Idle Switch: Erratic, Intermittent, Idle Validation Switch Circuit - Test
or Incorrect
3217 3 After treatment #1 Intake 02: Voltage Above Normal Oxygen Level - Test
3217 4 After treatment #1 Intake 02: Voltage Below Normal Oxygen Level - Test
3217 5 After treatment #1 Intake 02: Current Below Normal Oxygen Level - Test
3217 6 After treatment #1 Intake 02: Current Above Normal Oxygen Level - Test
3217 12 After treatment #1 Intake 02: Failure Oxygen Level - Test
3217 13 After treatment #1 Intake 02: Out of Calibration Oxygen Level - Test
3217 15 After treatment #1 Intake 02: High - least severe (1) Oxygen Level - Test
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 33


3219 15 After treatment #1 Intake Gas Sensor at Temperature: Oxygen Level - Test
High - least severe (1)
3219 17 After treatment #1 Intake Gas Sensor at Temperature: Oxygen Level - Test
Low - least severe (1)
3222 3 After treatment #1 Intake Gas Sensor Heater: Voltage Oxygen Level - Test
Above Normal
3222 4 After treatment #1 Intake Gas Sensor Heater: Voltage Oxygen Level - Test
Below Normal
3222 5 After treatment #1 Intake Gas Sensor Heater: Current Oxygen Level - Test
Below Normal
3242 3 Particulate Trap Intake Gas Temperature: Voltage Engine Temperature Sensor Open or
Above Normal Short Circuit - Test
3242 4 Particulate Trap Intake Gas Temperature: Voltage Engine Temperature Sensor Open or
Below Normal Short Circuit - Test
3251 0 Particulate Trap Differential Pressure: High- most Diesel Particulate Filter Collects
severe (3) Excessive Soot
3251 3 Particulate Trap Differential Pressure: Voltage Above Engine Pressure Sensor Open or
3251 4 Particulate Trap Differential Pressure: Voltage Below Engine Pressure Sensor Open or
3251 7 Particulate Trap Differential Pressure: Not Responding Diesel Particulate Filter Has
Properly Differential Pressure Problem
3251 10 Particulate Trap Differential Pressure: Abnormal Rate of Diesel Particulate Filter Has
Change Differential Pressure Problem
3251 16 Particulate Trap Differential Pressure: High-moderate Diesel Particulate Filter Collects
severity (2) Excessive Soot
3251 17 Particulate Trap Differential Pressure: Low - least severe Diesel Particulate Filter Has
(1) Differential Pressure Problem
3509 2 Sensor Supply Voltage 1: Erratic, Intermittent, or Incorrect 5 Volt Sensor Supply Circuit - Test
3697 6 Particulate Trap Lamp Command: Current Above Normal Indicator Lamp Circuit - Test
3698 6 Exhaust System High Temperature Lamp Command: Indicator Lamp Circuit - Test
Current Below Normal
4 - 34 S-100 • S-105 • S-120 • S-125 Part No. 1268494


3702 6 Diesel Particulate Filter Active Regeneration Inhibited Indicator Lamp Circuit - Test
Status: Current Above Normal
4765 3 After treatment #1 Diesel Oxidation Catalyst Intake Gas Engine Temperature Sensor Open or
Temperature: Voltage Above Normal Short Circuit - Test
4765 4 After treatment #1 Diesel Oxidation Catalyst Intake Gas Engine Temperature Sensor Open or
Temperature: Voltage Below Normal Short Circuit - Test
5055 17 Engine Oil Viscosity: Low - least severe (1) Oil Contains Fuel
5055 18 Engine Oil Viscosity: Low - moderate severity (2) Oil Contains Fuel
5099 6 Engine Oil Pressure Low Lamp Data: Current Above Normal Indicator Lamp Circuit - Test
5319 31 After treatment Diesel Particulate Filter Incomplete Diesel Particulate Filter Active
Regeneration Regeneration Was Interrupted
5324 7 Engine Glow Plug 1: Not Responding Properly Glow Plug Starting Aid - Test
5419 5 Engine Throttle Actuator #1: Current Below Normal Motorized Valve - Test
5419 6 Engine Throttle Actuator #1: Current Above Normal Motorized Valve - Test
5419 7 Engine Throttle Actuator #1: Not Responding Properly Motorized Valve - Test
5571 2 High Pressure Common Rail Fuel Pressure Relief Fuel Rail Pressure Problem
Valve: Erratic, Intermittent, or Incorrect
Valve: Not Responding Properly
Valve: Abnormal Rate of Change
Valve: Special Instruction
Valve: High-moderate severity (2)
5826 16 Emission Control System Operator Inducement Severity Refer to "Operator Inducement
High-moderate severity (2) Codes"
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 35

DIAGNOSTIC codes
Control System Fault Codes Using the TCON LCD
Note: Take care when using this method to avoid

How to Clear Boom Safety resetting threshold defaults.
Switch Faults 1 With the key switch off, press and hold the
Note: Beginning with software release 3.0, the button and turn the key switch to the on
boom envelope switches will latch and faults position. Release the button after five
must be reset in software or through the use seconds and press the buttons.
of the TCON LCD. They will not clear by re-
powering the machine. 2 Press the button until clear all safety
switch faults appears.
Note: There are two methods to reset the faults,
by using Web GPI or through the menu available 3 Select yes, then press the button.
on the TCON LCD.
4 Press the button until exit appears.
Using Web GPI
5 Select yes, then press the button.
1 Connect the device containing the WEB GPI
software to the TCON with an RS-232 cable. Note: This clears all latching faults, not standard
faults.
2 Select the Safety folder, then the Fault Status
screen.
3 Change any safety switch drop down menus
displaying fault to ok. Press send.
4 Exit Web GPI.
4 - 36 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Software
About This Section
This section explains various parts of the machine
software operating system and how to access
some of the adjustable parameters of the control
system.
Web GPI
Observe and Obey: The software system used on the machine is
called Web GPI. It is a software application that is
Troubleshooting and repair procedures shall be
typically used with a laptop computer. The laptop
completed by a person trained and qualified on
can be connected to the ground controls via a tee
the repair of this machine.
harness connector (Genie part number 75094).
Immediately tag and remove from service a
The Web GPI software can access all adjustable
damaged or malfunctioning machine.
parameters for the machine. It can also be used
Repair any machine damage or malfunction to aid in troubleshooting and viewing fault code
before operating the machine. history.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the Genie S-100 &
Genie S-105 Operator’s Manual and the
Genie S-120 & Genie S-125 Operator’s Manual.
Be sure that all necessary tools and parts are
available and ready for use.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 4 - 37

4 - 38 S-100 • S-105 • S-120 • S-125 Part No. 1268494

January 2019 Section 5 • 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/burn hazard. Contact

Troubleshooting and repair procedures shall be could result in death or serious
completed by a person trained and qualified on injury. Remove all rings, watches
the repair of this machine. and other jewelry.
Hydraulic Schematics
Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules and or spray.
operating instructions printed in the
Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-1

Section 5 • Schematics January 2019
Wire Circuit Legend
Circuit numbering Circuit suffix

1 Circuit numbers consist of three parts: the Definition Suffix
circuit prefix, circuit number and circuit suffix. AC Generator GEN
The circuit prefix indicates the type of circuit. Alternator Field AF
The circuit number describes the function Angle ANG
of the circuit. The circuit suffix provides an Auxiliary Boom Valve ABV
abbreviation for the number or may be used to Auxiliary Forward Valve AFV
further define the function of this portion of the Auxiliary Hydraulic Pump AH
circuit. It also may be used to indicate the final Auxiliary Platform Valve APV
end of the circuit, i.e., LS or limit sw. Auxiliary Reverse Valve ARV
Auxiliary Steer/Drive Valve ASV
2 The circuit number may be used more than once
Axle Extend Valve AXE
in a circuit.
Axle Oscillate AXO
Axle Retract Valve AXR
For Example: Axle Front Position FAP
C 74 PL – This is the circuit for the lockout
Axle Rear Position RAP
valve #1. C stands for control, 74 is the number of the circuit for Battery BAT
the primary #1 lock out valve. Boom Extended BEX
PL stands for Primary Lockout. Boom Stowed BST
S 62 BST – This is the circuit that communicates to the onboard Brake BRK
computers of the machine that the boom is fully stowed. S Bypass Valves BV
stands for safety, 62 is the number of the circuit for boom Calibrate CAL
stowed and BST stands for Boom Stowed.
CAN Signal CAN
P 48 LP – P stands for power. 48 is the circuit number for work CAN Shield SHD
lamps and LP stands for Lamp. CATS Module CAT
R 48 LP – R stands for relay. In this case it is the wire that feeds Chain Break CNK
the relay coil for the work lamp. All other numbers remain the Data High DTH
same. Data Low DTL
Drive Chassis Controller DCN
Circuit prefix Drive Enable DE
C........Control Drive Enable Left DEL
Drive Enable Right DER
D........Data
Electrical Displacement Control EDC
E........Engine Envelope Light ENV
G........Gauges Engine Speed Select ESP
N........Neutral Engine Status Lamp ESL
Envelope Lockout ENL
P........Power
Extend/retract Lockout ERL
R........Relay Output Filter Restricted FLR
S........Safety Filter Switch FLT
V........Valve
Flashing Beacon FB
Float Switch FS
Footswitch Signal FTS
Forward FWD
Fuel Pump FP
Fuel Select (gas/LP) FL
Fuel Solenoid FSL
5 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Wire Circuit Legend
Definition Suffix Definition Suffix

Function Enable FE Pressure Comp Enable PCE
Ground Control TCN Pressure Sender PSR
Ground GND Pressure Switches PS
Horn HRN Primary Boom Angle Sensor PBS
High RPM HS Primary Boom Down PBD
Hydraulic Generator HG Primary Boom Ext/Ret Lockout Valve PBL
Ignition IGN Primary Boom Extend PBE
Jib Bellcrank Down JBD Primary Boom Extend/Retract Flow Control PER
Jib Bellcrank Up JBU Primary Boom Retract PBR
Jib Sensor JBS Primary Boom Angle Sensor PBS
Jib U/D Control JUD Primary Boom Down PBD
Jib Down JD Primary Boom Ext/Ret Lockout Valve PBL
Jib Up/Down Flow Control JFC Primary Boom Extend PBE
Jib Select Valve JSV Primary Boom Extend/Retract Flow Control PER
Jib Up JU Primary Boom Retract PBR
Jib E/R Control JER Primary Boom Up PBU
Jib Ext JBE Primary Boom Up/Dwn Flow Control PUD
Jib Ret JBR Primary Boom Extend/Retract Signal PLS
Jib Rotate Left (CCW) JRL Primary Boom Up/Down Signal PES
Jib Rotate Right (CW) JRR Primary Lockout PL
Joystick 5 VDC Power JPW Primary Length Sensor PSL
Lamps LPS Propel Signal JPL
Left Front LF Program Setup Enable PSE
Left Front Steer Sensor LFS Propel Lockout PLL
Left Rear LR Proportional Valve PRV
Left Rear Steer Sensor LRS Proximity Sensor PXS
Limit Switch LS Receptacle REC
Lift Speed Reduction LSR Recovery RCV
Load Sensor LDS Retract Lockout RL
Lockout LO Return RET
Low RPM LS Reverse REV
Low fuel LOF Right Front RF
Motor Shift (Speed) MS Right Front Steer Sensor RFS
Multi Function Valve MFV Right Rear RR
Platform Control PCN Right Rear Steer Sensor RRS
Primary Ext/Ret Lockout PEL RPM RPM
Platform Level Down PLD Secondary Boom Angle Sensor SBS
Platform Level Flow Control PLF Secondary Boom Elevated SBL
Platform Level Up PLU Sec Boom Down SBD
Platform Rotate Flow Control PRF Sec Boom Extend SBE
Platform Rotate Control PRC Sec Boom Extend/Retract Flow Control SER
Platform Rotate Left (CCW) PRL Sec Boom Retract SBR
Platform Rotate Right (CW) PRR Sec Boom Up SBU
Power PWR Sec Boom Up/Dwn Flow Control SUD
Power to Length Sensor PSL Secondary Boom SB
Platform Tilt Alarm PTA This list continues on the next page.
Platform Tilt Sensor PTS
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-3

Wire Circuit Legend
Definition Suffix Wire Coloring

Secondary Boom Lockout Valve (Extend) SLE
Secondary Boom Lockout Valve (Riser Down) SLD 1 All cylinder extension colors are solid and all
Sensor SEN retract functions are striped black. When using
Spare SP black wire, the stripe shall be white.
Speed Sensor SS
2 All rotations that are LEFT or CW are solid,
Start Aid (Glow Plug or choke) SA
RIGHT or CCW are striped and black. When the
Starter STR
wire is black, the stripe is white.
Steer Control Signal STC
Steering Valve Clockwise SCW 3 All proportional valve wiring is striped.
Steering Valve Counter Clockwise SCC
Temp Sender TSR
Temp Switches TS Wire Color Legend
Tether TET
BL Blue
Tilt Alarm X axis TAX
BL/BK Blue/Black
Tilt Alarm Y axis TAY
BL/RD Blue/Red
Turntable or Ground Control Panel TCN
BL/WH Blue/White
Turntable Rotate Flow Control TRF
BK Black
Turntable Rotate Right (CW) TRR
BK/RD Black/Red
Turntable Rotate Signal TRS
BK/WH Black/White
Turntable Tilt Alarm TTA
BR Brown
Turntable Tilt Sensor TTS
GN Green
Test Switch TSW
GN/BK Green/Black
GN/WH Green/White
RD Red
RD/BK Red/Black
RD/WH Red/White
OR Orange
OR/BL Orange/Blue
OR/BK Orange/Black
OR/RD Orange/Red
WH White
WH/BK White/Black
WH/RD White/Red
YL Yellow
5 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Wire Circuit Legend
Color, Circuit #, and Primary function Color, Circuit #, and Primary function
RD 1 Primary boom up drive WH/BK 31 Reverse/EDC-B
RD/BK 2 Primary boom down drive WH/RD 32 Brake
RD/WH 3 Primary boom up/dwn FC BK 33 Start
proportional valve drive BK/WH 34 Start aid (glow plug or choke)
WH 4 Turntable rotate left valve drive BK/RD 35 High engine speed select
WH/BK 5 Turntable rotate right valve drive BL 36 Steer clockwise
WH/RD 6 Turntable rotate FC proportional BL/BK 37 Steer counterclockwise
valve drive BL/WH 38 Gas
BK 7 Primary boom extend BL/RD 39 LP
BK/WH 8 Primary boom retract OR 40 Limit switch signal stowed
BK/RD 9 Primary boom Extend/Retract OR/BK 41 RPM signal
proportional valve drive OR/RD 42 Boom retracted signal
BL 10 Secondary boom up valve drive GN 43 Jib up
BL/BK 11 Secondary boom down valve drive GN/BK 44 Jib down
BL/WH 12 Secondary boom up/dwn FC GN/WH 45 AC Generator
proportional valve drive WH 46 Drive horn
BL/RD 13 Drive enable WH/BK 47 Output power enable
OR 14 Platform level up valve WH/RD 48 Work lamp
OR/BK 15 Platform level down valve WH/BK 49 Motion lamp
OR/RD 16 Platform up/dwn FC proportional BL 50 Auxiliary boom
valve drive BL/WH 51 Auxiliary steer
GN 17 Platform rotate left valve driver BL/RD 52 Auxiliary platform
GN/BK 18 Platform rotate right valve driver WH/BK 53 Boom envelope safety valve cutoff
GN/WH 19 Jib select valve driver circuit BK/WH 54 Power to safety interlock switches
RD 20 12V battery supply (engine)
WH 21 12V ignition supply GN/BK 55 Axle oscillation
BK 22 Keyswitch power to platform RD 56 Foot switch/TCON estop power
ESTOP RD/WH 57 Boom down safety interlock
WH 23 Power to platform RD/BK 58 Safety interlock to engine
RD 24 Power to warning senders GN/WH 59 Chain break circuit
WH/BK 25 Power to oil pressure sender GN/WH 60 Axle extend
WH/RD 26 Power to temp sender GN 61 Axle retract
RD 27 Auxiliary power OR 62 Boom stowed (safety)
RD/BK 28 Platform level alarm OR/RD 63 Power to boom envelope safety
RD/WH 29 Drive motor shift (speed) switch
WH 30 Forward/EDC-A This list continues on the next page.
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-5

Wire Circuit Legend
OR/BK 64 Power for operational switches BK 99 J1708 - (low)
BL/WH 65 Low fuel indication WH/RD 100 Outrigger lowered
BL 66 Drive enable WH/BK 101 Outrigger raised
BL 67 Secondary boom not stowed OR 102 Pothole protector up
RD 68 Primary boom lowered OR/RD 103 Pothole protector down
(operational) BK/WH 104 Proprietary data buss –
BL 69 Primary boom #1 extended (i.e. ITT or AP)
BL/WH 70 Primary boom #2 retracted BK/RD 105 Proprietary data buss +
BL/BK 71 Primary boom #2 extended (i.e. ITT or AP)
GN 72 Secondary boom extend GN 106 Spare
GN/BK 73 Secondary boom retract RD 107 Alternator field
RD 74 Primary #1 Lockout BL/WH 108 Engine status
RD/WH 75 Primary #2 Lockout GN/WH 109 Sensor pwr
BL 76 Pri boom #3 extended BK 110 Sensor return
WH 77 Lower angle #1 operational OR 111 Steer signal
WH/BK 78 Upper angle #2 operational RD 112 Steer signal to solenoid valve
BK 79 power from TCON ESTOP OR/RD 113 Multi function valve
N/A 80 Can 2.0/J1939 Shield BK/RD 114 Load moment overweight
GN 81 Can 2.0/J1939 Low RD/BK 115 Load moment underweight
YL 82 Can 2.0/J1939 High OR 116 Hydraulic oil cooler
GN/WH 83 Tilt signal x axis RD 117 Flashing beacon
GN/BK 84 Tilt signal y axis OR 118 Lift speed reduction
GN 85 Tilt sensor power BL 119 Hydraulic pressure sensor output
OR 86 Hydraulic filter restricted OR 120 Oil cooler fan
RD 87 Platform level safety power GR 121 Axle oscillate LEFT
RD/BK 88 Platform level safety output GN/BK 122 Axle oscillate RIGHT
BR 89 Platform level safety ground RD/BK 123 Primary boom angle signal
RD/BK 90 Proximity kill operational
RD/WH 91 Gate Interlock RD/WH 124 Secondary boom angle signal
WH/BK 92 Motor speed (LO/HI) operational
WH/RD 93 Motor bypass WH/RD 125 Secondary boomlockout
WH 94 Load sensor (Ext Enable)
OR 95 Tether ESTOP return WH/BK 126 Secondary boom lockout
RD 96 Tether power (Riser Down Enable)
BK 97 Tether ESTOP power GN 127 ECU test switch
WH 98 J1708 + (high) OR/RD 128 Low engine speed
5 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Wire Circuit Legend
RD/BK 129 Descent alarm BL/WH 163 Pri extend/retract signal
WH/RD 130 Travel alarm RD/WH 164 Pri up/down signal
BL 131 Motion alarm WH/RD 165 TT Rotate signal
GN 132 Platform load input OR 166 Boom length signal safety
GN/WH 133 Platform load alarm OR/BK 167 Boom length signal operational
GN/BK 134 Key switch power BL/RD 168 Primary boom hydraulic valve
BL/WH 135 Fuel pump lockout
RD 136 Power to safety module GN 169 Envelope active LED
RD/WH 137 Propel power (P_38) WH/RD 170 Load sense relay source
RD/BK 138 Pri boom up/sec boom dwn-Ext WH/BK 171 Load sense relay sink
(P_11/30) BL 172 UP/DN flow control ground
WH/RD 139 Turntable rot FC safety (P_39) BK 173 Ext/Ret flow control ground
OR/RD 140 Boom envelope safety WH 174 Key switch power, ground position
RD 141 Primary boom angle signal safety WH/BK 175 Load sensor signal operational
OR 142 Secondary boom angle signal GN/WH 176 Secondary extend/retract FC
safety BL/RD 177 Extend/retract lockout
BL/RD 143 Drive enable left BK 178 Control module status light
BL/WH 144 Drive enable right GN 179 Drive power relay
RD/WH 145 Calibrate BK 180 Lift power relay
BL 146 Jib bellcrank up FC OR 181 48 Volt alternator field (or battery)
BL/BK 147 Jib bellcrank down FC RD 182 24 Volt battery
BL/WH 148 Jib bellcrank sensor BL 183 Envelope or load sense recovery
GN/WH 149 Jib Up/Down FC WH 184 Program setup enable
GN/BK 150 Hydraulic generator bypass WH 185 Encode A
GN 151 Hydraulic EDCoutput BL 186 Encode B
BK 152 Injector retard BL 187 Bootstrap or program enable
BK 153 Jib extend GN 188 Safety cross check
BK/WH 154 Jib retract BK 189 Data receive
OR/RD 155 Pressure comp enable BK/WH 190 Data transmit
GN/WH 156 Jib Up/Down WH/RD 191 Multi-Function pressure relief
BK/RD 157 Jib Ext/Ret WH/BK 192 Jib rotate left
BL/RD 158 Spare WH/RD 193 Jib rotate right
BL/WH 159 Steer joystick signal WH/RD 194 Speed select input
WH/RD 160 Propel joystick signal OR/RD 195 Electric brake source
WH/BK 161 Sec boom joystick signal YL 196 2.5V Sensor power
OR 162 Joystick 5 VDC power BR N/A Ground or return
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-7

Limit Switches
Types of Limit Switches Limit Switch Numbering

There are two types of limit switches, which are LSAX1RO Front axle retract proximity
found in various locations throughout the machine: LSAX2RO Rear axle retract proximity
mechanical-type operational or safety switches LSAX1EO Front axle extend proximity
and magnetic proximity switches. As in aircraft, LSAX2EO Rear axle extend proximity
which features redundant safety systems, each LSAX1ES Front axle extend safety
mechanical safety switch is backed up with an LSAX2ES Rear axle extend safety
independently functioning proximity switch. LSB6S Cable tension safety
LSB7DS Boom 11° angle safety
The mechanical-type operational or safety LSB3RS Boom 3 foot (0.9 m) extend safety
switches are used to sense a positive displacement LSB2RS •• Boom 101 feet (30.8 m) extend
or movement of the limit switch actuator, or safety
arm, as the machine moves through its range of LSB9AS •• Boom 65° angle safety
operational functions. Included in this group are LSB8AS Boom 50° angle safety
envelope limit switches, which sense the extended LSB4ES Boom 76 feet (23.2 m) extend
length and angle of the boom, position of the axles safety
and rotational position of the turntable. LST1O Drive enable mechanical
For example, when the 53° operational switch is LSB1DO Boom 10° mechanical
activated by achieving a 53° boom angle, the boom LSB2RO •• Boom >100 feet (30.5 m)
may then be extended beyond 75 feet (22.9 m). retract proximity
Another example is the drive enable limit switch, (changed to mechanical-
which disables the drive function anytime the boom S-100/105- sn 160
is rotated past the rear axles, indicated by the S-120/125- sn 628)
'square' end of the drive chassis. LSB3RO Boom >3 feet (0.9 m) stowed
In some cases, the engine will be stopped if safety mechanical
parameters are exceeded. LSB3EO Boom 75 feet (22.9 m)
Magnetic proximity switches are used to sense extend proximity
very specific positions of a part of the machine in (changed to mechanical-
relation to the remainder of the machine. Proximity S-100/105- sn 160
switches must be correctly aligned for the machine S-120/125- sn 628)
functions to operate. Proximity switches are found LSB4EO •• Boom 100 feet (30.5 m)
at the front and rear axle, the turntable and several extend proximity
locations on the boom. (changed to mechanical-
S-100/105- sn 160
S-120/125- sn 628)
Numbering Legend LSB13AO Boom 53° angle proximity
Circuit number LSB14AO •• Boom 68° angle proximity
D Down
LSB19LO Load moment mechanical
AX Axle A Angle
B Boom L Load moment
T Turntable E Extend
LS Limit switch R Retract O Operational (•• S-120 and S-125 models only)
S Safety
LS AX 1 R O
5 - 8 S-100 • S-105 • S-120 • S-125 Part No. 1268494
limit switches
120 ft / 36.6 m

68 65
100 ft / 30.5 m
LSB2RO
102 ft
90 ft / 27.4 m (31.1 m)
LSB4EO LSB2RS
100 ft 101 ft
(30.5 m) (30.8 m)
80 ft / 24.4 m
LSB8AS LSB13AO LSB13AO LSB8AS

50 53 70 ft / 21.3 m 53 50
LSB4ES LSB3EO 60 ft / 18.3 m LSB3EO LSB4ES

75.5 ft 75 ft 75 ft 75.5 ft
(23 m) (22.9 m) (22.9 m) (23 m)
50 ft / 15.2 m
40 ft / 12.2 m
30 ft / 9.1 m
LSB7DS LSB7DS
11 LSB1DO 20 ft / 6.1 m LSB1DO 11
10 10
10 ft / 3 m
LSB3RS LSB3RO LSB3RO LSB3RS

3.5 ft (1.1 m) 3 ft (0.9 m) 3 ft (0.9 m) 3.5 ft (1.1 m)
0 ft / 0 m
S-100 & S-105 Models S-120 & S-125 Models

(S-100 shown) (S-120 shown)
LSAX1RO LSAX2RO
LSAX1EO LST10 LSAX2ES LSAX2EO
LSAX1ES
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-9

Relay Layout
a b c d e
a Fuel solenoid relay (Deutz F4L913 models only).

b Oil cooler relay.
c Engine cold start relay.
d Starter relay.
e Horn relay.
f Flashing beacon relay.
g CR17 relay (K7) - powers C35RPM circuit
(Hi/low solenoid).
h CR16 relay (K8) - powers C34SA circuit
(Engine cold start).
i CR12 relay (K4) - powers primary valves 1 and g
2, ignition, glow plug, starter relay, generator, and
the boom retract, multifunction and platform rotate
valve coils. h
j CR14 relay (K2) - powers P7R or S56PRV circuit
including the auxiliary valve, boom extend/retract
and turntable rotate valve coils. i
k CR10 relay (K6) - powers C21IGN and C107AF
circuits (Fuel on/off solenoid and alternator field).
l CR15 relay (K1) - powers P22R or C03PBF circuit j
(Boom up/down valve coil).
m CR13 relay (K5) - powers P_7 and throttle relay.
k
n CR11 relay (K3) - powers P-6R2 or P54ENG circuits.
n m
5 - 10 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Drive Chassis Controller Pin Legend
DCON
DRIVE CHASSIS DCON
DRIVE CHASSIS
CONTROLLER
CONTROLLER
J2
1 = VLVRET - BR J1
2 = V61AXRT - GR 1 = GND-DCON - BR
3 = V60AXEX - GN/WH 2 = P21DCON - WH
4 = V29MS - RD/WH 3 = P53LS - GR
5 = (UNUSED) 4 = (UNUSED)
6 = (UNUSED) 5 = S56PRV - RD
7 = (UNUSED) 6 = C61AXRT - GR
8 = V36RRS - BL 7 = (UNUSED)
9 = V37RRS - BL/BK 8 = P61LS - GR
10 = C111RRS - OR 9 = C61LS - GR J1
11 = C111LRS - OR 10 = (UNUSED) BLACK
12 = C111RFS - OR 11 = (UNUSED) 23 PIN
13 = C111LFS - OR 12 = (UNUSED) CONNECTOR
14 = VLVRET2 - BR 13 = (UNUSED)
15 = V32BRK - WH/RD 14 = (UNUSED)
J2
16 = V36LRS - BL 15 = C61LS(A) - GR
1 8 WHITE
17 = V37LRS - BL/BK 16 = (UNUSED) 23 PIN
18 = V36RFS - BL 17 = D81CAN(-) - GR CONNECTOR
19 = P110RT - BK 18 = D82CAN(+) - YL 16 23
20 = P109ANG - GN/ 19 = (UNUSED)
WH 20 = (UNUSED)
21 = V37RFS - BL/BK 21 = (UNUSED)
22 = V36LFS - BL 22 = (UNUSED) PIN NUMBERING FOR
23 = P61LS(A) - GN 23 PIN
23 = V37LFS - BL/BK
CONNECTORS
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 11

Platform Controller Pin Legend
J1
BLACK
23 PIN
PCON PCON CONNECTOR
PLATFORM PLATFORM
CONTROLLER CONTROLLER
J2 J1 J2
1 = VLVRET - BR 1 = GNDPCON - BR WHITE
2 = (UNUSED) 2 = P52PCON - BL/RD 23 PIN
3 = C17PRL - GR 3 = (UNUSED) CONNECTOR
4 = C18PRR - GR/BK 4 = S56PRV - RD/WH
5 = C43JU - GR 5 = (UNUSED)
6 = C44JD - GR/BK 6 = (UNUSED)
7 = C14PLU - OR 7 = P56PRV - RD
8 = C15PLD - OR/BK 8 = (UNUSED)
9 = (UNUSED) 9 = (UNUSED)
10 = R90PXS - RD/BK 10 = (UNUSED)
11 = C90PXS - RD/BK 11 = (UNUSED)
12 = RET94LDS - GR 12 = (UNUSED)
13 = C94LDS - WH 13 = (UNUSED)
14 = R94LDS - BK 14 = (UNUSED)
15 = C88PTS - RD/BK 15 = C47OUT - WH/BK
16 = R56PTS - RD 16 = C46HN - WH 1 8
17 = C56PTS - RD 17 = D81CAN(+) - YL
18 = (UNUSED) 18 = D82CAN(-) - GR
19 = PLATRET - BR 19 = (UNUSED) 16 23
20 = C84TAY - GR/BK 20 = (UNUSED)
21 = P85PTS - GR 21 = (UNUSED)
22 = PTSRET - BR 22 = (UNUSED)
23 = P87PTS - RD 23 = P23PCON - BK PIN NUMBERING FOR
23 PIN
CONNECTORS
5 - 12 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Turntable Controller Pin Legend
24
1
J4
1 8 WHITE
EMERGENCY STOP
35 PIN RAISE BOOM
CONNECTOR RETRACT BOOM

MACHINE
12
35
16 23 NOT LEVEL
PLATFORM
NOT LEVEL
EXTEND AXLE
J3
16
1
61227 A
WHITE
PIN NUMBERING FOR
23 PIN
23 PIN
CONNECTOR
23
8
CONNECTORS
AUXILIARY POWER
J5
WIRE LOOM HIGH SPEED
FUNCTION ENABLE
24
1
LOW SPEED
FUNCTION ENABLE
1 12 J2
BLACK
35 PIN
24 35 CONNECTOR
ALARM
12
35
16
J1
1
PIN NUMBERING FOR RUN
35 PIN BLACK SERVICE

BYPASS
CONNECTORS 23 PIN RECOVERY
CONNECTOR
23
TCON TCON TCON TCON

TURNTABLE TURNTABLE TURNTABLE TURNTABLE
CONTROLLER CONTROLLER CONTROLLER CONTROLLER
J2 J2 J3 J4
(S-120 & S-125 MODELS) (S-100 & S-105 MODELS) 1 = (UNUSED) 1 = VLVRET4 - BR
1 = GNDDCON - BR 1 = GNDDCON - BR 2 = R35RPM - BK/RD 2 = C03PBF - RD/WH
2 = P21DCON - RD 2 = P21DCON - RD 3 = C21IGN - WH 3 = C09PERF - BK/RD
3 = P53LS - WH/BK 3 = P53LS - WH/BK 4 = C34SA - BK/WH 4 = C06TRF - WH/RD
4 = P54ENG - BK/WH 4 = P54ENG - BK/WH 5 = V30FWD - WH 5 = (UNUSED)
5 = P56PRV - RD 5 = P56PRV - RD 6 = V31REV - WH/BK 6 = (UNUSED)
6 = P57PBD - RD/WH 6 = P57PBD - RD/WH 7 = C46HRN - WH 7 = C01PBU - RD
7 = P58LS - RD/BK 7 = P58LS - RD/BK 8 = (UNUSED) 8 = C02PBD - RD/BK
8 = S59CNBK - GR/WH 8 = S59CNBK - GR/WH 9 = C33STR - BK 9 = C07PBE - BK
TCON 9 = C60AXEX - GR/WH 9 = C60AXEX - GR/WH 10 = C30EDC - WH 10 = C08PBR - BK/WH
TURNTABLE 11 = C31EDC - WH/BK 11 = (UNUSED)
10 = C61AXRT - GR 10 = C61AXRT - GR
CONTROLLER 11 = S62BSTO - OR 11 = S62BSTO - OR 12 = C25PSR - WH/BK 12 = (UNUSED)
13 = C26TSR - WH/RD 13 = R49LP - WH/BK
J1 12 = P63LS - OR/RD
13 = C64LS - OR/BL
12 = P63LS - OR/RD
13 = C64LS - OR/BL 14 = RET85TTSR - BR 14 = VLVRET5 - BR
1 = GNDPCON - BR
14 = C65LOFL - BL/WH 14 = C65LOFL - BL/WH 15 = P85TTSR - GN 15 = S2PLD2 - GN/BK
2 = P52PCON - WH
15 = C66DREN - BL 15 = C66DREN - BL 16 = VLVRET2 - BR 16 = S7PLE2 - GR/WH
3 = C46HN - WH
16 = (UNUSED) 16 = (UNUSED) 17 = (UNUSED) 17 = S7PLE1 - BL/BK
4 = C47OUT - WH/BK
17 = C68PBD - RD 17 = C68PBD - RD 18 = C41RPM - OR/BK 18 = S2PLD1 - BL.RD
5 = P23PCON - BK
18 = C89PBE - BK 18 = (UNUSED) 19 = C107AF - RD 19 = (UNUSED)
6 = S56PRV - RD/WH
19 = C70PBE - BL/WH 19 = C70PBE - BL/WH 20 = C83TAX - GR/WH 20 = (UNUSED)
7 = P56PRV - RD
20 = C71PBE - BL/BK 20 = C71PBE - BL/BK 21 = C84TAY - GR/BK 21 = (UNUSED)
8 = R48LP - WH/RD
21 = (UNUSED) 21 = (UNUSED) 22 = C45GEN - GR/WH 22 = (UNUSED)
9 = R117FB - RD
22 = (UNUSED) 22 = (UNUSED) 23 = VLVRET3 - BR 23 = C113MFV - OR/RD
10 = (UNUSED)
23 = V74PRLO - RD 23 = V74PRLO - RD 24 = (UNUSED)
11 = (UNUSED)
24 = V75PRLO - RD/WH 24 = V75PRLO - RD/WH 25 = C0RTRL - WH
12 = (UNUSED)
25 = SNSR GND - BR 25 = SNSR GND - BR 26 = C05TRR - WH/BK
13 = (UNUSED)
26 = (UNUSED) 26 = (UNUSED) 27 = VLVRET7 - BR
14 = (UNUSED)
28 = (UNUSED)
15 = P97TET - BK 27 = G119SR - BL
28 = C76PBE - BL
27 = G119SR - BL
28 = (UNUSED)
TCON 29 = (UNUSED)
16 = (UNUSED) TURNTABLE
29 = C77AS - WH 29 = C77AS - WH 30 = VLVRET6 - BR
17 = D81CAN(-) - GR
30 = C78PS - WH/BK 30 = (UNUSED) CONTROLLER 31 = (UNUSED)
18 = D82CAN(+) - YL
32 = C27AUX - RD
19 = (UNUSED) 31 = (UNUSED) 31 = (UNUSED) J5 33 = (UNUSED)
20 = (UNUSED) 32 = (UNUSED) 32 = (UNUSED) 1 = BATVLV - RD
33 = (UNUSED) 33 = (UNUSED) 2 = BATGND - BR 34 = (UNUSED)
21 = (UNUSED)
34 = (UNUSED) 34 = (UNUSED) 3 = BATGND - BR 35 = (UNUSED)
22 = (UNUSED)
23 = P95TET - OR 35 = VLVRET1 - BR 35 = VLVRET1 - BR 4 = BATECU - RD
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 13

Engine Relay and Fuse Panel Legend - Deutz TD2011 and

Perkins 1104D Models
Deutz TD2011L04i and Perkins 1104D-44T Models
7 8 11
F20 F23
1
CR77A CR28 CR17 9 10

12
F22 F7
13
4 5 6 15 16
CR77B CR41 CR5 CR1 CR15
14
Number Component Description

1 CR77A PCE#1
2 CR28 Engine / Fule Relay
3 CR17 Hydraulic Oil Cooler Fan Relay
4 CR77B PCE#2
5 CR41 Flashing Beacon Relay
6 CR5 Horn Relay
7 F20 Fuse, 20A, RPM Solenoid
8 F23 Fuse, 30A, Eng / Start / Fuel
9 F22 Fuse, 60A, Glow Plug
10 F7 Fuse, 20A, Hydraulic Oil Cooler / Horn
11 B3BAT Fused Power from B1
12 B1BAT Power from Battery
13 R21PIGN Ignition
14 02PGND Ground
15 CR1 Start Relay
16 CR15 Glow Plug Relay
5 - 14 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Engine Relay and Fuse Panel Legend - Deutz TD2.9 Models
Deutz TD2.9 Models
9 10 13
F27 F23
1 2 3 4
CR39 CR77A CR2 CR17 11 12

14
F22 F7
15
5 6 7 8 30 17
86 85
CR28 CR77B CR41 CR5 CR15
87
16

1 CR39 Engine Shutdown
2 CR77A PCE # 1
3 CR2 Engine Alt. Relay
4 CR17 Hydraulic Oil Cooler / Fan Relay
5 CR28 Fuel Pump
6 CR77B PCE#2
8 CR5 Horn Relay
15 R21PIGN Ignition
16 02PGND Ground
17 CR17 Glow Plug Relay
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 15

Engine Relay and Fuse Panel Legend - Perkins 854F Models
Perkins 854F-34T Models
9 10 13
86
F27 F23
1 2 3
30
CR77A 87 CR2 CR17 11 12
14
85 F22 F7
15
2 4
4 5 7 7 8 30 18
FX1 FX2 86 85
CR77B CR41 CR5 CR81
1 3 87
16

1 CR77A PCE # 1
2 CR2 Engine Alt
3 CR17 Hydraulic Oil Cooler Fan Relay
4 CR77B PCE#2
5 FX1 Fuse, 30A, ECU Power
6 FX2 Fuse, 20A, Key Switch Power
8 CR5 Horn Relay
15 R21PIGN Ignition
16 02PGND Ground
17 CR1 Engine Starter
18 CR81 ECU Power
5 - 16 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Telematics Connector Pin Legend
Genie installed Telematics connector is wried with an Active High digital input.
Connector Pin Numbering
Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector.
Pin Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case
1 System Power 12VDC Battery Positive - constant power Supply power to device
5 Amp Max. allowed
draw
2 System Ground 0VDC Battery Negative Device Ground
3 Digital Output 1 12VDC Engine Run Hour Meter Monitor Engine Hours
12V = engine run, 0V = engine off
4 Digital Output 2 12VDC Key Switch Activation Monitor mechine utilization
12V = key switch run, 0V = key switch off
5 Digital Output 3 12VDC Foot Switch Monitor mechine utilization
12V = active, 0V = inactive
6 Digital Input 1 12VDC Remote Disable Engine Start Remotely Prevent Engine Start
7* Databus H CAN HIGH Genie Databus J1939 Engine Messages, Receive
Proprietary Genie Telematics Message
8* Databus L CAN LOW Genie Databus J1939 Engine Messages, Receive
Proprietary Genie Telematics Message
*Tier IV engine models only, J1939 engine message available.
*Genie proprietary databus support.
Wireless Certifications
Telematic device(s) should comply with specific wireless carrier certifications where applicable and
comply with the following:
North America PTCRB, FCC/IC
Europe CE, R&TTE
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 17

Electrical Symbols Legend
CB1 FS1
BLK
OPS1 BLK
15A PR1 N.C.
WHT Circuit breaker Foot switch

Quick disconnect with amperage Oil pressure switch
Power relay normally closed
terminal
P1
H1
T-circuits
connect Emergency Stop
Horn or alarm button normally
closed
Toggle switch Sending unit
FB
Connection FAN
no terminal CR4
A B C
Flashing beacon N.O.
PULL IN
HOLD
Hydraulic oil
Control relay contact cooling fan
G1
Circuits crossing normally open
no connection Fuel or RPM
solenoid
Gauge OTS2
Aux
N.O. Pump
HM Oil temperature
Diode switch Auxiliary pump
normally open Coil
Hour meter
+
CTS1 KS2
RUN
SERVICE BYPASS/
N.O. RECOVERY
KEY SWITCH
SERVICE BYPASS
1 2
A-A
RECOVERY
-
L3 Coolant temperature
3 4
A-B
switch B-B
Tilt sensor
Battery
3 4
normally open
LED 3 4
C-B
2 1
86 30
F1 1 2
C-A
87a
85 87
A B C B-A 5 4
25A 1 2
RD
BK
BL
Fuse Relay
with amperage Service bypass/
Starting aid: recovery
glow plug or key switch
flame ignitor
Steer sensor
OFF
KS1
STARTER
MAIN
PCON A-A
1
KEYSWITCH
2
D1
TCON Power relay
ALTERNATOR
Starter motor 3 4
A-B
Chassis ground EXCT
B-A
BAT BAT 1 2
+ -
AUX MAIN
B-B
STA. 3 4
LS3
REGULATOR
N.O.H.C N.C.H.O
IND.
Current limiting
Battery separator Limit switch ALTERNATOR Main key switch device
5 - 18 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Hydraulic Symbols Legend
25 psi
(1.7 bar)
Accumulator
Differential
Filter with sensing valve Directional valve
bypass valve .035" pilot operated
(0.89 mm) 2 position, 2 way
relief setting
Orifice with size
Shut off valve Solenoid operated

proportional valve Solenoid operated 3 position,
Pump
fixed displacement 4 way, directional valve
Check valve
200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
bi-directional, Priority
variable displacement flow regulator valve
Relief valve
with pressure setting
o
Hydraulic oil cooler
Solenoid operated 2 position,
3 way, directional valve
Motor
bi-directional
Directional valve 3000 psi
(mechanically activated) (206.8 bar)
3:1
Brake
Motor Pilot operated 3 position,

2-speed, 3 way, shuttle valve Counterbalance valve
bi-directional with pressure and pilot ratio
E
Pump prime mover 50% 50%
(engine or motor)
Flow divider/combiner valve
with pressure balancing orifice
and flow percentages
2 position, 2 way
solenoid valve
Double acting
cylinder
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5 - 19

5 - 20 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Safety Circuit Schematic
CB1
VR1
D23 PWR
40A
P_15 STAT TO
IN 1 OUT 1 TCON/J2/23 TURNTABLE FLOW CONTROL
D14 5A ROTATE VALVE
P_9A
CR17 30 86 CR11 30 86 CR12 30 86 IN 2 OUT 2
(K2) (K3) (K4) NFET
87a 87 85 87a 87 85 87a 87 85

PWR GND
STAT
IN 1 OUT 1
IN 2 OUT 2 TCON/J4/32 TO AUXILIARY RELAY
CR16
(K8) 87a NFET
P_6R2
P_6R1
P_9A PWR GND PWR GND
STAT 30 TCON/J3/4
STAT
P_7R P_7R IN 1 OUT 1 87 IN 1 OUT 1 TCON/J4/3
TO TURNTABLE FLOW CONTROL
IN 2 OUT 2 TCON/J4/8 TO BOOM DOWN VALVE ROTATE VALVE IN 2 OUT 2
TCON/J2/5 TCON/J2/4 TCON/J2/3 TCON/J2/6 86 85
NFET NFET
P57PBD P57PBD CHOKE PWR GND
P53LS P53LS P53LS
STAT
TO FORWARD VALVE
IN 1 OUT 1 TCON/J3/5
P54ENG CR17 IN 2 OUT 2 TCON/J3/6
(K7) 87a TO REVERSE VALVE
NFET NFET
PWR GND
30
STAT 87
TCON/J3/2 TO HI/LO SOLENOID
IN 1 OUT 1
IN 2 OUT 2
88
88
86 85
P_7R
LSB2RS
P_16
LSB9AS NFET NFET
LSB7DS 101' (30.8 m) 65 DEGREES HI/LO
DCON/J1/3 GND PWR PWR GND
BOOM DOWN STAT STAT
TO DRIVE LP RELAY TCON/J4/35 TCON/J2/23
20 K OUT 1 IN 1 IN 1 OUT 1 TO PRIMARY 1 LOCKOUT VALVE
SJ1 R3 TCON/J3/9 OUT 2 IN 2 IN 2 OUT 2
TO STARTER RELAY
LSAX1ES
AXLE EXTEND NFET NFET
SJ2
D16
GND PWR PWR GND
STAT STAT
TO ROTATE CCW VALVE TCON/J4/10 OUT 1 IN 1 IN 1 OUT 1 TCON/J2/24 TO PRIMARY 2 LOCKOUT VALVE
LSB8AS LSB4ES OUT 2 IN 2 IN 2 OUT 2
50 DEGREES 80' (24.4 m) LSAX2ES NFET NFET
AXLE EXTEND GND PWR PWR GND
STAT STAT
P_14
P_11
TO ROTATE CW VALVE TCON/J4/23
TCON/J4/25 OUT 1 IN 1 IN 1 OUT 1 TO MULTIFUNCTION VALVE
P58LS TO ROTATE CCW VALVE

TCON/J4/26 OUT 2 IN 2 IN 2 OUT 2
C60AXEX
S62BSTO
88
88
P57PBD
P57PBD
CR10
P53LS
(K6) 87a
P58LS TCON/J2/7 P_9B PWR GND
C60AXEX C60AXEX TCON/J2/9 D13
STAT 30 TCON/J3/3 TO FUEL SOLENOID
IN 1 OUT 1 87
IN 2 OUT 2
NFET 86 85
S62BSTO S62BSTO TCON/J2/11
(P_14)
P_11 PWR GND
P63LS
STAT
D17
LSB3RS IN 1 OUT 1
BOOM RETRACT TCON/J4/7
IN 2 OUT 2 TO BOOM UP VALVE
NFET
P63LS TCON/J2/12
P_10 PWR GND
(P_18)
STAT
IN 1 OUT 1
88
LSB6S IN 2 OUT 2 TCON/J4/9 TO BOOM EXTEND VAVLE

CABLE TENSION
NFET
S59CNBK TCON/J2/8
C61AXRT TCON/J2/10
MONITORED BY ECU
P53LS DCON/J1/3
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-21

Safety Circuit Schematic
5-21
5-22

S-100 (from serial number S100D-1001 to 1381)
5-24
5-23
J
TELBAT-RD J224-01 SYS_P0WER
5-24
TELGND-BR J224-02 GROUND
C211GN-WH J224-03 IGNITION STATUS
TO SHEET 6 P23PCON-BK J224-04 STOWED STATUS
TO SHEET 6 S56PRV-RD/WH J224-05 FOOTSWITCH STATUS
C226TEL-BL J224-06 REMOTE DISABLE
J224-07 CAN HIGH(+)
J224-08 CAN LOW(-)
6A
CB
J224 GRAY 8 PIN
Section 6 • Schematics
TELEMATICS HARN
MAIN (SYS)
BAT
AUXMAIN
-
+
P114BAT-RD
ENGINE BLOCK
-
+
START BAT POWER HARN
J5 BLACK 4 PIN
CB
20 A
FUSE
SYS_BAT_PWR
RELAY
BATVLV-RD P1-01
25A
STARTER
BATGND-BR P1-02 SYS_BAT_GND
70 A FUSE
BATGND-BR P1-03 AUX/START_BAT_GND
AUX/START_BAT_PWR
4
BATECU-RD P1-04
STARTER
1
30
S-100 • S-105 • S-120 • S-125

C33STR-BK
5
87a 87 85
86
BAT GND-BR
C226TEL-BL
C211GN-WH
AUX.
PUMP
PR1
TO J4-30 REMOTE CONTROL
-BAT
VLVRET6-BR J
+AUX
+BAT
C229TEL-BL/BK
WHITE 35
2
5
ENGINE HARN
85
86
J3 WHITE 23 PIN
87
30
1
TO J4-32
4
P46HRN-WH
87a
C27AUX-RD
WHITE 35 PIN
P1-01
R35RPM-BK/RD P1-02 THROTTLE
S-613
P116HYD-OR
+
MOM N.O.
BAT.
C21IGN-WH P1-03 IGNITION/FUEL
TIME DELAY
TROMBETTA
C34SA-BK/WH P1-04 START ASSIST
P1-05 FWD
BK-COM
Part No. 1268494

January 2019
REGULATOR
WH-PULL
RD-HOLD
P1-06 REV
-
C46HRN-WH P1-07 SERVICE_HORN
ALTERNATOR
BAT.
STA.
IND.
15A
EXCT.
P1-08
CB7
C41RPM-OR/BK C33STR-BK P1-09 STARTER_RELAY
C107AF-RD C31EDC(-)-WH/BK P1-10 C31EDC(-)-WH/BK
BAT GND-BR C30EDC(+)-WH P1-11 C30EDC(+)-WH
4
C25PSR-WH/BK P1-12 OIL_PRESSURE
1
R46HRN-WH
30
C26TSR-WH/RD P1-13 OIL/WATER_TEMP
VLVRET2-BR
5
RET85TTSR-BR P1-14 TT_TILT_SNSR_GND
86
87a 87 85
HORN
P85TTSR-GN P1-15 TT_TILT_SNSR_PWR
SERVICE
VLVRET2-BR P1-16 VALVE_RTN2
HORN
RELAY
P1-17
1
C41RPM-OR/BK P1-18 ALTENATOR_RPM
RD RD-HOLD
HOLD P1-19
2
C107AF-RD ALT_FIELD_WIRE
WH WH-PULL IN
PULL IN
3
C83TAX-GN/WH P1-20 TT_TILT_X_AXIS
BK BK-COM
C84TAY-GN/BK P1-21 TT_TILT_Y_AXIS
HI/LO SPEED
C45GEN-GN/WH P1-22 AC_GENERATOR
SOLENOID
P34SA-RD
P1-23 VALVE_RTN3
VLVRET2-BR
C31EDC-WH/BK
P114BAT-RD
BAT GND-BR
REV VLV B
SOLENOID
J32-ENG HARN
3
2
C45GEN-GN/WH 1
C30EDC-WH
GLOW
FWD VLV A PLUG
SOLENOID
RELAY
5
2
VLVRET2-BR C34SA-BK/WH
86
4
1
R34SA-RD
30
85 87 87a
GLOW PLUGS
15 A FUSE
HYD COOLER
P85TTSR-GN
N.O.
OTS1
C84TAY-GN/BK
COLD START RELAY

RET85TTSR-BR
C83TAX-GN/WH
ADVANCE
5
2
BAT GND-BR C116HYD-OR P31-ENG HARN

86
J31-TILT SNSR
4
P116HYD-OR
1
30
-
-
85 87 87a
+
+
BAT GND-BR R116HYD-OR

FAN
SEE GENERATOR OPTIONS PAGE
C21IGN-WH TURNTABLE TILT

FUEL
PUMP
SENSOR
C21IGN-WH
FUEL SHUTDOWN
C25PSR-WT/BK
0-20 DEGREE
OIL PRESSURE
AT 4.5 DEGREES
SENSOR ALARM SET
C26TSR-WT/RD
OIL TEMP SENDER
BAT GND-BR
C211GN-WH J224-03 IGNITION STATUS L
TO SHEET 6 P23PCON-BK J224-04 KEYSWITCH POWER
J224-07 CAN HIGH(+)
J224-08 CAN LOW(-)
6A
CB
J224 GRAY 8 PIN
TELEMATICS HARN
MAIN (SYS)
BAT
AUXMAIN
-
+
P114BAT-RD
ENGINE BLOCK
-
+
POWER HARN
START BAT
J5 BLACK 4 PIN
CB
20 A
FUSE
SYS_BAT_PWR
RELAY
BATVLV-RD P1-01
25A
STARTER

70 A FUSE

AUX/START_BAT_PWR
4
BATECU-RD P1-04
STARTER
1
30
C33STR-BK
2
5
87a 87 85
86
BAT GND-BR
C226TEL-BL
C211GN-WH
AUX.
PUMP
PR1
-BAT
VLVRET6-BR
+AUX
+BAT
C229TEL-BL/BK
WHITE 35
2
5
ENGINE HARN
85
86
J3 WHITE 23 PIN
87
30
1
TO J4-32
4
P46HRN-WH
87a
C27AUX-RD
WHITE 35 PIN
P1-01
S-613
P116HYD-OR
+
MOM N.O.
BAT.

TIME DELAY
TROMBETTA

P1-05 FWD
BK-COM
REGULATOR
WH-PULL
RD-HOLD
P1-06 REV
-

ALTERNATOR
BAT.
STA.
IND.
15A
EXCT.
P1-08
CB7

4

1
R46HRN-WH
30

VLVRET2-BR
2

86
87a 87 85
HORN

SERVICE

HORN
RELAY
P1-17
1

RD RD-HOLD
HOLD P1-19
2
WH WH-PULL IN
PULL IN
3

BK BK-COM
January 2019
HI/LO SPEED
SOLENOID
P34SA-RD
P1-23 VALVE_RTN3
Part No. 1268494
VLVRET2-BR
C31EDC-WH/BK
P114BAT-RD
BAT GND-BR
REV VLV B
SOLENOID
J32-ENG HARN
3
2
C45GEN-GN/WH 1
C30EDC-WH
GLOW
FWD VLV A PLUG
SOLENOID
RELAY
5
2
86
4
1
R34SA-RD
30
85 87 87a
GLOW PLUGS
15 A FUSE
HYD COOLER
P85TTSR-GN
N.O.
OTS1
C84TAY-GN/BK
COLD START RELAY

RET85TTSR-BR
C83TAX-GN/WH
ADVANCE
5
2

86
J31-TILT SNSR
4
P116HYD-OR
1
30
-
-
85 87 87a
+
+

FAN
S-100 • S-105 • S-120 • S-125

FUEL
PUMP
SENSOR

C21IGN-WH
FUEL SHUTDOWN
C25PSR-WT/BK
0-20 DEGREE
OIL PRESSURE
AT 4.5 DEGREES
SENSOR ALARM SET
C26TSR-WT/RD
OIL TEMP SENDER
5-25
BAT GND-BR

5-25
5-26

S-100 (from serial number S100D-1674)
5-28
5-27
5-28
J224-07 CAN HIGH(+)
J224-08 CAN LOW(-)
6A
CB
J224 GRAY 8 PIN
TELEMATICS HARN
MAIN (SYS)
BAT
Q
STL
STS
GND
AUX MAIN
-
+
P114BAT-RD
ENGINE BLOCK
-
+
POWER HARN
START BAT
J5 BLACK 4 PIN
CB
20 A
FUSE
SYS_BAT_PWR
RELAY
BATVLV-RD P1-01
25A
STARTER
70 A FUSE
AUX/START_BAT_PWR
4
BATECU-RD P1-04
STARTER
1
30
C33STR-BK
5
87a 87 85
86
BAT GND-BR
C226TEL-BL
C211GN-WH
S-100 • S-105 • S-120 • S-125

AUX.
PUMP
PR1
-BAT
VLVRET6-BR
+AUX
+BAT
C229TEL-BL/BK
WHITE 35
5
ENGINE HARN
85
86
J3 WHITE 23 PIN
87
30
1
TO J4-32
P46HRN-WH
87a
C27AUX-RD
WHITE 35 PIN
P1-01
S-613
P116HYD-OR
+
MOM N.O.
BAT.
TIME DELAY
TROMBETTA
P1-05 FWD
BK-COM
REGULATOR
WH-PULL
RD-HOLD
P1-06 REV
-
ALTERNATOR
BAT.
STA.
IND.
15A
EXCT.
P1-08
CB7
Part No. 1268494

January 2019
4
1
R46HRN-WH
30
VLVRET2-BR
5
86
87a 87 85
HORN
SERVICE
HORN
RELAY
P1-17
1
RD RD-HOLD
HOLD P1-19
2
WH WH-PULL IN
PULL IN
3
BK BK-COM
HI/LO SPEED
SOLENOID
P34SA-RD
P1-23 VALVE_RTN3
VLVRET2-BR
C31EDC-WH/BK
P114BAT-RD
BAT GND-BR
REV VLV B
SOLENOID
J32-ENG HARN
3
2
C45GEN-GN/WH 1
C30EDC-WH
GLOW
FWD VLV A PLUG
SOLENOID
RELAY
5
2
86
4
1
R34SA-RD
30
85 87 87a
GLOW PLUGS
15 A FUSE
HYD COOLER
P85TTSR-GN
N.O.
OTS1
C84TAY-GN/BK
COLD START
RET85TTSR-BR
RELAY
C83TAX-GN/WH
ADVANCE 5
2

86
J31-TILT SNSR
4
P116HYD-OR
1
30
-
-
85 87 87a
+
+

FUEL
PUMP
SENSOR
C21IGN-WH
FUEL SHUTDOWN
C25PSR-WT/BK
0-20 DEGREE
OIL PRESSURE
AT 4.5 DEGREES
SENSOR ALARM SET
C26TSR-WT/RD
OIL TEMP SENDER
BAT GND-BR

5-30
5-29

Number Com ponent Descr iption

1 Horn Relay
2 Engine Fule Relay
3 Oil Cooler
4 Start Relay
5 Glow Plug Relay
6 Speed Solenoid
7 Fuse, 30A, Eng / Start / Fuel
8 Fuse, 60A, Glow Plug
9 Fuse, 20A, Hydraulic Oil Cooler / Horn
10 B3PBAT Fused Power from B1
11 B1PBAT Power from Battery
12 R21PIGN Ignition Fuse, 20A, RPM Solenoid
13 02PGND Ground
5-30 S-100 • S-105 • S-120 • S-125 Part No. 1268494

J
J224-07 CAN HIGH(+)
J224-08 CAN LOW(-)
6A
CB
J224 GRAY 8 PIN
TELEMATICS HARN
MAIN (SYS)
BAT
AUXMAIN
-
+
P114BAT-RD
ENGINE BLOCK
-
+
POWER HARN
START BAT
J5 BLACK 4 PIN
CB
20 A
FUSE
BATVLV-RD P1-01 SYS_BAT_PWR

25A
P34SA-RD
RELAY

70 A FUSE
STARTER

AUX/START_BAT_PWR
4
BATECU-RD P1-04
STARTER
1
30
C33STR-BK
2
5
86
87a 87 85
BAT GND-BR
C226TEL-BL
C211GN-WH
AUX.
PUMP
PR1
REMOTE CONTROL
-BAT
TO J4-30 VLVRET6-BR
+BAT
+AUX
C229TEL-BL/BK
ENGINE HARN
WHITE 35 PIN
5
85
86
J3 WHITE 23 PIN
87
30
P46HRN-WH
C27AUX-RD
1
TO J4-32
4
87a
WHITE 35 PIN P1-01

S-500

MOM N.O.
+
BAT.
P116HYD-OR

TIME DELAY
TROMBETTA

P1-05 FWD
BK-COM
REGULATOR
WH-PULL
RD-HOLD
P1-06 REV
-
ALTERNATOR

BAT.
STA.
IND.
EXCT.
15A
P1-08
CB 7

4

1
R46HRN-WH
30

VLVRET2-BR
2
5
87a 87 85

86
January 2019
HORN

SERVICE

HORN
RELAY
P1-17
Part No. 1268494
1

RD RD-HOLD
HOLD
2
C107AF-RD P1-19 ALT_FIELD_WIRE

WH WH-PULL IN
PULL IN
3

BK BK-COM
HI/LO SPEED
SOLENOID C45GEN-GN/WH P1-22 AC_GENERATOR
P34SA-RD
VLVRET2-BR
C31EDC-WH/BK
P114BAT-RD
BAT GND-BR
REV VLV B
SOLENOID
J32-ENG HARN
3
2
C45GEN-GN/WH 1
C30EDC-WH
FWD VLV A
SOLENOID GRID HEATER
RELAY
5
2
86
4
1
85 87 87a
30
R34SA-RD
275 A FUSE
HYD COOLER
GRID HEATER
N.O.
OTS1
RELAY
P85TTSR-GN
C84TAY-GN/BK
RET85TTSR-BR
5
C83TAX-GN/WH
BAT GND-BR C116HYD-OR

86
P116HYD-OR P31-ENG HARN

1
J31-TILT SNSR
30
85 87 87a

-
-
+
+
S-100 • S-105 • S-120 • S-125

BAT GND-BR

TURNTABLE TILT
SENSOR
C21IGN-WH
FUEL SOLENOID
RELAY
DEGREES
SET AT 4.5
C25PSR-WT/BK
0-20 DEGREE
OIL PRESSURE
SENSOR ALARM
C26TSR-WT/RD
OIL TEMP SENDER
5-31
BAT GND-BR

5-31
5-32

5-34
5-33
5-34
C211GN-WH J224-03 IGNITION STATUSL
J224-07 CAN HIGH(+)
J224-08 CAN LOW(-)
6A
CB
J224 GRAY 8 PIN
TELEMATICS HARN
MAIN (SYS)
BAT
AUXMAIN
-
+
P114BAT-RD
ENGINE BLOCK
-
+
POWER HARN
START BAT
J5 BLACK 4 PIN
CB
20 A
FUSE
25A
P34SA-RD
RELAY
70 A FUSE
STARTER

AUX/START_BAT_PWR
4
BATECU-RD P1-04
STARTER
1
30
87a 87
C33STR-BK
5
86
85
BAT GND-BR
C226TEL-BL
C211GN-WH
S-100 • S-105 • S-120 • S-125

AUX.
PUMP
PR1
REMOTE CONTROL
-BAT
TO J4-30 VLVRET6-BR
+BAT
+AUX
C229TEL-BL/BK
ENGINE HARN
2
WHITE 35 PIN
5
85
86
J3 WHITE 23 PIN
87
30
P46HRN-WH
C27AUX-RD
1
TO J4-32
4
87a
WHITE 35 PIN P1-01
S-500
MOM N.O.
+
BAT.
P116HYD-OR
TIME DELAY
TROMBETTA
P1-05 FWD
BK-COM
REGULATOR
WH-PULL
RD-HOLD
P1-06 REV
-
ALTERNATOR
BAT.
STA.
IND.
15A
EXCT.
CB7
P1-08
Part No. 1268494

January 2019
4
1
R46HRN-WH
30
VLVRET2-BR
5
87a 87 85
86
HORN
SERVICE
HORN
RELAY
P1-17
1
RD RD-HOLD
HOLD
2
WH WH-PULL IN
PULL IN
3
BK BK-COM
HI/LO SPEED
P34SA-RD
VLVRET2-BR
C31EDC-WH/BK
P114BAT-RD
BAT GND-BR
REV VLV B
SOLENOID
J32-ENG HARN
3
2
C45GEN-GN/WH 1
C30EDC-WH
FWD VLV A
RELAY
5
2
86
4
1
L
85 87 87a
30
R34SA-RD
275 A FUSE
15 A FUSE
HYD COOLER
GRID HEATER
N.O.
OTS1
RELAY
P85TTSR-GN
C84TAY-GN/BK
RET85TTSR-BR
5
C83TAX-GN/WH

86

1
J31-TILT SNSR
30
85 87 87a

-
-
+
+
BAT GND-BR
TURNTABLE TILT
SENSOR
C21IGN-WH
FUEL SOLENOID
RELAY
DEGREES
SET AT 4.5
C25PSR-WT/BK
0-20 DEGREE
OIL PRESSURE
SENSOR ALARM
C26TSR-WT/RD
OIL TEMP SENDER
BAT GND-BR

5-36
5-35
5-36
J224-07 CAN HIGH(+)
J224-08 CAN LOW(-)
6A
CB
J224 GRAY 8 PIN
TELEMATICS HARN
MAIN (SYS)
BAT
Q
STL
STS
GND
AUX MAIN
-
+
P114BAT-RD
ENGINE BLOCK
-
+
POWER HARN
START BAT
J5 BLACK 4 PIN
CB
20 A
FUSE
25A
P34SA-RD
RELAY
70 A FUSE
STARTER

AUX/START_BAT_PWR
4
BATECU-RD P1-04
STARTER
1
30
87a 87
C33STR-BK
5
86
85
BAT GND-BR
C226TEL-BL
C211GN-WH
S-100 • S-105 • S-120 • S-125

AUX.
PUMP
PR1
REMOTE CONTROL
-BAT
TO J4-30 VLVRET6-BR
+BAT
+AUX
C229TEL-BL/BK
ENGINE HARN
2
WHITE 35 PIN
5
85
86
J3 WHITE 23 PIN
87
30
P46HRN-WH
C27AUX-RD
1
TO J4-32
4
87a
WHITE 35 PIN P1-01
S-500
MOM N.O.
+
BAT.
P116HYD-OR
TIME DELAY
TROMBETTA
P1-05 FWD
BK-COM
REGULATOR
WH-PULL
RD-HOLD
P1-06 REV
-
ALTERNATOR
BAT.
STA.
IND.
EXCT.
P1-08
Part No. 1268494

January 2019
4
1
R46HRN-WH
30
VLVRET2-BR
5
87a 87 85
86
HORN
SERVICE
HORN
RELAY
P1-17
1
RD RD-HOLD
HOLD
2
WH WH-PULL IN
PULL IN
3
BK BK-COM
HI/LO SPEED
P34SA-RD
VLVRET2-BR
C31EDC-WH/BK
P114BAT-RD
BAT GND-BR
REV VLV B
SOLENOID
J32-ENG HARN
3
2
C45GEN-GN/WH 1
C30EDC-WH
FWD VLV A
RELAY
5
2
86
4
1
85 87 87a
30
R34SA-RD
275 A FUSE
HYD COOLER
GRID HEATER
N.O.
OTS1
RELAY
P85TTSR-GN
C84TAY-GN/BK
RET85TTSR-BR
5
C83TAX-GN/WH

86

1
J31-TILT SNSR
30
85 87 87a

-
-
+
+
BAT GND-BR
TURNTABLE TILT
SENSOR
C21IGN-WH
FUEL SOLENOID
RELAY
DEGREES
SET AT 4.5
C25PSR-WT/BK
0-20 DEGREE
OIL PRESSURE
SENSOR ALARM
C26TSR-WT/RD
OIL TEMP SENDER
BAT GND-BR
Electrical Schematic - Generator Options
5-38
5-37
Electrical Schematic - Generator Options
Belt-Driven Generator Option Hydraulic Generator Option
BLACK
CB 87a 3 WHITE
RED BLACK BLACK GREEN
T1 RED
J32-ENG HARN 1 30 4 AC
P32-GEN HARN 30A RD/12VDC RD BLACK
BLUE GENERATOR
87
C45GEN-GN/WH 1 WHITE YELLOW
WT BR/R45GEN(A) BR BLACK L1
2 86
85 5
T2 YELLOW WHITE
BAT GND-BR 2 GN YL/BAT GND YL WHITE WHITE
P114BAT-RD 3 BK RD BR/P45GEN(B)
T3 GREEN GND
1 2 3 4
BR DTP04-4P
PURPLE/F45GEN PR 1 2 3 4 GENERATOR
WHITE L2
PLUG
RD
BL
BK
JUMPER HARNESS
T4 GREEN BLACK
110 VAC REGULATOR
BLACK
WHT-NEUTRAL 5
120VAC 8
PURGE-BL
BLACK
AUTO
RESET CB
BLK-120VAC
PLUG
PLUG
15A
120VAC, 50Hz, 1 PH
120VAC GENERATOR W/REGULATOR.
P114 BAT-RD
PLUG
C45GEN-GR/WH
BATGND-BR
120VAC, 60Hz, 1 PH ENGINE HARNESS
C45GEN-GR/WH
P114 BAT-RD
BATGND-BR
87a 3 ENGINE HARNESS
PLUG
30A 1 30 4 RD/12VDC RD
J32-ENG HARN P32-GEN HARN
87
C45GEN-GN/WH 1 WT BR/R45GEN(A) BR
PLUG
2 86
PLUG
85 5
BAT GND-BR 2 GR YL/BAT GND YL
P114BAT-RD 3 BK RD BR/P45GEN(B) BR PURGE-BL
PURPLE/F45GEN PR
RED BLACK WHITE L2
T1
PLUG
RD
BK
BL
GENERATOR
WHT-NEUTRAL 220 VAC 1 2 3 4 JUMPER HARNESS
REGULATOR T2 GREEN GND DTP04-4P

YELLOW WHITE 1 2 3 4
220VAC WHITE WHITE

T3
AUTO
RESET CB
BLK-220VAC T4 GREEN BLACK BLACK L1
12.5A
YELLOW
BLACK AC
5 WHITE BLUE
GENERATOR
BLACK
RED
220VAC GENERATOR W/REGULATOR. BLACK GREEN
WHITE
8 BLACK BLACK
240VAC, 50Hz, 1 PH
5-38 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Electrical Schematic - 12 kW Generator

(welder option)
NEUTRAL BUSS BAR
12.5 KW HYDRAULIC GENERATOR
NEMA 4 CONTROL BOX
L1 L2 L3
MODIFIED ENCLOSURE WIRING Y X
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
208 VAC
OUTLET
L2 3 6 Z
RED RED
SX CONTROLLER
5 4
SAUER #K23334 WHITE
N L3
1 2 WHITE
TERMINAL CIRCUIT COLOR
A1 P23PWR RD/WH N
A2 SENSOR POWER +5V RD BLACK

L1
A3 BATTERY- BR
GROUND MADE UP OF
B1 V151HG GR BLACK GREEN MULTIPLE 8GA CONDUCTORS
BLACK 12GA
B2 NC BETWEEN MAJOR ASSEMBLIES
B3 V150HG GR/BK
GREEN 20 AMP CIRCUIT
C1 TxD YEL BREAKER
C2 RxD GR
C3 /BOOT GROUND
STUD ON 6 GA 4 CONDUCTOR
D1 JOYSTICK WH PANEL SILVER BRASS
110 VAC
D2 NC GFI
D3 NC
SILVER BRASS BLACK 10GA WHITE
E1 NOT USED
6 GA 4 CONDUCTOR
E2 NOT USED GREEN
E3 NOT USED 120 VAC GREEN
GFI
F1 NOT USED BLACK
GREEN 10GA
F2 C45GEN GR/WH
F3 NOT USED
ENCLOSURE 10 GA 3 CONDUCTOR
10 GA 3 CONDUCTOR
RELAY
OMRON
CR50
A B C D E F SX CONTROLLER
PIN# COLOR
12
10
11
4
9
8
7
6
1
5
2
WH
BK
BK
BK
PLUG
BR
GR/BK
GR/WH
WH/BK
BR
WH/BK
WH
WH
1 32 4
J3-10
BR
EDC - J159-3 WH/BK EDC-
2
5
J159-7
U4
1 J3-11
EDC + J159-2 WH EDC+
6
1 J159-6
RD
2
P23PWR
GND
C45GEN
C31EDC-
C30EDC+
C31EDC-(A)
C30EDC+(A)
P23PWR
GND1
P23PWR(A)
V150HG
CKT#
7
8
3 GND1 J159-4
J159
J159-12 GND Y75-2
GR
J129 GR
BYPASS COIL
DIVERTER MANIFOLD
YEL
J159-10
Y75-1
B A
FROM GENERATOR MANIFOLD

PILOT PRESSURE SIGNAL
J159-1
C
BK-2 BK P23PWR(A)
C57-2
PRESSURE SWITCH
N.O.
V151HG GR
200 PSI
BR
V150HG GR/BK
PS4
TCON
J129
RS232 CONNECTOR
RD-1
J159-5 BK RD/WH
TERM CIRCUIT 2 1
J3-22
C45GEN GR/WH
A TxD
C57-1
1K
RD/WH
2
B RxD 4
J129 B RS232RxD
3
J159-9
3
1
C GND
A RS232TxD
124 ohms
124 ohms
GR/WH
CR50
OMRON RELAY
F3 DIG IN 2
F2 DIG IN 1 GENERATOR ON
F1 DIG IN 0
E3 NOT USED
E2 NOT USED
E1 NOT USED
D3 DIG IN 3 NC
D2 ANALOG 1 NC
D1 ANALOG 0 JOYSTICK
B3 DIGITAL OUTPUT BYPASS/OMRON

B2 VALVE 1 NC
B1 VALVE 0 FWD COIL
C2 RxD
C1 TxD
C3 BOOT
A3 BATTERY-
A2 SENSOR POWER +5 VDC
A1 BATTERY +
RD/WH
6 5
PCON
J159-1 P23PWR BK
SX CONTROLLER
J159
(TO EDC HARNESS)
8 7
PIN# COLOR CIRCUIT #
GR/BK
J21-18
J21-17
1 WH/RD P23PWR(A)
2 WH C30EDC+
GR
3 WH/BK C31EDC-
4 BK/RD GND1 PUMP
5 BL/RD P23PWR WH/RD AUXILIARY

10A
RD BATTERY
6 RD C30EDC+(A) FUSE
4 SECOND
TIME DELAY MODULE
7 RD/BK C31EDC-(A) WH
D82CAN+ YL
D81CAN- GR
PUMP
AUXILIARY
GND
3 GND 5 SW INPUT
8 OR/RD GND2
9 10 11 12
1
2 COM
1 N.O.
8 N.C.
9 GR/WH C45GEN
WH/BK
2
10 GR/BK V150HG
RD/WH
3
11 RD/WH P23PWR
U36
BK/RD
12 GR GND
4
5
BL/RD J159
(12V STUD)
P23PWR WH P23PWR J1-18
7
6
J1-17
RD
RELAY
RD/BK
HIGH IDLE J3-2
CR4
OR/RD
DCON
RD/WH
VALVE J31-18
J32-4
MOTOR STROKE J31-17
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-39

Electrical Schematic - 12 kW Generator

(welder option)
5-39
5-40
8
7
6
5
4
3
2
1
A
TELBAT-RD J224-01 SYS_POWER
C21IGN-WH J224-03 IGNITION STATUS


B
6A
J224-07 CAN HIGH (+)
CB
J224-08 CAN LOW (-)
MAIN (SYS) BAT

Q TELEMATICS
AUX MAIN
STL
STS
GND
-
+
B2BAT-RD B2BAT-RD
J224 GRAY 8 PIN
TELEMATICS HARN
P114BAT-RD
C
B1BAT-RD
ENGINE BLOCK
-
+
POWER HARN
START BAT
J5 BLACK 4 PIN
30 A
20 A
60 A
20 A
CB
P1-01 SYS_BAT_PWR
RELAY
BATVLV-RD
GLOW PLUG
25A
STARTER
SPEED SOLENOID
ENG FUEL/STARTER
HORN/HYD COOLER
STARTER
87a
4
B1ENG-RD BATECU-RD P1-04 AUX/START_BAT_PWR
30
D
R33STR-BK
87
P35RPM-BK/RD
C33 STR-BK C33 STR-BK
85
86
2
5
BAT GND-BR
C21IGN-WH
C226TEL-BL
AUX.
PUMP
REMOTE CONTROL
RELAY NC
PR1
C229TEL-BL/BK
5
2
-BAT
TO J4-30
E
ENGINE HARN
+AUX
+BAT
VLVRET6-BR
85
86
WHITE 35 PIN
J3 WHITE 23 PIN
87
30
TO J4-32
1
87a
WHITE 35 PIN C27AUX-RD
P3-01
S-613
B3BAT/14-RD
+
MOM N.O.
BAT.
TIME DELAY

TROMBETTA

BK-COM
P3-05 FWD
F
WH-PULL
RD-HOLD
DETAIL B
P3-06 REV
REGULATOR
ALTERNATOR

BAT.
STA.
IND.
EXCT.
15A
CB7
P3-08
C41RPM-OR/BK C33TEL-BK P3-09 STARTER_RELAY

87a

1
30
R46HRN-WH
G
87

VLVRET2-BR
85
86
2

HORN
SERVICE
P85TTSR-GR P3-15 TT_TILT_SNSR_PWR

HORN
RELAY
VLVRET2-BR P3-16 VALVE RETURN 2
P3-17
1
C41RPM-OR/BK P3-18 ALTERNATOR_RPM

RD RD-HOLD
HOLD P3-19
2
WH WH-PULL IN
PULL IN
3
C83TAX-GR/WH P3-20 TT_TILT_X_AXIS

H
BK BK-COM
C84TAY-GR/BK P3-21 TT_TILT_Y_AXIS
HI/LO SPEED SOLENOID
C45GEN-GR/WH P3-22 AC_GENERATOR
P34SA-RD
P3-23 VALVE RETURN 3

VLVRET2-BR
C21IGN-WH
C30EDC(+)-WH
P114BAT-RD
BAT GND-BR
C45GEN-GR/WH
B1ENG-RD
J32-ENG HARN
FWD VLV A
I
3
2
1
SOLENOID
C31EDC(-)-WH/BK TO SHEET 16
REV VLV B GLOW PLUG

SOLENOID RELAY
5
2
85
86
87
January 2019
30
4
J
87a
R34SA-RD
ENG FUEL RELAY
Part No. 1268494
5
2
GLOW PLUGS
BAT GND-BR
85
86
87
R211GN-WH
30
4
P85TTSR-GR
C84TAY-GR/BK
HYD COOLER
RET85TTSR-BR
C83TAX-GR/WH
87a
RELAY
N.O.
OTS1
COLD START
ADVANCE
PERKINS 1104D-44T ENGINE
5
2

85
86
K
87
30
J31-TILT SNSR
4
B3BAT/14-RD
1
87a
-
-
+
+

R211GN-WH
FAN
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
TURNTABLE TILT
FUEL
PUMP
R21IGN-WH SENSOR
L
R21IGN-WH
FUEL SHUTDOWN
C25PSR-WH/BK
OIL PRESSURE
S-100 • S-105 • S-120 • S-125
C26TSR-WH/RD

OIL TEMP SENDER

M
BAT GND-BR
8
7
6
5
4
3
2
1
Perkins 1104D-44T Engine Electrical Schematic
5-41
Perkins 1104D-44T Engine Electrical Schematic
5-41
5-42
Perkins 854F-34T Engine Electrical Schematic
5-44
5-43
8
7
6
5
4
3
2
1
5-44
TELBAT-RD
TELGND-BR
J224-01
J224-02
SYS_POWER
GROUND
A

B

ENGINE CAN BUS
6A
CB
TO CAN GATEWAY
(SHEET 6)
J224-08 CAN LOW (-)
MAIN (SYS) BAT

Q TELEMATICS
AUX MAIN
STL
STS
GND
B2BAT-RD
-
+
B2BAT-RD
J224 GRAY 8 PIN
F7
TELEMATICS HARN
30A
C
ENGINE BLOCK
F27
-
+
50A
START BAT
POWER HARN
S-100 • S-105 • S-120 • S-125

J5 BLACK 4 PIN
F22 CB
CR1
60A 25A
RELAY
GND-BR P5-02 SYS_BAT_GND
STARTER
F23
STARTER
GND-BR P5-03 AUX/START_BAT_GND
87a
30A
4
B1ENG-RD BATECU-RD P5-04 AUX/START_BAT_PWR
30
R33STR-BK
87
D
85
86
2
5
C33RET K27-BK C33RET K27-BK
C33STR K53-BK C33STR K53-BK
AUX.
PUMP
Perkins 854F-34T Engine Electrical Schematic
C33STR-BK
C21IGN-WH
C229TEL-BL
C226TEL-BL
PR1
TO J4-30
Part No. 1268494

January 2019
ENGINE HARN
WHITE 35 PIN VLVRET6-BR
B4BAT-RD
B3BAT-RD
J3 WHITE 23 PIN
P34SA-RD
B3BAT-RD
B1ENG-RD
TO J4-32
E
WHITE 35 PIN C27AUX-RD REMOTE CONTROL

RELAY NC
P3-01
5
+
2
BAT.
85
86
P3-02 THROTTLE
87
30

1
87a
P3-04 START ASSIST
REGULATOR
ALTERNATOR
P3-05 FWD
-
DETAIL B
BAT.
STA.
GND-BR
IND.
P3-06 REV
EXCT.
F
P34SA-RD
C134KSP-GR/BK P3-08 KEY SWITCH POWER
C134KSP-GR/BK
C33STR K08-BK C33TEL-BK P3-09 STARTER_RELAY
C30EDC(-)-WH/BK P3-10 C31EDC(-)-WH/BK
J144-2
BAT GND-BR C107AF-RD C30EDC(+)-WH P3-11 C30EDC(+)-WH
J144-8 P3-12 OIL_PRESSURE
87a
P3-13 OIL/WATER_TEMP
4
1
30
R46HRN-WH RET85TTSR-BR P3-14 TT_TILT_SNSR_GND

87
VLVRET2-BR P85TTSR-GR P3-15 TT_TILT_SNSR_PWR

G
85
86
2
HORN
SERVICE
P3-17
HORN
RELAY
P3-18 ALTERNATOR_RPM
P3-19 ALT_FIELD_WIRE
C30EDC(+)-WH
FWD VLV A SOLENOID
C31EDC(-)-WH/BK
H
ECU POWER
REV VLV B SOLENOID RELAY
P114BAT-RD
5
BAT GND-BR
C20RET K28-BR C20RET K28-BR B4BAT-RD

C45GEN-GR/WH
85
86
FX1
J32-ENG HARN
87
R20PWR-RD R20PWR-RD P20PWR

30
3
2
1
FX2 30A
1
87a
P134KSP-GR/BK P134KSP-GR/BK
20A TO SHEET 16
I
R211GN-WH
C21TEL-WH
PERKINS 854F-E34T
HYD COOLER
RELAY
N.O.
OTS1
5
2
BAT GND-BR C116HYD-WH

85
86
87
30
4
P85TTSR-GN
B3BAT-RD
J
C84TAY-GR/BK
1
RET85TTSR-BR
C83TAX-GR/WH
87a

FAN
P31-ENG HARN
J31-TILT SNSR
-
-
+
+
0-20 DEGREE
SENSOR ALARM SET
AT 4.5 DEGREES
TURNTABLE TILT
GND-BR
K
SENSOR
IGNITION PWR
P34SA-RD
RELAY
R20PWR-RD
87a
1
C33RET K27-BK
C33STR K08-BK
C33STR K53-BK
C20RET K28-BR
C134KSP-GR/BK
P134KSP-GR/BK
4
30
87
85
86
C21IGN-WH
2
5
L
BAT GND-BR
TO SHEET 14
M
8
7
6
5
4
3
2
1
Perkins 854F-34T Engine Electrical Harness
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-45

Perkins 854F-34T Engine Harness
5-45
5-46
Deutz TD2011L04i Engine Electrical Schematic
5-48
5-47
8
7
6
5
4
3
2
1
5-48
A


B
6A
CB
J224-08 CAN LOW (-)
MAIN (SYS) BAT

Q TELEMATICS
AUX MAIN
STL
STS
GND
-
+
P114BAT-RD
J224 GRAY 8 PIN
TELEMATICS HARN
C
ENGINE BLOCK
-
+
S-100 • S-105 • S-120 • S-125

START BAT
POWER HARN
30 A
J5 BLACK 4 PIN
CB
FUSE
RELAY
FUSE
70 A FUSE
25A
STARTER
STARTER
BATGND-BR P5-03
87a
4
BATECU-RD P5-04 AUX/START_BAT_PWR
30
P33STR-BK
87
D
C33 STR-BK
85
86
2
5
BAT GND-BR
C21IGN-WH
C226TEL-BL
Deutz TD2011L04i Engine Electrical Schematic
AUX.
PUMP
REMOTE CONTROL
Part No. 1268494

January 2019
RELAY NC
PR1
C229TEL-BL/BK
5
2
TO J4-30
ENGINE HARN
WHITE 35 PIN VLVRET6-BR

85
86
J3 WHITE 23 PIN
BAT-
87
P46HRN-WH
BAT+
AUX+
P116HYD-OR
30
4
E
TO J4-32
1
87a
WHITE 35 PIN C27AUX-RD
P3-01
S-613
MOM N.O.
+
BAT.
TIME DELAY
TROMBETTA
BK-COM
P3-05 FWD
WH-PULL
RD-HOLD
DETAIL B
P3-06 REV
REGULATOR
ALTERNATOR
-
15A
F

CB7
BAT.
STA.
IND.
EXCT.
J144-1 P3-08
C41RPM-OR/BK C33TEL-BK P3-09 STARTER_RELAY

J144-2
J144-8 C25PSR-WH/BK P3-12
87a
OIL_PRESSURE
4
1
30

87
G

85
86
2
VLVRET2-BR P3-16 VALVE RETURN 2
HORN
SERVICE
P3-17
HORN
RELAY
C41RPM-OR/BK P3-18 ALTERNATOR_RPM

1
RD RD-HOLD C83TAX-GR/WH P3-20 TT_TILT_X_AXIS

HOLD
2
WH WH-PULL IN C84TAY-GR/BK P3-21 TT_TILT_Y_AXIS

PULL IN
3
BK BK-COM C45GEN-GR/WH P3-22 AC_GENERATOR

HI/LO SPEED SOLENOID
P34SA-RD
H

VLVRET2-BR
C30EDC(+)-WH
P114BAT-RD
BAT GND-BR
C45GEN-GR/WH
J32-ENG HARN
FWD VLV A
3
2
1
SOLENOID
C31EDC(-)-WH/BK
TO SHEET 16
I
REV VLV B GLOW PLUG

SOLENOID RELAY
5
2
85
86
87
30
4
1
87a
R34SA-RD
GLOW PLUG COLD WEA

RELAY
10A
J
87a
1
P85TTSR-GN
4
30
C84TAY-GR/BK
RET85TTSR-BR
C83TAX-GR/WH
87
COLD WEA VLV

85
86
SOLENOID
2
HYD COOLER
P31-ENG HARN
RELAY
N.O.
OTS1
J31-TILT SNSR
5
2
-
-
+
+

85
86
87
30
4
DEUTZ ENGINE
0-20 DEGREE
P116HYD-OR SENSOR ALARM SET
1
K
87a
AT 4.5 DEGREES
BAT GND-BR R116HYD-OR TURNTABLE TILT
FAN
SENSOR
FUEL SOLENOID
BAT GND-BR RELAY
5
2
VLVRET2-BR C21IGN-WH
85
86
87
R21IGN-WH
TO LSB7DS BOOM STOWED SWITCH
30
J144-7 P21IGN-WH
1
87a
L
FUEL SOLENOID
RELAY
J144-5
C25PSR-WH/BK
OIL PRESSURE
J144 -3
C26TSR-WH/RD
OIL TEMP SENDER

TO SHEET 5
BAT GND-BR
M
8
7
6
5
4
3
2
1
Deutz TD2.9 Engine Electrical Schematic
5-50
5-49
8
7
6
5
4
3
2
1
5-50
A
C21 IGN-WH J224-03 IGNITION STATUS

TO SHEET 6
P23PCON-BK J224-04 KEYSWITCH POWER


B
ENGINE CAN BUS
6A
CB
TO CAN GATEWAY J224-07 CAN HIGH (+)
(SHEET 6)
J224-08 CAN LOW (-)
MAIN (SYS) BAT

Q TELEMATICS
AUX MAIN
STL
STS
GND
B2BAT-RD
-
+
B2BAT-RD
J224 GRAY 8 PIN
F7
TELEMATICS HARN
20A
C
ENGINE BLOCK
F27
-
+
S-100 • S-105 • S-120 • S-125

20A
START BAT
POWER HARN
J5 BLACK 4 PIN
F22 CB
60A 25A
GND-BR P5-02 SYS_BAT_GND
F23
STARTER
GND-BR P5-03 AUX/START_BAT_GND
30A P5-04 AUX/START_BAT_PWR
BATECU-RD
Deutz TD2.9 Engine Electrical Schematic
AUX.
PUMP
Part No. 1268494

January 2019
C33STR-BK
C21IGN-WH
C229TEL-BL
C226TEL-BL
PR1
TO J4-30
ENGINE HARN
VLVRET6-BR REMOTE CONTROL

WHITE 35 PIN
B3BAT-RD
J3 WHITE 23 PIN
B3BAT-RD
RELAY NC
B1ENG-RD
P20PWR-RD
TO J4-32
P34SA-BK/WH
E
C27AUX-RD
2
WHITE 35 PIN
85
86
87
30
P3-01
4
+
BAT.
1
87a
P3-02 THROTTLE
P3-04 START ASSIST
REGULATOR
FWD
ALTERNATOR
P3-05
-
DETAIL B
BAT.
STA.
02 GND-BR
IND.
P3-06 REV
EXCT.
F
P20PWR-RD
C134KSP-GR/BK P3-08 KEY SWITCH POWER
C134KSP-GR/BK
C33STR-BK C33 TEL-BK P3-09 STARTER_RELAY

J144-2
J144-8 P3-12 OIL_PRESSURE
87a
P3-13 OIL/WATER_TEMP
4
1
30

87

G
85
86
2
HORN
SERVICE
P3-17
HORN
RELAY
P3-18 ALTERNATOR_RPM
P3-19 ALT_FIELD_WIRE

C30EDC(+)-WH
FWD VLV A SOLENOID
C31EDC(-)-WH/BK
H
GLOW PLUG
REV VLV B SOLENOID RELAY
B3BAT-RD
5
BAT GND-BR
C34RET-GR/WH C34RET-GR/WH C34SA-BK/WH

C45GEN-GR/WH
85
86
J32-ENG HARN
87
R34SA-RD R34SA-RD
30
3
2
1
4
1
87a
R34SA-RD
TO SHEET 16
COLD WEA
GLOW PLUG
RELAY
I
10A
R211GN-WH
87a
1
4
30
87
COLD WEA VLV

85
86
SOLENOID
2
HYD COOLER
RELAY
N.O.
OTS1
5
2
BAT GND-BR C116HYD-WH

85
86
87
30
4
P85TTSR-GN
J
B3BAT-RD
C84TAY-GR/BK
1
RET85TTSR-BR
C83TAX-GR/WH
87a

FAN
P31-ENG HARN
J31-TILT SNSR
C135FP-BL/WH
-
-
+
+
5
2
DEUTZ ENGINE 2.9L TURBO
C135RET-WH
85
86
0-20 DEGREE
SENSOR ALARM SET
87
AT 4.5 DEGREES
30
TURNTABLE TILT
1
K
87a
FUEL PUMP SENSOR

IGNITION PWR
FUEL PWR RELAY
RELAY
87a
1
4
30
87
85
86
C21ENG-WH
2
5
L
ENG SHUTDOWN
RELAY
5
2
VLVRET2-BR C21IGN-WH
85
86
87
30
P21IGN-WH
1
87a
R21RET-WH R21IRET-WH
J144-7 TO SHEET 5
BAT GND-BR
TO SHEET 12
M
8
7
6
5
4
3
2
1
Deutz TD2.9 Engine Electrical Harness
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-51

Deutz TD2.9 Engine Electrical Harness
5-51
5-52
Hydraulic Schematic - 12 kW Generator

(welder option)
OIL COOLER
3.5 GPM / 13.25L/min DRIVE PUMP
A
PMP B CLR PMP A
WELDER
MANIFOLD
CW
0.030 inch /
0.76 mm PRESSURE SWITCH
200 PSI / 13.8 BAR
CV N.O.
CX
CU
270 PSI / 18.6 BAR
@ 3.5 GPM / 13.25 L/min
CY
G2
21 GPM /
79.5 L/min
MTR B MTR A G1
79.5 L/min
21 GPM /
HYDRAULIC
4
COUPLER
ROTARY
3
TANK
21CC
G2 G1
GENERATOR
12.5 KW
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-53

Hydraulic Schematic - 12 kW Generator

(welder option)
5-53
5-54
Hydraulic Schematic, S-100 • S-105 Models

(serial number 136)
5-56
5-55

(serial number 136)
T P
PLATFORM MANIFOLD
P1 3 gpm 3 gpm
S-105
TURNTABLE ROTATE PRIMARY LIFT PRIMARY1 EXT. CB
TEST CD PRL
DISTRIBUTION MANIFOLD 3GPM 11GPM/5GPM 18GPM/6GPM CE D
PLATFORM ROTATE
P3 OUT T2 CO 0.030 CA
0.3 GPM
T1
G G
AG 3000 psi AC CC
P1 IN E E T1 PRR
AD P1 OUT
HIGH 3.0 GPM 0.030
D
PRESS A B
P2 IN 0.1GPM
FILTERS AF P2 OUT CF CI
CHARGE FILTER
AA PLU
AB AE CP
CH C
CG
PLATFORM LEVEL
100 100
87 PSI PSI A B
PSI P2A IN P3A IN
PLD
C
0.63 GPM
J
CJ
2500 psi
CM JU
B Ps Fa Fe 1-2 1-2 1-2 CL
1.25 GPM / 0.75 GPM

TRL TRR UP DWN EXT EXT RET CK D
FH
JIB
b a JD
Mb 1800psi FQ
H CN
FA
LS
4250 25
PSI 3000 psi CQ D
PSI FC
FR 500 psi
M 1.7 .3 AUX. FD
4.6 in.cu.
PUMP
E 6 17 10
FG FF FB
4250
PSI P1 PLATFORM ROTATE
290 0.3 GPM
PSI 25
0.030
25 PSI
PSI TEST PRL
Ma D
GE
GO GD
FL FJ FM GB GA
A X1 X2 R T1 T2 S
LS T1 GC
B PRR
A P2 OUT
T1
P 0.030 D
FK
FP 0.040 DIA GF
TP GI GH
PLU
0.1GPM
3 3 FI C
PSI PSI FE GG
2600 psi
TANK
T FUNCTION MANIFOLD T1
PLD
GJ
HYDRAULIC SWIVEL LS
J
4 WHEEL DRIVE B T 3 gpm
GQ
PLATFORM LEVEL
MANIFOLD 500 psi 0.47 GPM
A
A B 4.6 in.cu.
B P 3 gpm PLATFORM MANIFOLD
RB A S-100
FRONT LEFT FRONT RIGHT FRONT AXLE EXTENSION
REAR REAR AXLE EXTENSION
FRB STEERING STEERING
RIGHT REAR LEFT REAR RIGHT
I D I D
FRONT STEERING STEERING
DL RIGHT
COUNTERBALANCE
FRA
VALVE
DH FLR FLB FRB FRR FAE FAR RLR RLB RRB RRR
DK P RAE RAR RATIO
RA
FLB
PRESS
AUXILIARY
DRIVE EK EM EG EH A 2:1 5000 PSI
50% A OPTION B
LB 50%
50%
ENN EJJ EKK EII EOO EPP EMM ELL B 4.5:1 5000 PSI
50%
2.0 GPM
0.1GPM
DC DE C 1.5:1 3000 PSI
DF 1.40 2.00 2.00 1.40 EX 1.40 2.00 2.00 1.40
DB 50%
50% DD JE JD GPM GPM GPM GPM EQQ GPM GPM GPM GPM
D 3:1 3000 PSI
JF JC
EQ EV ER EW ET EE
2.0 GPM
1800 psi EU EJ E 4.5:1 3000 PSI

DI
FRONT TP
2.7 GPM EY
DG FLA
LEFT
EB EA F 3:1 900 PSI
REAR ES ED EC
JA JB
LS LS
G 3:1 600 PSI
LEFT LA DJ 250 PSI TEST
DM P1
H 3:1 3200 PSI
DP P1 EZ
TANK 3000 psi I 3:1 2200 PSI
EP EO
DN 0.030 0.1GPM
T
DO DA
BRAKE BRAKE T1 Note: 'alpha' callouts refer
FOUR WHEEL STEER MANIFOLD to components shown in the
2 SPD 2 SPD manifold illustrations.
Refer to the Repair Section.
5-56 S-100 • S-105 • S-120 • S-125 Part No. 1268494


(from serial number 137 to serial number 290)
HIGH Primary extension T

PLATFORM MANIFOLD
PRESS CB valve ratio P1 P
CHARGE FILTER FILTERS
changed to 'K' at 3 gpm S-105
3 gpm CB
Serial No. 150 TEST PRL
CE CD
D
PLATFORM ROTATE
100 100
87 PSI PSI TURNTABLE ROTATE PRIMARY 1 EXT. CO 0.030 CA
PSI PRIMARY LIFT
3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM
0.3 GPM
CC
T1 PRR
G G
0.030
E E D
0.1GPM CF CI
B Ps Fa Fe
A B PLU
CP
CH C
PLATFORM LEVEL
CG
b a
PLD
0.63 GPM
Mb
A B
4250
PSI C
J
CJ
E 6 17 10 Oil cooler location 1-2 1-2 1-2
P3 T2 TRL CM JU
AUX. before Serial No. 248 TRR UP DWN EXT EXT RET CL
1.25 GPM / 0.75 GPM

4250 CK D
PSI PUMP OIL COOLER FH
290
PSI Drive pump AE
Ma .3 1.7 M 1800psi
JIB
changed to H
JD
P3A FA CN
A
9 GPM at 25 PSI FQ
X1 X2 R T1 T2 S LS
Serial No. 253 FC CQ D
FR
FD 500 psi
TP3
4.6 in.cu.
25 25
PSI FG FF FB
PSI
3000 psi
Oil cooler location PLATFORM ROTATE
3 3 P1
PSI PSI after Serial No. 247 0.3 GPM
AC
TANK TEST 0.030
PRL
P2 FL FJ FM GE D
OIL COOLER GO GD
GB GA
AF AD
P1 AG
T1 GC
PRR
25 PSI
FK
TP AA .040 DIA 0.030 D
Hydraulic Swivel FP
numbered at 4 3 1 2 5 GF
GI GH
Serial No. 255 P2A AB
FI 230 psi PLU
0.1GPM C
TP2 GG
1 5 FE
4 3 2B 2A 2600 psi
HYDRAULIC SWIVEL T1 PLD
GJ
T3 P2 OUT LS
Valve FP changed from LS
110 psi to 230 psi at
FUNCTION MANIFOLD J
4 WHEEL DRIVE Serial No. 151 T
GQ
3 gpm PLATFORM LEVEL
MANIFOLD 500 psi 0.47 GPM
A B 4.6 in.cu.
B P 3 gpm PLATFORM MANIFOLD
RB A S-100
REAR
FRB
RIGHT
FRONT
DL RIGHT FRONT LEFT FRONT RIGHT FRONT AXLE EXTENSION REAR AXLE EXTENSION COUNTERBALANCE VALVE
FRA STEERING STEERING
RATIO PRESS
DH I D I D
DK REAR LEFT REAR RIGHT
RA
FLB STEERING STEERING A 5:1 5000 PSI
B 4.5:1 5000 PSI
50%
LB 50%
50% 50% FLR FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR C 1.5:1 3500 PSI
2.0 GPM
P
DC DE
AUXILIARY D 3:1 3000 PSI
DF DRIVE EK EM EG EH
DB 50%
50% DD A OPTION B E 4.5:1 3000 PSI
ENN EJJ EKK EII EOO EPP EMM ELL
2.0 GPM
DI 0.1GPM F 3:1 900 PSI

FRONT
2.7 GPM
DG FLA
LEFT 1.40 2.00 2.00 1.40 EX 1.40 2.00 G 3:1 600 PSI
REAR 2.00 1.40
JE JD GPM GPM GPM GPM EQQ GPM GPM GPM GPM
LEFT
JF JC
EQ EV ER EW EE
H 3:1 3200 PSI
LA DJ 250 PSI TEST 1800 psi ET EU EJ
DM TP
EY
I 3:1 2200 PSI
DP EB EA
TANK
JA ES ED EC J 1.5:1 2000 PSI
JB
LS LS
DN 0.030 K 1:1 600 PSI
P1 P1 EZ
DO DA 3000 psi
BRAKE BRAKE
EP EO Note: 'alpha' callouts refer
The manifold relief valve T 0.1GPM to components shown in the
2 SPD 2 SPD EZ was removed at manifold illustrations.
Serial No. 148
T1 Refer to the Repair Section.
FOUR WHEEL STEER MANIFOLD
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-57


5-57
5-58

5-60
5-59

PLATFORM MANIFOLD
T P
TURNTABLE ROTATE PRIMARY LIFT PRIMARY1 EXT. S-105
HIGH 3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM P1 3 gpm 3 gpm
PRESS CB
FILTERS TEST CD PRL
CHARGE FILTER CE D
PLATFORM ROTATE
K G CO 0.030 CA
E E
0.3 GPM
100 100
87 PSI PSI
PSI CC
T1 PRR
A B 0.030
D
0.1GPM CF CI
PLU
CP
C
PLATFORM LEVEL
M1 E D A B CH CG
C
PLD
0.63 GPM
315
PSI
M5
J
A 1-2 1-2 1-2 CJ
3625 P3 T2 TRL TRR UP DWN EXT EXT RET
M4 PSI CM JU
CL
FQ
1.25 GPM / 0.75 GPM

CK D
AE FA
E 3625 9 17 10 H JD
JIB
PSI AUX. P3A FH
FR CN
PUMP 1800psi LS
TP3-4 FC
D
.3 1.7 M FD CQ
500 psi
4.6 in.cu.
B L1 L2 M2 S FF FB
3000 psi FG
AC
25 25 PLATFORM ROTATE
PSI P1 0.3 GPM
PSI P2 FL FJ FM
TEST 0.030
PRL
AF GE D
3 3 AD GO GD
PSI PSI GB GA
P1 AG
TANK
T1 GC
FK PRR
TP AA .040 DIA
CHECK VALVE FP 0.030 D
REMOVED AT
S/N 291 P2A GF
25 PSI AB GI GH
230 psi PLU
FI 0.1GPM C
TP2 GG
FE
2600 psi
T1 PLD
GJ
4 3 1 2 5
T3 P2 OUT LS-4 LS
J
HYDRAULIC SWIVEL FUNCTION MANIFOLD GQ
PLATFORM LEVEL
500 psi 0.47 GPM
4 3 1 2B 2A 5
4.6 in.cu.
3 gpm 3 gpm
FRONT AXLE REAR AXLE
T P
EXTENSION EXTENSION
T TEST A B PLATFORM MANIFOLD
X
TO FUNCTION MANIFOLD T2
FRONT FRONT LEFT FRONT RIGHT S-100
I D I D TO FUNCTION MANIFOLD P3
REAR M7 M8 RIGHT STEERING STEERING
RIGHT
FR FH
REAR LEFT REAR RIGHT
FE STEERING STEERING
CDR
FF M6
M5
50% 50% P FLR FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR COUNTERBALANCE VALVE
FP FJ RATIO PRESS
280 PSI
FN EG
2.0 2.0 EK EM EH A 5:1 5000 PSI
GPM GPM FL
FQ 50% 50% ENN EJJ EKK EII EOO EPP EMM ELL B 4.5:1 5000 PSI
50% 50% C 1.5:1 3500 PSI
2.0 GPM FM
FD FK D 3:1 3000 PSI
1.40 2.00 2.00 1.40 EX 1.40 2.00 2.00
M3 M4 1.40
GPM GPM GPM GPM EQQ GPM GPM GPM GPM E 4.5:1 3000 PSI
FG FD EV ER EW EE
EQ 1800 psi ET EU EJ
ES F 3:1 900 PSI
TP
0.030 EY G 3:1 600 PSI
CDL EB EA ED EC
FRONT
H 3:1 3200 PSI
FA FI LEFT I 3:1 2200 PSI
REAR M1 FB FC M2
LEFT LS
J 1.5:1 2000 PSI
LBRAKE LBRAKE P1
K 1:1 600 PSI
L2SPEED L2SPEED
EO
EP
R2SPEED R2SPEED T 0.1GPM
Note: 'alpha' callouts refer
RBRAKE RBRAKE to components shown in the
T1 manifold illustrations.
4WD TRACTION MANIFOLD FOUR WHEEL STEER MANIFOLD
5-60 S-100 • S-105 • S-120 • S-125 Part No. 1268494


PLATFORM MANIFOLD
TURNTABLE ROTATE PRIMARY LIFT PRIMARY1 EXT. T P
3 GPM
11 GPM / 5 GPM
18 GPM / 6 GPM
S-105
P1 3 gpm 3 gpm
HIGH
CB
PRESS TEST PRL
A B K G CE CD
D
PLATFORM ROTATE
CHARGE FILTER FILTERS
CO 0.030 CA
E E
0.3 GPM
100 100
87 PSI PSI
PSI A B CC
T1 PRR
0.030
D
0.1GPM CF CI
C
PLU
C CP
C
PLATFORM LEVEL
CH CG
M1 E D
PLD
0.63 GPM
315
PSI
M5
J
1-2 1-2 CJ
A 1-2
3625 P3 T2 TRL TRR UP DWN EXT EXT RET
M4 PSI CM JU
CL
FQ
1.25 GPM / 0.75 GPM

CK D
AE FA
E 3625 9 17 10
PSI AUX. P3A JD
JIB
FR CN
PUMP 1800psi
TP3-4 FC LS
.3 1.7 M FD D
CQ
500 psi
B L1 L2 M2 S FF FB 4.6 in.cu.
3000 psi FG
AC
25 25
PSI PSI P2 FL FJ FM PLATFORM ROTATE
P1 0.3 GPM
3 3 AF AD
PSI PSI TEST 0.030
AG PRL
P1 GE D
TANK GO GD
GB GA
FK
TP AA .040 DIA
FP
T1 GC
PRR
P2A AB
230 psi 0.030 D
FI 0.1GPM
TP2 GF
FE GI GH
2600 psi PLU
4 3 1 2 5
T1 C
GG
HYDRAULIC SWIVEL T3 P2 OUT LS-4
4 3 1 2B 2A 5
FUNCTION MANIFOLD GJ
PLD
LS
J
GQ
PLATFORM LEVEL
500 psi 0.47 GPM
4.6 in.cu.
3 gpm 3 gpm
T P
T TEST A B
PLATFORM MANIFOLD
FRONT AXLE REAR AXLE TO FUNCTION MANIFOLD T2
S-100
X
FRONT EXTENSION EXTENSION TO FUNCTION MANIFOLD P3

REAR M7 M8 RIGHT FRONT LEFT FRONT RIGHT
RIGHT
FR FH STEERING STEERING
I D I D REAR LEFT
FE REAR RIGHT
CDR STEERING STEERING
FF M6
M5
COUNTERBALANCE
50% 50%
FP FJ
P FLR FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR VALVE
280 PSI
FN 2.0 2.0 RATIO PRESS
GPM
FQ 50%
GPM FL EK EM EG EH
50% A 5:1 5000 PSI
50% 50% ENN EJJ EKK EII EOO EPP EMM ELL B 4.5:1 5000 PSI
2.0 GPM FM
FD FK C 1.5:1 3500 PSI
M3 M4
1.40 2.00 2.00 1.40 EX 1.40 2.00 2.00 D 3:1 3000 PSI
FG 1.40
FD GPM GPM GPM GPM EQQ GPM GPM GPM GPM E 4.5:1 3000 PSI
EQ EV ER EW 1800 psi ET EE EU EJ
0.030 ES F 3:1 900 PSI
CDL
TP EY
EA ED G 3:1 600 PSI
FRONT EB EC
FA FI LEFT I 3:1 2200 PSI
REAR M1 FB FC M2
LEFT
LS J 1.5:1 2000 PSI
LBRAKE LBRAKE
K 1:1 600 PSI
P1
L2SPEED L2SPEED
EO
R2SPEED R2SPEED EP Note: 'alpha' callouts refer
0.1GPM
RBRAKE RBRAKE
T to components shown in the
manifold illustrations.
T1
4WD TRACTION MANIFOLD FOUR WHEEL STEER MANIFOLD
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-61


5-61
5-62

5-64
5-63

T P
PLATFORM MANIFOLD
TURNTABLE ROTATE PRIMARY LIFT PRIMARY 1 EXT. PRIMARY 2 EXT. P1 3 gpm 3 gpm
S-125
P3 OUT T2 3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM
CB
TEST CD PRL
DISTRIBUTION CE D
PLATFORM ROTATE
T1 CO 0.030 CA
G G F G
AG
MANIFOLD 3000 psi AC E
0.3 GPM
P1 IN P1 OUT E
AD
HIGH 3.0 GPM CC
T1 PRR
PRESS P2 IN A B
FILTERS AF P2 OUT 0.030
CHARGE FILTER D
AA 0.1GPM CI
AB AE CF
100 100
87 PSI PSI A B PLU
PSI P2A IN P3A IN CP
C CH C
CG
PLATFORM LEVEL
PLD
0.63 GPM
2500 psi
J
B Ps Fa Fe 1-2 1-2 0-1 CJ
1-2 0-1
TRL TRR UP DWN EXT EXT RET RET
EXT
CM JU
CL
BO
1.25 GPM / 0.75 GPM

BH BN CK D
b a
Mb 1800psi
H BA
JIB
BQ JD
4250 25
PSI 3000 psi CN
PSI BC
BR LS
M 1.7 .3 AUX. BD
CQ D
PUMP 500 psi
E 6 17 10 4.6 in.cu.
BF
4250 BB
BG
PSI
290
PSI 25
PSI
25 PSI
P1 PLATFORM ROTATE
Ma
0.3 GPM
BL BJ BM TEST 0.030
A X2 R T1 T2 S
PRL
X1 GE D
GO GD
GB GA
LS
B A
T1 P2 OUT
P T1 GC
BK PRR
BP 0.040 DIA 0.030
TP
D
3 3 BI GF
PSI PSI
GI GH
2600 psi 0.1 GPM PLU
TANK
T
BE
FUNCTION MANIFOLD T1 GG
C
HYDRAULIC SWIVEL PLD

GJ
LS
4 WHEEL DRIVE B J
MANIFOLD A GQ
A B T 3 gpm PLATFORM LEVEL
B 500 psi 0.47 GPM
4.6 in.cu.
RB A
P 3 gpm PLATFORM MANIFOLD
REAR FRONT LEFT FRONT RIGHT FRONT AXLE EXTENSION
REAR AXLE EXTENSION S-120
RIGHT REAR LEFT REAR RIGHT
I D I D
FRONT STEERING STEERING
DL RIGHT
COUNTERBALANCE
FRA
VALVE
DH FLR FLB FRB FRR FAE FAR RLR RLB RRB RRR
DK P RAE RAR RATIO
RA
FLB
PRESS
AUXILIARY
DRIVE EK EM EG EH A 5:1 5000 PSI
50% A OPTION B
LB 50%
50%
ENN EJJ EKK EII EOO EPP EMM ELL B 4.5:1 5000 PSI
50%
2.0 GPM
0.1GPM
DC DE C 1.5:1 3000 PSI
DF 1.40 2.00 2.00 1.40 EX 1.40 2.00 2.00 1.40
DB 50%
50% DD JE JD GPM GPM GPM GPM EQQ GPM GPM GPM GPM
D 3:1 3000 PSI
JF JC
EQ EV ER EW ET EE
2.0 GPM
1800 psi EU EJ E 4.5:1 3000 PSI

DI
FRONT TP
2.7 GPM EY
DG FLA
LEFT
EB EA F 3:1 900 PSI
REAR ES ED EC
JA JB
LS LS
G 3:1 600 PSI
LEFT LA DJ 250 PSI TEST
DM P1
H 3:1 3200 PSI
DP P1 EZ
TANK 3000 psi I 3:1 2200 PSI
EP EO
DN 0.030 T
0.1GPM J 1.5:1 2000 PSI
DO DA
BRAKE BRAKE T1 Note: 'alpha' callouts refer
FOUR WHEEL STEER MANIFOLD to components shown in the
2 SPD 2 SPD manifold illustrations.
5-64 S-100 • S-105 • S-120 • S-125 Part No. 1268494


Primary extension
CB valve ratio changed
to ‘K’ at Serial No. 562 T P
PLATFORM MANIFOLD
HIGH
PRESS TURNTABLE ROTATE PRIMARY LIFT PRIMARY 1 EXT. PRIMARY 2 EXT. P1 3 gpm 3 gpm
S-125
CHARGE FILTER FILTERS 3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM
CB
TEST CD PRL
CE D
PLATFORM ROTATE
100 100
87 PSI PSI G G F G CO 0.030 CA
PSI
E E
0.3 GPM
CC
A B T1 PRR
0.030
D
0.1GPM CF CI
B Ps Fa Fe
Drive Pump changed A B
PLU
to 9 GPM at C CP
CH C
Serial No. 1029 CG
PLATFORM LEVEL
b a
PLD
Mb
0.63 GPM
4250
PSI
1-2 1-2 0-1 1-2 0-1
P3 T2 TRL TRR UP DWN EXT EXT EXT RET RET J
CJ
Oil Cooler location
E 6 17 10 before Serial No. 985 BN
BO
AUX. CM JU
AE CL
4250
1.25 GPM / 0.75 GPM

1800psi
PSI PUMP OIL COOLER H CK D
290 P3A BH BA
PSI BQ
Ma .3 1.7 M
BC
JIB
TP3 BR JD
BD
A X2 R T1 T2 S 25 PSI CN
X1
30 PSI LS
BS CQ D
3000 psi BF BB 500 psi
Oil Cooler location BG
Check valve BS 4.6 in.cu.
25
PSI
25 after Serial No. 984 added at
PSI AC
OIL COOLER Serial No. 575
P2 BL BJ BM
3 3 P1 PLATFORM ROTATE
PSI PSI AF 0.3 GPM
AD
TANK TEST 0.030
P1 AG PRL
GE D
25 PSI GO GD
BK GB GA
TP-4 AA .040 DIA
BP
Hydraulic Swivel T1 GC
PRR
P2A AB
numbered at 4 3 1
BI 230 psi
2 5 0.1GPM 0.030
Serial No. 1032 TP2-4 D
BE
2600 psi
GF
GI GH
HYDRAULIC SWIVEL 4 3 1 2B 2A 5
T1
PLU
T3 P2 OUT LS C
Valve BP changed from FUNCTION MANIFOLD GG
110 psi to 230 psi
4 WHEEL DRIVE at Serial No. 575 PLD
B GJ
MANIFOLD
A
LS
B J
RB
A FRONT AXLE REAR AXLE GQ
T 3 gpm PLATFORM LEVEL
EXTENSION EXTENSION 500 psi 0.47 GPM
FRONT LEFT FRONT RIGHT
4.6 in.cu.
REAR
RIGHT
P 3 gpm PLATFORM MANIFOLD
I D I D
FRONT S-120
DL RIGHT REAR LEFT STEERING REAR RIGHT STEERING
FRA
DH FLR FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR
RA DK P
FLB
AUXILIARY COUNTERBALANCE VALVE
DRIVE EK EM EG EH
50% A OPTION B RATIO PRESS
LB 50% ENN EJJ EKK EII EOO EPP EMM ELL
50% 50%
0.1GPM A 5:1 5000 PSI
2.0 GPM
DC DE
DF 1.40 2.00 2.00 1.40 EX 1.40 2.00
B 4.5:1 5000 PSI
50% 2.00 1.40
DB 50% DD JE JD GPM GPM GPM GPM EQQ GPM GPM GPM GPM 1.5:1 3500 PSI
JF JC C
EQ EV ER EW ET EE
2.0 GPM
1800 psi EU EJ
DI D 3:1 3000 PSI
FRONT TP
2.7 GPM EY
REAR DG FLA EB EA E 4.5:1 3000 PSI
LEFT EC
LEFT JA JB ES ED
LS LS F 3:1 900 PSI
LA DJ 250 PSI TEST
DM
G 3:1 600 PSI
DP P1 P1
EZ
TANK 3000 psi H 3:1 3200 PSI
EO
EP I 3:1 2200 PSI
DN 0.030 0.1GPM
T
J 1.5:1 2000 PSI
DO DA K 1:1 600 PSI
BRAKE BRAKE T1
Manifold relief valve FOUR WHEEL STEER MANIFOLD
2 SPD 2 SPD
EZ was removed at Note: 'alpha' callouts refer
Serial No. 522
to components shown in the
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-65


5-65
5-66

5-68
5-67

PRIMARY LIFT PRIMARY 1 EXT. PRIMARY 2 EXT.
TURNTABLE ROTATE
3 GPM
11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM PLATFORM MANIFOLD
T P
S-125
P1 3 gpm 3 gpm
CHARGE FILTER K G F G
HIGH CB
TEST CD PRL
PRESS E E CE D
PLATFORM ROTATE
FILTERS CO 0.030 CA
87
0.3 GPM
PSI A B
CC
100 100 T1 PRR
PSI PSI 0.030
D
M1 E D 0.1GPM CF CI
A B
PLU
C CP
C
PLATFORM LEVEL
CH CG
315
PSI
PLD
0.63 GPM
M5
A
3625
M4 PSI CJ
J
1-2 1-2 0-1 1-2 0-1
P3 T2 TRL TRR UP DWN EXT EXT EXT RET RET CM JU
CL
9 17 10
1.25 GPM / 0.75 GPM

E 3625 BN BO
CK D
PSI AUX. AE 1800psi

BA JD
JIB
PUMP BQ
H BH
CN
P3A
BR LS
.3 1.7 M
BC
D
TP3 CQ
BD 500 psi
B L1 L2 M2 S 4.6 in.cu.
30psi BS
BG BF BB
3000 psi
25 25 PLATFORM ROTATE
PSI PSI AC P1 0.3 GPM
TEST 0.030
P2 BL BJ BM PRL
GE D
3 3 GO GD GA
PSI PSI GB
AF AD
TANK
P1 AG GC
T1
PRR
BK 0.030 D
TP AA
BP 0.040 DIA GF
GI GH
PLU
4 3 1 2 5 P2A AB C
230 psi GG
BI 0.1GPM
HYDRAULIC SWIVEL TP2
2600 psi
BE PLD
3 2B 2A GJ
4 1 5
T1 LS
J
T3 P2 OUT LS GQ
PLATFORM LEVEL
FUNCTION MANIFOLD 500 psi
4.6 in.cu.
0.47 GPM
3 gpm 3 gpm
T P
EXTENSION EXTENSION PLATFORM MANIFOLD
TEST A B TO FUNCTION MANIFOLD T2
T S-120
X
TO FUNCTION MANIFOLD P3
FRONT FRONT LEFT FRONT RIGHT
REAR M7 M8 RIGHT I D I D
RIGHT STEERING STEERING
FR FH REAR LEFT
REAR RIGHT
STEERING
STEERING
FE
CDR
FF M6
M5
50% P FLR FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR
50%
FP FJ
280 PSI
FN 2.0 2.0 EK EM EG
EH
GPM GPM FL
FQ 50% 50% ENN EJJ EKK EII EOO EPP EMM ELL
COUNTERBALANCE VALVE
50% 50% RATIO PRESS
2.0 GPM FM
FD FK 1.40 2.00 2.00 1.40 EX 1.40 2.00 A 5:1 5000 PSI
M3 2.00 1.40
M4 GPM GPM GPM GPM EQQ GPM GPM GPM GPM B 4.5:1 5000 PSI
FG FD EQ EV ER EW 1800 psi ET EE EU EJ
ES C 1.5:1 3500 PSI
TP
0.030 EY D 3:1 3000 PSI
EB EA ED EC
CDL E 4.5:1 3000 PSI
FRONT
FA FI LEFT LS F 3:1 900 PSI
REAR M1 FB FC M2
LEFT G 3:1 600 PSI
P1
LBRAKE LBRAKE
H 3:1 3200 PSI
L2SPEED L2SPEED EO
EP I 3:1 2200 PSI
T 0.1GPM
R2SPEED R2SPEED J 1.5:1 2000 PSI
K 1:1 600 PSI
RBRAKE RBRAKE
T1
FOUR WHEEL STEER MANIFOLD Note: 'alpha' callouts refer

4WD TRACTION MANIFOLD to components shown in the
5-68 S-100 • S-105 • S-120 • S-125 Part No. 1268494


T P
TURNTABLE ROTATE PRIMARY LIFT PRIMARY 1 EXT. PRIMARY 2 (SECONDARY) EXT.
3 GPM 11 GPM / 5 GPM 18 GPM / 6 GPM 18 GPM / 5 GPM P1 3 gpm 3 gpm
CB
TEST PRL
CE CD
D
PLATFORM ROTATE
CHARGE FILTER A B K G F G CO 0.030 CA
HIGH
PRESS E E
0.3 GPM
FILTERS
87 CC
PSI A B T1 PRR
100 100 0.030
PSI PSI D
0.1GPM CF CI
M1 E D C PLU
CP
CH C
PLATFORM LEVEL
C CG
315
PSI
0.63 GPM
M5 PLD
A
3625
M4 PSI J
1-2 CJ
1-2 0-1 1-2 0-1
P3 T2 TRL TRR UP DWN EXT EXT EXT RET RET
CM JU
E 3625 9 17 10 BN BO
CL
1.25 GPM / 0.75 GPM

CK D
PSI AUX. AE 1800psi
BA BQ
PUMP
P3A JD
JIB
BR
.3 1.7 M
BC
CN
TP3 LS
BD
D
B L1 L2 M2 S 30psi BS CQ
500 psi
BG BF BB
4.6 in.cu. PLATFORM MANIFOLD
3000 psi
S-125
25 25
PSI PSI AC
PLATFORM ROTATE
P2 BL BJ BM P1
0.3 GPM
3 3
PSI PSI AF 0.030
AD TEST PRL
TANK GE D
P1 AG GO GD
GB GA
BK
TP AA
BP 0.040 DIA T1 GC
PRR
0.030 D
P2A AB
230 psi 0.1GPM
BI GF
TP2 GI GH
BE PLU
2600 psi
C
T1 GG
4 3 1 2 5
T3 P2 OUT LS
HYDRAULIC SWIVEL FUNCTION MANIFOLD GJ
PLD
4 3 1 2B 2A 5 LS
J
GQ
PLATFORM LEVEL
500 psi 0.47 GPM
4.6 in.cu.
3 gpm 3 gpm
T P
PLATFORM MANIFOLD
TO FUNCTION MANIFOLD T2
TO FUNCTION MANIFOLD P3
S-120
T TEST A B EXTENSION EXTENSION
X
FRONT
REAR M7 M8 RIGHT
RIGHT FRONT LEFT FRONT RIGHT I I REAR LEFT REAR RIGHT
D D
FR FH STEERING STEERING STEERING STEERING
FE COUNTERBALANCE VALVE
CDR
FF M6 RATIO PRESS
M5
A 5:1 5000 PSI
50% 50% B 4.5:1 5000 PSI
P FLR FLB FRB FRR FAE FAR RAE RAR RLR RLB RRB RRR
FP FJ
280 PSI C 1.5:1 3500 PSI
FN 2.0 2.0
GPM GPM FL EK EM EG D 3:1 3000 PSI
FQ 50% EH
50%
E 4.5:1 3000 PSI
50% 50% ENN EJJ EKK EII EOO EPP EMM ELL
2.0 GPM FM F 3:1 900 PSI
FD FK
M3 M4 G 3:1 600 PSI
1.40 2.00 2.00 1.40 EX 1.40 2.00 2.00 1.40
FG FD GPM GPM GPM GPM EQQ GPM GPM GPM GPM
EQ EV ER EW 1800 psi ET EE EU EJ I 3:1 2200 PSI
0.030 ES
TP J 1.5:1 2000 PSI
EY
CDL EB EA ED
FRONT EC K 1:1 600 PSI
FA FI LEFT
REAR M1 FB FC M2
LEFT LS
LBRAKE LBRAKE
P1
L2SPEED L2SPEED Note: 'alpha' callouts refer
EO
R2SPEED R2SPEED
EP to components shown in the
T 0.1GPM
RBRAKE RBRAKE
T1
FOUR WHEEL STEER MANIFOLD
4WD TRACTION MANIFOLD
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-69


5-69
5-70

(from serial number 3146 to S12514D-921)
5-72
5-71

(from serial number 3146 to S12514D-921)
5-72 S-100 • S-105 • S-120 • S-125 Part No. 1268494


(from serial number S12514D-922)
Part No. 1268494 S-100 • S-105 • S-120 • S-125 5-73


(from serial number S12514D-922)
5-73
5-74
9
8
7
6
5
4
3
2
1
11
13
12
10
AXLE RETRACT
AXLE EXTEND
P2
P1
P8
P7
P6
P2
P1
P2
P1
P5
P4
P3
P2
P1
P11
P33
P32
P31
P30
P29
P28
P27
P26
P25
P24
P23
P21
P20
P10
P18
P17
P16
P157
MOTOR SPEED
VLVRET-BR P2-01 VALVE RTN1
J2
J1
J8
J7
J6
J2
J1
J2
J1
J5
J4
J3
J2
J1
J11
J33
J32
J31
J30
J29
J28
J27
J26
J25
J24
J23
J21
J20
J10
J18
J17
J16
J157
V61AXRT-GR P2-02 AXLE RETRACT
J144
BRAKE
V60AXEX-GR/WH P2-03 AXLE EXTEND PLUG NO JACK NO
RR STEER RIGHT V29MS-RD/WH P2-04 MOTOR SPEED

RD P2-05
A
P2-06
A
BL P2-07
B
BK V36RRS-BL P2-08 RR STEER RIGHT
C
LR STEER RIGHT V37RRS-BL/BK P2-09 RR STEER LEFT
RD C111RRS-OR P2-10 RR STEER SNSR
A
C111LRS-OR P2-11 LR STEER SNSR
PCON MANIFOLD/TILT SENSOR

BL C111RFS-OR P2-12 RF STEER SNSR
B
10 WAY ENGINE HARN TO ENGINE
TCON PCB TO MEMBRANE SWITCH
PCON PCB TO MEMBRANE SWITCH

BK C111LFS-OR P2-13 LR STEER SNSR
C
4 WAY ENGINE HARN-AC GENERATOR
6 WAY ENGINE HARN TO TILT SENSOR
9 WAY DEUTSCH TETHER CONNECTOR
2 WAY DEUTSCH-PWR HARN/ENG HARN

RF STEER RIGHT VLVRET2-BR P2-14 VALVE RTN2
RD V32BRK-WH/RD P2-15 BRAKE
A
2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
CONNECTOR DESCRIPTION AND/OR LOCATION
2 WAY DEUTSCH SLIP RING TO DCON HARNESS

V36LRS-BL P2-16 LR STEER RIGHT
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR

6 WAY DEUTSCH DCON SLIP RING TO DCON HARN
BL V37LRS-BL/BK P2-17 LR STEER LEFT
B
BLACK 23 PIN AMP CONNECTOR TCON TO BOOM HARN
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN

BLACK 35 PIN AMP CONNECTOR TCON TO LIMIT SWITCH
V36RFS-BL P2-18 RF STEER RIGHT

WHITE 23 PIN AMP CONNECTOR TCON TO ENGINE HARN
BK
C
6 WAY DEUTSCH DCON SAFETY SW LIMIT SW TO SLIP RING
BLACK 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN
8 WAY DEUTSCH LIMIT SW HARN TO UPPER LIMIT SW HARN

LF STEER RIGHT P110RT-BK P2-19 STEER SNSR GND

2 WAY DEUTSCH LOAD SENSE LIMIT SWITCH TO BOOM HARN
3 WAY DEUTSCH CAN CONNECTOR SLIP RING TO DCON HARN

3 WAY DEUTSCH CAN CONNECTOR BOOM HARN TO SLIP RING
4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN

2 WAY DEUTSCH DCON ECU PWR LIMIT SW HARN TO SLIP RING
WHITE 35 PIN AMP CONNECTOR TCON TO FUNCTION MANIFOLD
RD P109ANG-GR/WH P2-20 STEER SNSR PWR

WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
A
V37RFS-BL/BK P2-21 RF STEER LEFT
BL V36LFS-BL P2-22 LF STEER RIGHT
B
BK V37LFS-BL/BK P2-23 LF STEER LEFT
C
B
RR STEER RIGHT
ALARM-
RR STEER LEFT
PCON
ALARM+
ALARM
LR STEER RIGHT
LR STEER LEFT
S1-1
RF STEER RIGHT
S1-2
P20
J20
RF STEER LEFT
ROTATE
J2 WHITE 23 PIN
1 S1-3
LF STEER RIGHT
DRIVE CHASSIS HARN

2
LF STEER LEFT S2-1
3
S2-2
LEVEL
4
S2-3
5
PLATFORM PLATFORM
6 S3-1
JIB
3
7 S3-2
P
LSAX1RO GND-DCON-BR P1-01 DCON ECU GND
4
8 S3-3
P21DCON-WH P1-02 DCON ECU PWR
9
P53LS-RD P1-03 P_6R1
10
TERM 3 & 4
P1-04
J1-BL/BK
ARE CLOSED
WHEN AXLES
11
LIMIT SWITCHES
S56PRV-RD P1-05 P_7R
AXLE RETRACTION
3
ARE RETRACTED
12
C
P
LSAX2RO C61AXRT-GR P1-06 P12
4
13
P1-07 P1
14 H1_GND 1
P61LS-GR P1-08 AXLE NOT RET PWR
15 H1_PWR 2
C61LS-GR P1-09 AXLE NOT RET SIG
16 H1_XOUT 3
P1-10 CAN SHIELD
P
LSAX1EO 17 H1_YOUT 4
P1-11 RS232 RXD
4
JOYSTICK
18 5
BOOM UP/DWN &
P1-12 RS232 TXD

TURNTABLE ROTATE
19 6
P1-13 BOOT
20
TERM 3 & 4
J4-GR/BK
P1-14
ARE CLOSED
WHEN AXLES
21 P2
ARE EXTENDED
C61LS(A)-GR P1-15 AXLE NOT EXT SIG
LIMIT SWITCHES
H2_GND 1
AXLE EXTENTION
P
LSAX2EO 22
P1-16 2
4
H2_PWR
23
D81CAN- -GR P1-17 CAN LOW 3
24
D82CAN+ -YL P1-18 CAN HIGH H2_YOUT 4
25
JOYSTICK
P1-19 RS232 GND 5

BOOM EXT/RET
26
P57PBD-RD/WH P1-20 6
27
31
P1-21
LSAX1ES 28
P1-22 P3
H3_GND 1
24
29
P61LS(A)-GR P1-23 AXLE NOT EXT PWR
D
30 H3_PWR 2
3
H3_YOUT 4
NOT USED
J2-BL/RD
J3-OR/BL
5
AXLE NOT EXT

LIMIT SWITCHES
6
31
LSAX2ES P4
J1 BLACK 23 PIN
DCON
C60AXEX-GR/WH H4_GND 1
24
P63LS-OR/RD
DRIVE CHASSIS HARN

H4_PWR 2
H4_XOUT 3
H4_YOUT 4
J18-DRIVE CHASSIS HARN

JOYSTICK

H4_RKOUT 5
DRIVE & STEERING
NOT USED 6
ECU
ESTOP_2
VLVRET-BR P1-01 VLV RTN

PCON
E-STOP
OUT PWR ENABLE
P1-02
GNDDCON-BR
ESTOP_1
PWR-PCON ESTOP
P57PBD-RD/WH
P21DCON-RD
S56PRV-RD
C61AXRT-GR
P53LS-WH/BK
P63LS-OR/RD
D81CAN- -GR
D82CAN+ -YL
C60AXEX-GR/WH
PLAT ROT CCW C17PRL-GR P1-03 ON/OFF VLV3_A
PLAT ROT CW C18PRR-GR/BK P1-04 ON/OFF VLV3_B
E
C
A
B
4
5
3
2
2
6
1
1
JIB UP C43JU-GR P1-05 PROP VLV2_A
JIB DOWN C44JD-GR/BK P1-06 PROP VLV2_B
C
A
B
4
5
3
2
2
6
P16
P18
1
1
P17
OPTIONAL
PLAT LEVEL UP C14PLU-OR P1-07 PROP VLV1_A

PROX KILL SW.
P157
GR
PLAT LEVEL DN C15PLD-OR/BK P1-08 PROP VLV1_B
YEL
YL
BL
BK
BR
OR
RD
GR
31
WH
P1-09
J157
R90PXS-RD/BK P1-10 PROX KILL GND

88
88
88
24
88
88
88
88
88
88
88
88
C90PXS-RD/BK P1-11 PROX KILL CMD
GR/YL P1-12 LOAD SNSR GND
P12
P11
P18
P9A
P7R
WH P1-13 LOAD SNSR OUT
P6R1
OR
(SLIP RING)
(SLIP RING)
CAN LOW
CAN HIGH
BK P1-14 LOAD SNSR PWR

BK
CAN SHIELD
ES0509J
RD C88PTS-RD/BK P1-15 SAFE PL TILT OUT
YL
BL
DCON GND BK
R56PTS-RD
1
BR
P1-16 FOOT SW PWR
DCON PWR RD
GR
OR
WH
GR
YEL
C56PTS-RD P1-17 FOOT SW RTN
6
5
4
3
2
1
2
1
B
A
LOAD SENSOR OPTION
C
J6
J7 P1-18
J8
1
PLAT SENSOR GND PLATRET-BR P1-19 PL TILT SNSR GND

B
A
6
5
4
3
2
1
2
1
C
2
2
TILT SENSOR SIG OUT C84TAY-GR/BK P1-20 PL TILT SNSR

FOOTSWITCH
3
TILT SENSOR PWR P85PTS-GR P1-21 PL TILT SNSR PWR

F
TILT SWITCH GND PTSRET-BR P1-22 SAFE PL TILT GND U20

5
PWR TO TILT SWITCH P87PTS-RD P1-23 SAFE PL TILT PWR
Electrical Schematic
Genie S-125(from serial number S12515D-984)
6
S132LDS-BL/WH
PLATFORM
ASSEMBLY

OUT FRM TILT SWITCH
P6-BOOM HARN
TILT SENSOR
P7-LIMIT SW HARN
P8-LIMIT SW HARN
P33-PCON
MANIFOLD
J31-TILT SNSR
PCON MANIFOLD
J2 WHITE 23 PIN
R56PTS-RD P1-15 SAFE PL TILT OUT

P1
PCON
31
C56PTS-RD P1-16 FOOT SW PWR 1

KILL
PROX
P1
24
2 HORN
1
P1
3 AC GENERATOR
OPTIONAL
P1
PROXIMITY
KILL WIRING
4 AUXILIARY
2
FOOTSWITCH
G
P1
5 START ASSIST
GNDPCON-BR P1-01 PCON GND P1

PCON MEMBRANE PANEL
6 START
P52PCON-WH P1-02 PCON PWR
1
P1-03 P1
FUSE 2 7 DRIVE ENABLE
S56PRV-RD/WH P1-04 P7
K2
K1
3
J3 10PIN
5A P1
2 86
2 86
1 30
P1-05
1 30
4 SPARE 1
P6R
8
P7R
P1-06
87
87
5
85 5
85 5
P1
4
87a 3
4
87a 3
P56PRV-RD P1-07 P22

6 9 AXLE RETRACT
P1-08
7
P1-09 P1
8 10
J1 10PIN
P1-10 CAN SHIELD

9
P1-11 RS232_RXD
10 P2
P1-12 RS232_TXD 1 ENGINE SPEED
P1-13 BOOT
P2
P1-14 2 AXLE EXTEND
J2 10PIN
C47OUT-WH/BK P1-15 OUT PWR ENBL

P2
C46HN-WH P1-16 HRN RLY CNTRL 3 DRIVE SPEED
H
D81CAN- -GR P1-17 CAN-

P2
D82CAN+ -YL P1-18 CAN+ 4 FRONT STEER
P1-19 RS232_GND
P2
P1-20 5 REAR STEER
P1-21
P2
P1-22 6 CRAB STEER
P23PCON-BK P1-23 PWR-PCON ESTOP

P2
7 COORD STEER
P2
8 SPARE 2
P2
BOOM HARN
MEMBRANE/LED INTERFACE CARD
9 FUEL TYPE
P2
J1 BLACK 23 PIN
10
I
P52PCON-WH
D82CAN+ -YL
D81CAN- -GR
P56PRV-RD
D81CAN- -GR
C46HN-WH
D82CAN+ -YL
GNDPCON-BR
S56PRV-RD
P63LS-OR/RD
C47OUT-WH/BK
S56PRV-RD/WH
C61AXRT-GR
P23PCON-BK
GNDDCON-BR
P21DCON-RD
P53LS-WH/BK
P57PBD-RD/WH
C60AXEX-GR/WH
S132LDS-BL/WH
5A
FUSE
GNDPCON-BR P1-01 PCON GND

BK
P52PCON-WH P1-02 PCON POWER
RD
C46HN-WH P1-03 HORN RELAY COIL
C47OUT-WH/BK P1-04 OUT PWR ENBL LT BL
P23PCON-BK P1-05 PWR-PCON ESTOP PR
S56PRV-RD/WH P1-06 P_7 YL/WH
P56PRV-RD P1-07 P_22 GR/WH
R48LP-WH/RD P1-08 WORK LT
SERV. BYPASS
RUN
R117FB-RD P1-09 FLASHING BEACON ALARM GND 16

RECOVERY
P1-10 CAN SHIELD ALARM PWR 15

P1-11 RS232 RXD TCON MODE 14
J
P1-12 RS232 TXD P11 13

S132LDS-BL/WH P1-13 LOAD SENSOR INPUT P7 12
P56PRV-RD
P1-14 CAL FREQ 1 OPER. REC. 11 OR

P97TET-BK P1-15 TET ESTOP PWR P22 10 LT GR
P1-16 NOT USED P15 SERV. OR OPER. REC. 9 WT
D81CAN- -GR P1-17 CAN LOW P7R 8 BR
D82CAN+ -YL P1-18 CAN HIGH P6R1 7 GY
P1-19 RS232 GND OUTPUT PWR ENABLE 6 PR
P1-20 PCON MODE 5 BL
P1-21 TO MICRO TCON OR PCON MODE 4 YL
P1-22 TETHER ESTOP 3
PCON
TCON
J27-BOOM HARN
P95TET-OR P1-23 TET ESTOP RET TCON ESTOP 2

OFF
PWR TO TCON ESTOP 1
GR
86
86
87
87
TO WORK LIGHTS 87a
TO FLASHING BEACON 87a
PK
30
85
30
85
BOOM HARN
K
TN
12 VOLT
J1 BLACK 23 PIN
P27-LIMIT SW
PRI LO#1 O
SERV. OR SERVICE OR
RECOVERY BM 100' I
OPER. REC. MODE
BM 3' I
P15 PWR IN SERV OR BM DWN ST I
RECOVERY
PROVIDES PWR AUX HYD O
TO MINIMAL MLT FNC VLV O
HARDWARE
BM RET O
BM DWN O
BM E/R FC O
PLD
BM U/D FC O
L
P56PRV-RD
P23PCON-BK
GNDDCON-BR
P21DCON-RD
S56PRV-RD
C61AXRT-GR
P57PBD-RD/WH
P63LS-OR/RD
P53LS-WH/BK
C60AXEX-GR/WH
S56PRV-RD/WH
TCON
J27
P27
P53LS-WH/BK
GNDDCON-BR P2-01 DCON ECU GND
P53LS-WH/BK
5 31
P21DCON-RD P2-02 DCON ECU PWR

P54ENG-BK/WH 3-10A
LSB2RS P_6R1
SJ2-BK/RD P53LS-WH/BK P2-03
101'
SJ1-WH/RD P54ENG-BK/WH P2-04 P_6R2
24 6
S2PLD2-GR/BK S56PRV-RD P2-05 P_7R

J21
P21
C69PBE-BK FUSE
8 WAY
P_9A
8 WAY
P57PBD-RD/WH
P56PRV-RD
P2-06
31
1
LSB2RO P58LS-RD/BK P58LS-RD/BK P2-07 P_9B

M
100' P53LS-WH/BK S59CNBK-GR/WH P2-08 P_10

24
3
C64LS-OR/BK P54ENG-BK/WH C60AXEX-GR/WH P2-09 P_11

BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
TO HORN BUTTON
PRI BOOM DOWN STATUS
LOCKOUT VALVE #1 SIG
BOOM DWN RECOVERY SIGNAL
PRI BOOM LENGTH 3' STATUS
PWR TO TCON ESTOP

MULTI FUNCTION VLV RECOVERY SIGNAL

AUXILIARY HYD RECOVERY SIGNAL
C69PBE-BK C61AXRT-GR P2-10 P_12

5
S59CNBK-GN/WH S62BSTO-OR P2-11 P_14

P264 WAY
J264 WAY1
6
S59CNBK S2PLD1-BL/RD P63LS-OR/RD P2-12 P_18

2
P_6R2
31
7
OUT PWR ENABLE
P7R
PCON POWER
P9A
P11
P6R1
P10
S2PLD2-GR/BK C64LS-OR/BL P2-13 OPER SW PWR

P_7
P_22
LSB6S
TCON MODE
3
8
CHNBRK C65LOFL-BL/WH P2-14 FST1S

TO PLD
24
4
P63LS C66DREN-BL P2-15 LST10

TO MICRO
1
C76PBE-BL SJ1-WH/RD P2-16

31
2
LSB4EO SJ2-BK/RD C68PBD-RD P2-17 LSB1DO

3
100' EXT C76PBE-BL C69PBE-BK P2-18 LSB2RO

TO PLD
24
4
C64LS-OR/BK C70PBE-BL/WH C70PBE-BL/WH P2-19 LSB3RO

TO MICRO
5
C71PBE-BL/BK P63LS-OR/RD C71PBE-BL/BK P2-20 LSB3EO

6
31
S62BSTO-OR P2-21
LSB3EO
7
75' EXT C61AXRT-GN P2-22

24
8
C64LS-OR/BK P57PBD-RD/WH V74PRLO-RD P2-23 PRI#1 LO TO PLD

S62BSTO-OR C64LS-OR/BK V75PRLO-RD/WH P2-24 PRI#2 LO TO MICRO
31
P63LS-OR/RD C71PBE-BL/BK SNSR GND-BR P2-25 SNSR GND

N
LSB3RS
3.5 EXT P57PBD-RD/WH SJ3-WH P2-26
TO MICRO
24
9 10 11 12
C61AXRT-GN S56PRV-RD G119SR-BL P2-27 AUX HYD PRESS SIG

P53LS-WH/BK C76PBE-BL P2-28 LSB4EO
P20
J20
SJ1-WH/RD C77AS-WH P2-29 LSB13AO

12 WAY
5 31
12 WAY
SJ2-BK/RD C78PS-WH/BK P2-30

LSB4ES LSB14AO
75.5' P58LS-RD/BK P2-31
P53LS-WH/BK
P57PBD-RD/WH
24 6
SJ1-WH/RD P2-32
S2PLD1-BL/RD
5 31
SJ2-BK/RD P2-33
C70PBE-BL/WH LSB8AS
50 DEG P58LS-RD/BK P2-34
31
S56PRV-RD
LSB3RO P57PBD-RD/WH VLVRET1-BR P2-35 VLV RET
24 6
3' EXT SJ3-WH S7PLE1-BL/BK

24
C64LS-OR/BK P53LS-WH/BK
P53LS-WH/BK
5 31
LSB9AS P54ENG-BK/WH
65 DEG SJ2-BK/RD
SJ1-WH/RD
24 6
S7PLE2-GR/WH
J2 BLACK 35 PIN
C78AS-WH/BK
3
LIMIT SWITCH HARNESS
LSB14AO
P
O
68 DEG C64LS-OR/BK
4
C77AS-WH
3
1
LSB13AO
P
53 DEG C64LS-OR/BK
4
2
S56PRV-RD
3
31
31
C60AXEX-GN/WH
4
LSB7DS
11 DEG P53LS-WH/BK
24
24
S62BSTO-OR
P_7
P11
P_22
P10
P7R
P6R1
P9A
P_6R2
P_9B
PCON POWER
TCON MODE
OUT PWR ENABLE
C68PBD-BL
PWR TO TCON ESTOP
TO HORN BUTTON
31
SJ3-WH
LSB1DO
10 DEG P56PRV-RD
24
C64LS-OR/BK
C66DREN-BL
PRESSURE SENSOR
31
OPTIONAL HYDRAULIC
LST1O
DRV
S-120/125
ENABLE
24
C64LS-OR/BK
FST1S C65LOFL-BL/WH
1
LOW TELBAT-RD J224-01 SYS_POWER

LIMIT SWITCHES
C64LS-OR/BK
2
FUEL FS TELGND-BR J224-02 GROUD

P
PRI 1 LO V74PRLO-RD C211GN-WH J224-03 IGNITION STATUS

PRI 2 LO V75PRLO-RD/WH P23PCON-BK J224-04 STOWED STATUS
VLVRET1-BR S56PRV-RD/WH J224-05 FOOTSWITCH STATUS
6A
CB
J224-07 CAN HIGH

J224-08 CAN LOW
AUX MAIN TO MICRO

P_6R2
OUT PWR ENABLE
P_9B
PWR TO TCON ESTOP
-
+
P9A
P_7
TCON MODE
P_22
P6R1
P10
P7R
P11
PCON POWER
P114BAT-RD
MAIN (SYS)
BAT
ENGINE BLOCK
-
+
TCON
POWER HARN
START BAT
J5 BLACK 4 PIN
CB 5 5 5
85 87a 85 87a 85 87
U95
SYS_BAT_PWR
U32
BATVLV-RD P5-01 87 87a

25A 87
RELAY
20 A
P5-02 SYS_BAT_GND K5 86 30 K4 86 30 K3 86 30
70 A FUSE
BATGND-BR
FUSE
STARTER
AUX/START_BAT_GND 2 1 2 1 2 1
BATGND-BR P5-03
4

1
Q
P33STR-BK
30
TO MICRO
TO MICRO
2 1 2 1
2
5
87a 87 85
86
K1 86 30 K2 86 30
BAT GND-BR
85 87 87a 85 87 87a
5 4 5 4
2 1 2 1
2 1


K7 86 30 K8 86 30
TO MICRO
TO MICRO
AUX.
DETAIL B
PUMP
TO HORN BUTTON
K6 86 30
REMOTE
HIGH CURRENT VALVE PROPEL OUTPUT 87 87a 87 87a

85 85 87 87a
C21IGN-WH
C226TEL-BL
PR1 85
5
86
2
V30FWD-WH P3-05 FWD 5 4 5 4

VLVRET6-BR 5
-BAT
4
+BAT
+AUX
V31REV-WH/BK P3-06 REV

ENGINE HARN
4
J3 WHITE 23 PIN
P46HRN-WH
P116HYD-OR
30
CONTROL 85 87 87a
C27AUX-RD
TO MICRO
P3-01
MOM N.O.
+
BAT.
TIME DELAY
TROMBETTA

TO MICRO
C34SA-BK/WH P3-04 CHOKE/GLOW PLUG
P3-05 FWD
REGULATOR
BR-COM
WH-PULL
RD-HOLD
(DETAIL B ) P3-06 REV

-
ALTERNATOR

BAT.
STA.
IND.
EXCT.
TO MICRO
15A
R
TO MICRO
CB 7
J144-1 P3-08
TO MICRO
C31EDC-WH/BK P3-10 C31EDC-WH/BK
J144-2
P_22R
BAT GND-BR C107AF-RD C30EDC-WH P3-11 C30EDC-WH

J144-8
C26TSR-WH/RD P3-13 OIL/WATER_TEMP TO MICRO
4
1

30

2
5
86

HORN
P3-17
SERVICE
HORN
87a 87 85 RELAY
HI/LO

SPEED

1
SOLENOID

HOLD TO MICRO
2

PULL IN
3

P34SA-RD
VLVRET2-BR VLVRET3-BR P3-23 VALVE_RTN3
C31EDC-WH/BK
S
REV VLV B
SOLENOID
P114BAT-RD
S56PRV
BAT GND-BR
C30EDC-WH
C27AUX-RD
VLVRET6-BR
J32-ENG HARN
S2PLD1-BL/RD
S7PLE1-BL/BK
3
2
C45GEN-GR/WH 1
S2PLD2-GR/BK
S7PLE2-GR/WH
FWD VLV A
SOLENOID
P7R
P_22R
P10
RELAY
P9A
P11
P6R1
5
86
GLOW PLUG2
VLVRET2-BR C34SA-BK/WH J10

P10
START
4
15
1
R34SA-RD
30
85 87 87a
STRT ASST
GLOW PLUG 14
10 A
SCROLL R
30
1

4
13
GOLD VLV A SCRL F/ENT
SOLENOID
2
12
RELAY
87 85
86
P85TTSR-GR
C84TAY-GR/BK
RET85TTSR-BR
C83TAX-GR/WH
N.O.
SEE GENERATOR OPTIONS
- BUTTON
OTS1
86
5
HYD COOLER
11
2
P31-ENG
BAT GND-BR C116HYD-OR HARN
+ BUTTON
4
P116HYD-OR J31-TILT 10
1

30
85 87 87a
SNSR
T
BAT GND-BR R116HYD-OR GAS/LP

TILT
ENGINES SHOWN
9
SENSOR
FAN
ENG SPEED
TURNTABLE
4.5 DEGREE
BAT GND-BR
FUEL
8
S100- S/N 865
RELAY
RELAY ADDED
S120- S/N 2782
AUXILIARY
86
5
SOLENOID
2
VLVRET2-BR C21IGN-WH 7
DEUTZ BF4L-2011/TD2011-LO4I
R21IGN-WH
4
J144-7 SEC. UP
P21IGN-WH
1
30
85 87 87a
6
FUEL
RELAY
BOOM UP
SOLENOID
C25PSR-WH/BK 5
OIL PRESSURE
C26TSR-WH/RD 4
OIL TEMP SENDER

BAT GND-BR 3
TO PLD
1
TO MICRO
S2PLD2-GR/BK 2
2
S7PLE2-GR/WH
TCON
S7PLE1-BL/BK TO PLD 1
U
MANIFOLD HARN
J4 WHITE 35 PIN
S2PLD1-BL/RD TO MICRO
P23 J23 VLVRET4-BR P4-01 VALVE_RTN4
4WAY 4WAY
BOOM UP/DWN F.C. C03PBF-RD/WH P4-02 BOOM_UP/DOWN_VLV
P
BOOM EXT/RET F.C. C09PERF-BK/RD P4-03 BOOM_EXT/RET_VLV

P
TURNTABLE CW/CCW F.C. C06TRF-WH/RD P4-04 TURNTABLE_ROTATE_VLV

P
TO MICRO
P4-05 J11
P11 ROOM RET
P4-06 TO MICRO
15
BOOM UP VLV C01PBU-RD P4-07 BOOM_UP_VLV
BOOM DOWN
BOOM DWN VLV C02PBD-RD/BK P4-08 BOOM_DOWN_VLV
14
BOOM EXTEND VLV C07PBE-BK P4-09 BOOM_EXTEND_VLV TO MICRO
BOOM EXT
BOOM RET VLV C08PBR-BK/WH P4-10 BOOM_RETRACT_VLV TO PLD
13
P4-11
RABBIT
P4-12
12
R49LP - WH/BK P4-13 DRIVE LIGHTS RELAY TO MICRO
SEC. DOWN
P4-14 TO MICRO
11
S2PLD2-GR/BK P4-15 LSB2RS MONITOR INPUT TO PLD
12 VOLT
2 86
TURTLE
1 30
S7PLE2-GR/WH P4-16 LSB9AS MONITOR INPUT

10
87
V
S7PLE1-BL/BK P4-17 LSB8RS MONITOR INPUT

85 5
4
87a 3
BOOM CCW
S2PLD1-BL/RD P4-18 LSB4ES MONITOR INPUT
9
P4-19
PLTFRM CCW
P4-20 TO PLD
8
P4-21 TO MICRO JIB UP
P4-22
TO DRIVELAMPS
7
MULTI FUNC VLV C113MFV-OR/RD P4-23 MULTI_FUNCT_VLV
PLTFRM UP
P4-24 TO MICRO
6
TURNTABLE ROT CW VLV C05TTL-WH P4-25 ROTATE_CW_VLV
PLTFRM DOWN
TURNTABLE ROT CCW VLV C06TTR-WH/BK P4-26 ROTATE_CCW_VLV TO MICRO
5
VALVE RTN7 P4-27 VALVE_RTN7
JIB DOWN
P4-28
4
P4-29 TO PLD
PLTFRM CW
VALVE RTN6 P4-30 VALVE_RTN6 TO MICRO 3
ES0509C
P4-31
BOOM CW
C27AUX-RD P4-32 AUX_RELAY
2
TO AUX HYD RELAY PR1 P4-33
TCON MEMBRANE PANEL
P4-34
1
P4-35
W
86
K3
86
30
S56PRV-RD
S56PRV-RD
C61AXRT-GR
85
P21DCON-RD
P63LS-OR/RD
P53LS-WH/BK
86
86
30
GNDDCON-BR
P57PBD-RD/WH
C60XES-GR/WH
86
K5
30
30
87 87a
J27
30
K7
85 87 87a K8
86
GNDDCON-BR P2-01
86
86
K2
P27
30
P21DCON-RD P2-02
3-10A
30
30
85 87 87a 85 87 87a 85 87 87a
P53LS-WH/BK P2-03
85 87 87a K6 85 87 87a K1
P54ENG-BK/WH P2-04
P2-05
J21
S56PRV-RD
P21
FUSE
8 WAY
8 WAY
P57PBD-RD/WH P2-06
P56PRV-RD
P58LS-RD/BK P58LS-RD/BK P2-07

2
S59CNBK-GR/WH P2-08
31
LSB6S C60AXEX-GR/WH P2-09

4
X
CHNBRK C61AXRT-GR P2-10

24
5
(CKT C35RPM-BK/RD)
S62BSTO-OR P2-11
6
S2PLD1-BL/RD P63LS-OR/RD P2-12

TURNTABLE ROTATE VLV.
K1 POWERS CKT P22R OR
C64LS-OR/BL P2-13
8
P2-14
S-100/105
C65LOFL-BL/WH
ROTATE CW, AND ROTATE CCW.
C66DREN-BL P2-15
VALVES AUX RELAY, BOOM EXT/RET,
P53LS-WH/BK P2-16
LIMIT SWITCHES
2
85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES:
P2-17
PRIMARY VALVES 1 & 2, THROTTLE (IGN),
P54ENG-BK/WH C68PBD-RD
(FUEL ON/OFF SOLENOID AND ALT FIELD)
BOOM RETRACT, MULTIFUNCTION VALVE,
P2-18
CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE)
K7 POWERS THROTTLE OR HI/LOW SOLENOID

K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD,
C70PBE-BL/WH C70PBE-BL/WH P2-19

K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH
GLOW PLUG, STARTER RELAY, AC GENERATOR,
K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY
C71PBE-BL/BK P63LS-OR/RD C71PBE-BL/BK P2-20

K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
31
S62BSTO-OR P2-21
LSB3EO
7

K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.
24
8
P2-23
DETAIL E - TCON RELAY PARKING
C64LS-OR/BK P57PBD-RD/WH
S62BSTO-OR C64LS-OR/BK P2-24
31
P63LS-OR/RD C71PBE-BL/BK SNSR GND-BR P2-25

LSB3RS
24
P2-27
Y
C61AXRT-GN S56PRV-RD G119SR-BL

P2-28
9 10 11 12 J20
P20
P53LS-WH/BK
P53LS-WH/BK C77AS-WH P2-29
12 WAY
12 WAY
5 31
P54ENG-BK/WH P2-30
LSB4ES
75.5' P58LS-RD/BK P2-31
P57PBD-RD/WH P2-32
24 6
S2PLD1-BL/RD P2-33
P53LS-WH/BK
P2-34
5 31
C70PBE-BL/WH P54ENG-BK/WH
LSB8AS
31
S56PRV-RD 50 DEG P58LS-RD/BK P2-35

LSB3RO
3' EXT SJ3-WH P57PBD-RD/WH
24 6
24
C64LS-OR/BK S7PLE1-BL/BK
C66DREN-BL
3 1
LST1O
DRV
ENABLE
24
C64LS-OR/BK
J2 BLACK 35 PIN
FST1S C65LOFL-BL/WH
1
LOW
Z
C64LS-OR/BK
2
FUEL FS
1
C77AS-WH
2
LSB13AO
3
C64LS-OR/BK
4
53 DEG
S56PRV-RD
4
31
C60AXEX-GN/WH
LSB7DS
11 DEG P53LS-WH/BK
24
S62BSTO-ORN
C68PBD-BL
31
SJ3-WH
LSB1DO
10 DEG P56PRV-RD
PRESSURE SENSOR
24
C64LS-OR/BK
OPTIONAL HYDRAULIC
S7PLE1-BL/BK
S2PLD1-BL/RD
9
8
7
6
5
4
3
2
1
11
13
12
10
AXLE RETRACT
AXLE EXTEND
P2
P1
P8
P7
P6
P2
P1
P2
P1
P5
P4
P3
P2
P1
P11
P33
P32
P31
P30
P29
P28
P27
P26
P25
P24
P23
P21
P20
P10
P18
P17
P16
P157
MOTOR SPEED
VLVRET-BR P2-01 VALVE RTN1
J2
J1
J8
J7
J6
J2
J1
J2
J1
J5
J4
J3
J2
J1
J11
J33
J32
J31
J30
J29
J28
J27
J26
J25
J24
J23
J21
J20
J10
J18
J17
J16
J157
V61AXRT-GR P2-02 AXLE RETRACT
J144
BRAKE
V60AXEX-GR/WH P2-03 AXLE EXTEND PLUG NO JACK NO
RR STEER RIGHT V29MS-RD/WH P2-04 MOTOR SPEED

RD P2-05
A
P2-06
A
BL P2-07
B
BK V36RRS-BL P2-08 RR STEER RIGHT
C
LR STEER RIGHT V37RRS-BL/BK P2-09 RR STEER LEFT
RD C111RRS-OR P2-10 RR STEER SNSR
A
C111LRS-OR P2-11 LR STEER SNSR
PCON MANIFOLD/TILT SENSOR

BL C111RFS-OR P2-12 RF STEER SNSR
B
10 WAY ENGINE HARN TO ENGINE

BK C111LFS-OR P2-13 LR STEER SNSR
C
4 WAY ENGINE HARN-AC GENERATOR
6 WAY ENGINE HARN TO TILT SENSOR
9 WAY DEUTSCH TETHER CONNECTOR
2 WAY DEUTSCH-PWR HARN/ENG HARN

RF STEER RIGHT VLVRET2-BR P2-14 VALVE RTN2
RD V32BRK-WH/RD P2-15 BRAKE
A
2 WAY DEUTSCH-BOOM HARN/LIMIT SW HARN
CONNECTOR DESCRIPTION AND/OR LOCATION
2 WAY DEUTSCH SLIP RING TO DCON HARNESS

V36LRS-BL P2-16 LR STEER RIGHT
4 WAY LIMIT SW TO OPTIONAL HYD PRESS SNSR

6 WAY DEUTSCH DCON SLIP RING TO DCON HARN
BL V37LRS-BL/BK P2-17 LR STEER LEFT
B
BLACK 23 PIN AMP CONNECTOR TCON TO BOOM HARN
BLACK 23 PIN AMP CONNECTOR PCON TO BOOM HARN

BLACK 35 PIN AMP CONNECTOR TCON TO LIMIT SWITCH
V36RFS-BL P2-18 RF STEER RIGHT

WHITE 23 PIN AMP CONNECTOR TCON TO ENGINE HARN
BK
C
6 WAY DEUTSCH DCON SAFETY SW LIMIT SW TO SLIP RING
BLACK 4 WAY MOLEX CONNECTOR TCON TO ENGINE HARN
WHITE 23 PIN AMP CONNECTOR PCON TO MANIFOLD HARN

LF STEER RIGHT P110RT-BK P2-19 STEER SNSR GND

2 WAY DEUTSCH LOAD SENSE LIMIT SWITCH TO BOOM HARN
3 WAY DEUTSCH CAN CONNECTOR SLIP RING TO DCON HARN

3 WAY DEUTSCH CAN CONNECTOR BOOM HARN TO SLIP RING
4 WAY DEUTSCH CHAIN BREAK TO UPPER LIMIT SWITCH HARN

2 WAY DEUTSCH DCON ECU PWR LIMIT SW HARN TO SLIP RING
WHITE 35 PIN AMP CONNECTOR TCON TO FUNCTION MANIFOLD
RD P109ANG-GR/WH P2-20 STEER SNSR PWR

WHITE 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
BLACK 23 PIN AMP CONNECTOR DCON TO DRIVE CHASSIS HARN
A
V37RFS-BL/BK P2-21 RF STEER LEFT
BL V36LFS-BL P2-22 LF STEER RIGHT
B
BK V37LFS-BL/BK P2-23 LF STEER LEFT
C
B
RR STEER RIGHT
ALARM-
RR STEER LEFT
PCON
ALARM+
ALARM
LR STEER RIGHT
LR STEER LEFT
S1-1
RF STEER RIGHT
S1-2
P20
J20
RF STEER LEFT
ROTATE
J2 WHITE 23 PIN
1 S1-3
LF STEER RIGHT
DRIVE CHASSIS HARN

2
LF STEER LEFT S2-1
3
S2-2
LEVEL
4
S2-3
5
PLATFORM PLATFORM
6 S3-1
JIB
3
7 S3-2
P
LSAX1RO GND-DCON-BR P1-01 DCON ECU GND
4
8 S3-3
P21DCON-WH P1-02 DCON ECU PWR
9
P53LS-RD P1-03 P_6R1
10
TERM 3 & 4
P1-04
J1-BL/BK
ARE CLOSED
WHEN AXLES
11
LIMIT SWITCHES
S56PRV-RD P1-05 P_7R
AXLE RETRACTION
3
ARE RETRACTED
12
C
P
LSAX2RO C61AXRT-GR P1-06 P12
4
13
P1-07 P1
14 H1_GND 1
P61LS-GR P1-08 AXLE NOT RET PWR
15 H1_PWR 2
C61LS-GR P1-09 AXLE NOT RET SIG
16 H1_XOUT 3
P1-10 CAN SHIELD
P
LSAX1EO 17 H1_YOUT 4
P1-11 RS232 RXD
4
JOYSTICK
18 5
BOOM UP/DWN &
P1-12 RS232 TXD

TURNTABLE ROTATE
19 6
P1-13 BOOT
20
TERM 3 & 4
J4-GR/BK
P1-14
ARE CLOSED
WHEN AXLES
21 P2
ARE EXTENDED
C61LS(A)-GR P1-15 AXLE NOT EXT SIG
LIMIT SWITCHES
H2_GND 1
AXLE EXTENTION
P
LSAX2EO 22
P1-16 2
4
H2_PWR
23
D81CAN- -GR P1-17 CAN LOW 3
24
D82CAN+ -YL P1-18 CAN HIGH H2_YOUT 4
25
JOYSTICK
P1-19 RS232 GND 5

BOOM EXT/RET
26
P57PBD-RD/WH P1-20 6
27
31
P1-21
LSAX1ES 28
P1-22 P3
H3_GND 1
24
29
P61LS(A)-GR P1-23 AXLE NOT EXT PWR
D
30 H3_PWR 2
3
H3_YOUT 4
NOT USED
J2-BL/RD
J3-OR/BL
5
AXLE NOT EXT

LIMIT SWITCHES
6
31
LSAX2ES P4
J1 BLACK 23 PIN
DCON
C60AXEX-GR/WH H4_GND 1
24
P63LS-OR/RD
DRIVE CHASSIS HARN

H4_PWR 2
H4_XOUT 3
H4_YOUT 4

JOYSTICK

H4_RKOUT 5
DRIVE & STEERING
NOT USED 6
ECU
ESTOP_2
VLVRET-BR P1-01 VLV RTN

PCON
E-STOP
OUT PWR ENABLE
P1-02
GNDDCON-BR
ESTOP_1
PWR-PCON ESTOP
P57PBD-RD/WH
P21DCON-RD
S56PRV-RD
C61AXRT-GR
P53LS-WH/BK
P63LS-OR/RD
D81CAN- -GR
D82CAN+ -YL
C60AXEX-GR/WH
PLAT ROT CCW C17PRL-GR P1-03 ON/OFF VLV3_A
PLAT ROT CW C18PRR-GR/BK P1-04 ON/OFF VLV3_B
E
C
A
B
4
5
3
2
2
6
1
1
JIB UP C43JU-GR P1-05 PROP VLV2_A
JIB DOWN C44JD-GR/BK P1-06 PROP VLV2_B
C
A
B
4
5
3
2
2
6
P16
P18
1
1
P17
OPTIONAL
PLAT LEVEL UP C14PLU-OR P1-07 PROP VLV1_A

PROX KILL SW.
P157
GR
PLAT LEVEL DN C15PLD-OR/BK P1-08 PROP VLV1_B
YEL
YL
BL
BK
BR
OR
RD
GR
31
WH
P1-09
J157
R90PXS-RD/BK P1-10 PROX KILL GND

88
88
88
24
88
88
88
88
88
88
88
88
C90PXS-RD/BK P1-11 PROX KILL CMD
GR/YL P1-12 LOAD SNSR GND
P12
P11
P18
P9A
P7R
WH P1-13 LOAD SNSR OUT
P6R1
OR
(SLIP RING)
(SLIP RING)
CAN LOW
CAN HIGH
BK P1-14 LOAD SNSR PWR

BK
CAN SHIELD
ES0509L
RD C88PTS-RD/BK P1-15 SAFE PL TILT OUT
YL
BL
DCON GND BK
R56PTS-RD
1
BR
P1-16 FOOT SW PWR
DCON PWR RD
GR
OR
WH
GR
YEL
C56PTS-RD P1-17 FOOT SW RTN
6
5
4
3
2
1
2
1
B
A
LOAD SENSOR OPTION
C
J6
J7 P1-18
J8
P1
1
PLAT SENSOR GND PLATRET-BR P1-19 PL TILT SNSR GND 1

B
A
6
5
4
3
2
1
2
1
C
2
2
TILT SENSOR SIG OUT C84TAY-GR/BK P1-20 PL TILT SNSR

FOOTSWITCH
P1
3
TILT SENSOR PWR P85PTS-GR P1-21 PL TILT SNSR PWR 2 HORN

F
TILT SWITCH GND PTSRET-BR P1-22 SAFE PL TILT GND U20

P1
5
PWR TO TILT SWITCH P87PTS-RD P1-23 SAFE PL TILT PWR 3 AC GENERATOR
Electrical Schematic
6
S132LDS-BL/WH
PLATFORM
ASSEMBLY
OUT FRM TILT SWITCH

P6-BOOM HARN
TILT SENSOR
P1
P7-LIMIT SW HARN
P8-LIMIT SW HARN
4 AUXILIARY
P1
5 START ASSIST
P33-PCON
MANIFOLD
J31-TILT SNSR
P1
PCON MEMBRANE PANEL
PCON MANIFOLD
6 START
J2 WHITE 23 PIN
1
P1
R56PTS-RD P1-15 SAFE PL TILT OUT 2 7 DRIVE ENABLE
PCON
31
3
J3 10PIN
C56PTS-RD P1-16 FOOT SW PWR

P1
KILL
4 8 SPARE 1
PROX
24
5
P1
1
6 9 AXLE RETRACT
7
P1
8 10
OPTIONAL
PROXIMITY
J1 10PIN
KILL WIRING
9
2
FOOTSWITCH
10 P2
G
1 ENGINE SPEED
P2
GNDPCON-BR P1-01 PCON GND 2 AXLE EXTEND
J2 10PIN
P52PCON-WH P1-02 PCON PWR

P2
P1-03 3 DRIVE SPEED
FUSE
S56PRV-RD/WH P1-04 P7
K2
K1
P2
5A
2 86
2 86
1 30
P1-05 4 FRONT STEER

1 30
P6R
P7R
P1-06
87
87
P2
85 5
85 5
4
87a 3
4
87a 3
P56PRV-RD P1-07 P22 5 REAR STEER

P1-08
P2
P1-09 6 CRAB STEER
P1-10 CAN SHIELD
P2
P1-11 RS232_RXD 7 COORD STEER
P1-12 RS232_TXD
P2
P1-13 BOOT 8 SPARE 2
P1-14
P2
MEMBRANE/LED INTERFACE CARD
C47OUT-WH/BK P1-15 OUT PWR ENBL 9 FUEL TYPE

C46HN-WH P1-16 HRN RLY CNTRL
H
P2
D81CAN- -GR P1-17 CAN- 10
D82CAN+ -YL P1-18 CAN+
P1-19 RS232_GND
P1-20
P1-21
P1-22
P23PCON-BK P1-23 PWR-PCON ESTOP
P1-08 DIGTAL IN 2
P1-07 DIGTAL IN 1
D81CAN- GR P1-06 MACHINE CAN LOW
BOOM HARN
D82CAN+ YL P1-05 MACHINE CAN HIGH

D227CAN- GR P1-04 ENGINE CAN LOW
J1 BLACK 23 PIN
D228CAN+ YL P1-03 ENGINE CAN HIGH

HARNESS
P1-02 CAN SHIELD

ENGINE CAN
ALM-GND-BR P1-01 GROUND

I
BUS TO ENGINE
A
B
C
D82CAN+ -YL
D81CAN- -GR
P56PRV-RD
D81CAN- -GR
D82CAN+ -YL
P52PCON-WH
C46HN-WH
S56PRV-RD
P63LS-OR/RD
GNDPCON-BR
S56PRV-RD/WH
C61AXRT-GR
P23PCON-BK
GNDDCON-BR
BUS TO
P21DCON-RD
P53LS-WH/BK
C47OUT-WH/BK
P57PBD-RD/WH
C60AXEX-GR/WH
S132LDS-BL/WH
120Ω
TELEMATICS
ENGINE CAN
5A
FUSE
GNDPCON-BR P1-01 PCON GND

BK
P52PCON-WH P1-02 PCON POWER
RD
C46HN-WH P1-03 HORN RELAY COIL
C47OUT-WH/BK P1-04 OUT PWR ENBL LT BL
P23PCON-BK P1-05 PWR-PCON ESTOP PR
S56PRV-RD/WH P1-06 P_7 YL/WH
P56PRV-RD P1-07 P_22 GR/WH
R48LP-WH/RD P1-08 WORK LT
SERV. BYPASS
RUN
R117FB-RD P1-09 FLASHING BEACON ALARM GND 16

RECOVERY
P1-10 CAN SHIELD ALARM PWR 15

P1-11 RS232 RXD TCON MODE 14
J
P1-12 RS232 TXD P11 13

S132LDS-BL/WH P1-13 LOAD SENSOR INPUT P7 12
P56PRV-RD
P1-14 CAL FREQ 1 OPER. REC. 11 OR

BB
BA
BC
P97TET-BK P1-15 TET ESTOP PWR P22 10 LT GR

ONLY
J152C
BC AC
NOTE:
P1-16 NOT USED P15 SERV. OR OPER. REC. 9 WT

TIER IV
ENGINES
BB AB BR
D81CAN- -GR P1-17 CAN LOW P7R 8
BA AA GY
D82CAN+ -YL P1-18 CAN HIGH P6R1 7
P1-19 RS232 GND OUTPUT PWR ENABLE 6 PR
J152C
P1-20 PCON MODE 5 BL

P1-21 TO MICRO TCON OR PCON MODE 4 YL
P1-22 TETHER ESTOP 3
PCON
TCON
J27-BOOM HARN
P95TET-OR P1-23 TET ESTOP RET TCON ESTOP 2

OFF
PWR TO TCON ESTOP 1
GR
86
86
87
87
TO WORK LIGHTS 87a
TO FLASHING BEACON 87a
PK
30
30
85
85
BOOM HARN
K
TN
12 VOLT
J1 BLACK 23 PIN
P27-LIMIT SW
PRI LO#1 O
SERV. OR SERVICE OR
RECOVERY BM 100' I
OPER. REC. MODE
BM 3' I
P15 PWR IN SERV OR BM DWN ST I
RECOVERY
PROVIDES PWR AUX HYD O
TO MINIMAL MLT FNC VLV O
HARDWARE
BM RET O
BM DWN O
BM E/R FC O
PLD
BM U/D FC O
L
P56PRV-RD
P23PCON-BK
GNDDCON-BR
P21DCON-RD
S56PRV-RD
C61AXRT-GR
P57PBD-RD/WH
P63LS-OR/RD
P53LS-WH/BK
C60AXEX-GR/WH
S56PRV-RD/WH
TCON
J27
P27
P53LS-WH/BK
GNDDCON-BR P2-01 DCON ECU GND
P53LS-WH/BK
5 31
P21DCON-RD P2-02 DCON ECU PWR

P54ENG-BK/WH 3-10A
LSB2RS P_6R1
SJ2-BK/RD P53LS-WH/BK P2-03
101'
SJ1-WH/RD P54ENG-BK/WH P2-04 P_6R2
24 6
S2PLD2-GR/BK S56PRV-RD P2-05 P_7R

J21
P21
C69PBE-BK FUSE
8 WAY
P_9A
8 WAY
P57PBD-RD/WH
P56PRV-RD
P2-06
31
1
LSB2RO P58LS-RD/BK P58LS-RD/BK P2-07 P_9B

M
100' P53LS-WH/BK S59CNBK-GR/WH P2-08 P_10

24
3
C64LS-OR/BK P54ENG-BK/WH C60AXEX-GR/WH P2-09 P_11

TO HORN BUTTON
PRI BOOM DOWN STATUS
LOCKOUT VALVE #1 SIG
PWR TO TCON ESTOP


C69PBE-BK C61AXRT-GR P2-10 P_12

5
S59CNBK-GN/WH S62BSTO-OR P2-11 P_14

P264 WAY
J264 WAY1
6
S59CNBK S2PLD1-BL/RD P63LS-OR/RD P2-12 P_18

2
P_6R2
31
7
OUT PWR ENABLE
P7R
PCON POWER
P9A
P11
P6R1
P10
S2PLD2-GR/BK C64LS-OR/BL P2-13 OPER SW PWR

P_7
P_22
LSB6S
TCON MODE
3
8
CHNBRK C65LOFL-BL/WH P2-14 FST1S

TO PLD
24
4
P63LS C66DREN-BL P2-15 LST10

TO MICRO
1
C76PBE-BL SJ1-WH/RD P2-16

31
2
LSB4EO SJ2-BK/RD C68PBD-RD P2-17 LSB1DO

3
100' EXT C76PBE-BL C69PBE-BK P2-18 LSB2RO

TO PLD
24
4
C64LS-OR/BK C70PBE-BL/WH C70PBE-BL/WH P2-19 LSB3RO

TO MICRO
5
C71PBE-BL/BK P63LS-OR/RD C71PBE-BL/BK P2-20 LSB3EO

6
31
S62BSTO-OR P2-21
LSB3EO
7

24
8
C64LS-OR/BK P57PBD-RD/WH V74PRLO-RD P2-23 PRI#1 LO TO PLD

S62BSTO-OR C64LS-OR/BK V75PRLO-RD/WH P2-24 PRI#2 LO TO MICRO
31
P63LS-OR/RD C71PBE-BL/BK SNSR GND-BR P2-25 SNSR GND

N
LSB3RS
TO MICRO
24
9 10 11 12
C61AXRT-GN S56PRV-RD G119SR-BL P2-27 AUX HYD PRESS SIG

P53LS-WH/BK C76PBE-BL P2-28 LSB4EO
P20
J20
SJ1-WH/RD C77AS-WH P2-29 LSB13AO

12 WAY
5 31
12 WAY
SJ2-BK/RD C78PS-WH/BK P2-30

LSB4ES LSB14AO
75.5' P58LS-RD/BK P2-31
P53LS-WH/BK
P57PBD-RD/WH
24 6
SJ1-WH/RD P2-32
S2PLD1-BL/RD
5 31
SJ2-BK/RD P2-33
C70PBE-BL/WH LSB8AS
50 DEG P58LS-RD/BK P2-34
31
S56PRV-RD
LSB3RO P57PBD-RD/WH VLVRET1-BR P2-35 VLV RET
24 6
3' EXT SJ3-WH S7PLE1-BL/BK

24
C64LS-OR/BK P53LS-WH/BK
P53LS-WH/BK
5 31
LSB9AS P54ENG-BK/WH
65 DEG SJ2-BK/RD
SJ1-WH/RD
24 6
S7PLE2-GR/WH
J2 BLACK 35 PIN
C78AS-WH/BK
3
LSB14AO
P
O
68 DEG C64LS-OR/BK
4
C77AS-WH
3
1
LSB13AO
P
53 DEG C64LS-OR/BK
4
2
S56PRV-RD
3
31
31
C60AXEX-GN/WH
4
LSB7DS
11 DEG P53LS-WH/BK
24
24
S62BSTO-OR
P_7
P11
P_22
P10
P7R
P6R1
P9A
P_6R2
P_9B
PCON POWER
TCON MODE
OUT PWR ENABLE
PWR TO TCON ESTOP
C68PBD-BL
TO HORN BUTTON
31
SJ3-WH
LSB1DO
10 DEG P56PRV-RD
24
C64LS-OR/BK
C66DREN-BL
PRESSURE SENSOR
31
OPTIONAL HYDRAULIC
LST1O
DRV
S-120/125
ENABLE
24
C64LS-OR/BK
FST1S C65LOFL-BL/WH
1
LOW TELBAT-RD J224-01 SYS_POWER

LIMIT SWITCHES
C64LS-OR/BK
2
FUEL FS TELGND-BR J224-02 GROUD

P
PRI 1 LO V74PRLO-RD C211GN-WH J224-03 IGNITION STATUS

PRI 2 LO V75PRLO-RD/WH P23PCON-BK J224-04 STOWED STATUS
VLVRET1-BR S56PRV-RD/WH J224-05 FOOTSWITCH STATUS
6A
CB
J224-07 CAN HIGH

J224-08 CAN LOW
AUX MAIN TO MICRO

P_6R2
OUT PWR ENABLE
P_9B
PWR TO TCON ESTOP
-
+
P9A
P_7
TCON MODE
P_22
P6R1
P10
P7R
P11
PCON POWER
P114BAT-RD
MAIN (SYS)
BAT
ENGINE BLOCK
-
+
TCON
POWER HARN
START BAT
J5 BLACK 4 PIN
CB 5 5 5
85 87a 85 87a 85 87
U95
SYS_BAT_PWR
U32
BATVLV-RD P5-01 87 87a

25A 87
RELAY
30 A
P5-02 SYS_BAT_GND K5 86 30 K4 86 30 K3 86 30
70 A FUSE
BATGND-BR
FUSE
STARTER
AUX/START_BAT_GND 2 1 2 1 2 1
BATGND-BR P5-03
4

1
Q
P33STR-BK
30
TO MICRO
TO MICRO
2 1 2 1
2
5
87a 87 85
86
K1 86 30 K2 86 30
BAT GND-BR
85 87 87a 85 87 87a
5 4 5 4
2 1 2 1
2 1


K7 86 30 K8 86 30
TO MICRO
TO MICRO
AUX.
DETAIL B
PUMP
TO HORN BUTTON
K6 86 30
REMOTE
HIGH CURRENT VALVE PROPEL OUTPUT 87 87a 87 87a

85 85 87 87a
C21IGN-WH
C226TEL-BL
PR1 85
5
86
2
V30FWD-WH P3-05 FWD 5 4 5 4

VLVRET6-BR 5
-BAT
4
+BAT
+AUX
V31REV-WH/BK P3-06 REV

ENGINE HARN
4
J3 WHITE 23 PIN
P46HRN-WH
P116HYD-OR
30
CONTROL 85 87 87a
C27AUX-RD
TO MICRO
P3-01
MOM N.O.
+
BAT.
TIME DELAY
TROMBETTA

TO MICRO
C34SA-BK/WH P3-04 CHOKE/GLOW PLUG
P3-05 FWD
REGULATOR
BR-COM
WH-PULL
RD-HOLD
(DETAIL B ) P3-06 REV

-
ALTERNATOR

BAT.
STA.
IND.
EXCT.
TO MICRO
15A
TO MICRO
CB 7
P3-08
R
J144-1 TO MICRO
C31EDC-WH/BK P3-10 C31EDC-WH/BK
J144-2
P_22R
BAT GND-BR C107AF-RD C30EDC-WH P3-11 C30EDC-WH

J144-8
C26TSR-WH/RD P3-13 OIL/WATER_TEMP TO MICRO
4
1

30

2
5
86

HORN
P3-17
SERVICE
HORN
87a 87 85 RELAY
HI/LO

SPEED

1
SOLENOID

HOLD TO MICRO
2

PULL IN
3

P34SA-RD
VLVRET2-BR VLVRET3-BR P3-23 VALVE_RTN3
C31EDC-WH/BK
REV VLV B
S
SOLENOID
P114BAT-RD
S56PRV
BAT GND-BR
C30EDC-WH
C27AUX-RD
VLVRET6-BR
J32-ENG HARN
S2PLD1-BL/RD
S7PLE1-BL/BK
3
2
C45GEN-GR/WH 1
S2PLD2-GR/BK
S7PLE2-GR/WH
FWD VLV A
SOLENOID
P7R
P_22R
P10
RELAY
P9A
P11
P6R1
5
86
GLOW PLUG2
VLVRET2-BR C34SA-BK/WH J10

P10
START
4
15
1
R34SA-RD
30
85 87 87a
STRT ASST
GLOW PLUG 14
10 A
SCROLL R
30
1

4
13
GOLD VLV A SCRL F/ENT
SOLENOID
2
12
RELAY
87 85
86
P85TTSR-GR
C84TAY-GR/BK
RET85TTSR-BR
C83TAX-GR/WH
N.O.
SEE GENERATOR OPTIONS
- BUTTON
OTS1
86
5
HYD COOLER
11
2
P31-ENG
BAT GND-BR C116HYD-OR HARN
+ BUTTON
4
P116HYD-OR J31-TILT 10
1

30
85 87 87a
BAT GND-BR R116HYD-OR SNSR

T
GAS/LP
TILT
ENGINES SHOWN
9
SENSOR
FAN
ENG SPEED
TURNTABLE
4.5 DEGREE
BAT GND-BR
FUEL
8
S100- S/N 865
RELAY
RELAY ADDED
S120- S/N 2782
AUXILIARY
86
5
SOLENOID
2
VLVRET2-BR C21IGN-WH 7
DEUTZ BF4L-2011/TD2011-LO4I
R21IGN-WH
4
J144-7 SEC. UP
P21IGN-WH
1
30
85 87 87a
6
FUEL
RELAY
BOOM UP
SOLENOID
C25PSR-WH/BK 5
OIL PRESSURE
C26TSR-WH/RD 4
OIL TEMP SENDER

BAT GND-BR 3
TO PLD
1
TO MICRO
S2PLD2-GR/BK 2
2
S7PLE2-GR/WH
TCON
S7PLE1-BL/BK TO PLD 1
MANIFOLD HARN
J4 WHITE 35 PIN
4
U
S2PLD1-BL/RD TO MICRO
P23 J23 VLVRET4-BR P4-01 VALVE_RTN4
4WAY 4WAY
BOOM UP/DWN F.C. C03PBF-RD/WH P4-02 BOOM_UP/DOWN_VLV
P
BOOM EXT/RET F.C. C09PERF-BK/RD P4-03 BOOM_EXT/RET_VLV

P
TURNTABLE CW/CCW F.C. C06TRF-WH/RD P4-04 TURNTABLE_ROTATE_VLV

P
TO MICRO
P4-05 J11
P11 ROOM RET
P4-06 TO MICRO
15
BOOM UP VLV C01PBU-RD P4-07 BOOM_UP_VLV
BOOM DOWN
BOOM DWN VLV C02PBD-RD/BK P4-08 BOOM_DOWN_VLV
14
BOOM EXTEND VLV C07PBE-BK P4-09 BOOM_EXTEND_VLV TO MICRO
BOOM EXT
BOOM RET VLV C08PBR-BK/WH P4-10 BOOM_RETRACT_VLV TO PLD
13
P4-11
RABBIT
P4-12
12
R49LP - WH/BK P4-13 DRIVE LIGHTS RELAY TO MICRO
SEC. DOWN
P4-14 TO MICRO
11
S2PLD2-GR/BK P4-15 LSB2RS MONITOR INPUT TO PLD
12 VOLT
2 86
TURTLE
1 30
S7PLE2-GR/WH P4-16 LSB9AS MONITOR INPUT

10
87
P4-17 LSB8RS MONITOR INPUT

V
S7PLE1-BL/BK
85 5
4
87a 3
BOOM CCW
S2PLD1-BL/RD P4-18 LSB4ES MONITOR INPUT
9
P4-19
PLTFRM CCW
P4-20 TO PLD
8
P4-21 TO MICRO JIB UP
P4-22
TO DRIVELAMPS
7
MULTI FUNC VLV C113MFV-OR/RD P4-23 MULTI_FUNCT_VLV
PLTFRM UP
P4-24 TO MICRO
6
TURNTABLE ROT CW VLV C05TTL-WH P4-25 ROTATE_CW_VLV
PLTFRM DOWN
TURNTABLE ROT CCW VLV C06TTR-WH/BK P4-26 ROTATE_CCW_VLV TO MICRO
5
VALVE RTN7 P4-27 VALVE_RTN7
JIB DOWN
P4-28
4
P4-29 TO PLD
PLTFRM CW
VALVE RTN6 P4-30 VALVE_RTN6 TO MICRO 3
ES0509C
P4-31
BOOM CW
C27AUX-RD P4-32 AUX_RELAY
2
TO AUX HYD RELAY PR1 P4-33
TCON MEMBRANE PANEL
P4-34
1
P4-35
W
86
K3
86
30
S56PRV-RD
S56PRV-RD
C61AXRT-GR
85
P21DCON-RD
P63LS-OR/RD
P53LS-WH/BK
86
86
30
GNDDCON-BR
P57PBD-RD/WH
C60XES-GR/WH
86
K5
30
30
87 87a
J27
30
K7
85 87 87a K8
86
GNDDCON-BR P2-01
86
86
K2
P27
30
P21DCON-RD P2-02
3-10A
30
30
85 87 87a 85 87 87a 85 87 87a
P53LS-WH/BK P2-03
85 87 87a K6 85 87 87a K1
P54ENG-BK/WH P2-04
P2-05
J21
S56PRV-RD
P21
FUSE
8 WAY
8 WAY
P57PBD-RD/WH P2-06
P56PRV-RD
P58LS-RD/BK P58LS-RD/BK P2-07

2
S59CNBK-GR/WH P2-08
31
LSB6S C60AXEX-GR/WH P2-09

4
CHNBRK P2-10
X
C61AXRT-GR
24
5
(CKT C35RPM-BK/RD)
S62BSTO-OR P2-11
6
S2PLD1-BL/RD P63LS-OR/RD P2-12

TURNTABLE ROTATE VLV.
K1 POWERS CKT P22R OR
C64LS-OR/BL P2-13
8
P2-14
S-100/105
C65LOFL-BL/WH
ROTATE CW, AND ROTATE CCW.
C66DREN-BL P2-15
VALVES AUX RELAY, BOOM EXT/RET,
P53LS-WH/BK P2-16
LIMIT SWITCHES
2
85 87 87a K4 K4 POWERS CIRCUIT P_6R1 OR VALVES:
P2-17
PRIMARY VALVES 1 & 2, THROTTLE (IGN),
P54ENG-BK/WH C68PBD-RD
(FUEL ON/OFF SOLENOID AND ALT FIELD)
BOOM RETRACT, MULTIFUNCTION VALVE,
P2-18
CKT C03PBF RD/WH. (BOOM UP/DOWN VALVE)
K7 POWERS THROTTLE OR HI/LOW SOLENOID

K2 POWERS CIRCUIT P7R OR CKT S56PRV-RD,
C70PBE-BL/WH C70PBE-BL/WH P2-19

K3 POWERS CIRCUIT P_6R2 OR P54ENG-BK/WH
GLOW PLUG, STARTER RELAY, AC GENERATOR,
K5 POWERS CIRCUIT P_7 AND THROTTLE RELAY
C71PBE-BL/BK P63LS-OR/RD C71PBE-BL/BK P2-20

K8 POWERS CHOKE OR GLOW PLUG (C34SA-BK/WH)
31
S62BSTO-OR P2-21
LSB3EO
7

K6 POWERS CIRCUIT C21IGN-WH AND CIRCUIT C107AF-RD.
24
8
P2-23
DETAIL E - TCON RELAY PARKING
C64LS-OR/BK P57PBD-RD/WH
S62BSTO-OR C64LS-OR/BK P2-24
31
P63LS-OR/RD C71PBE-BL/BK SNSR GND-BR P2-25

LSB3RS
24
C61AXRT-GN S56PRV-RD G119SR-BL P2-27

Y
P2-28
9 10 11 12 J20
P20
P53LS-WH/BK
P53LS-WH/BK C77AS-WH P2-29
12 WAY
12 WAY
5 31
P54ENG-BK/WH P2-30
LSB4ES
75.5' P58LS-RD/BK P2-31
P57PBD-RD/WH P2-32
24 6
S2PLD1-BL/RD P2-33
P53LS-WH/BK
P2-34
5 31
C70PBE-BL/WH P54ENG-BK/WH
LSB8AS
31
S56PRV-RD 50 DEG P58LS-RD/BK P2-35

LSB3RO
3' EXT SJ3-WH P57PBD-RD/WH

Serviceandrepairmanual: Serial Number Range

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ServiceandRepairManual

Serial Number Range

Part No. 1268494

Compliance Find a Manual for this Model

Copyright © 2015 by Terex Corporation

1268494 Rev B January 2019

Genie is a registered trademark of Terex South Dakota, Inc.in

ii S-100 • S-105 • S-120 • S-125 Part No. 1268494

A2 9/2016 Introduction Serial Number Legend

A3 2/2017 Specifications Performance Specifications

A4 3/2017 Repair Procedures Update illustration for cable adjustment

Section - Schematics,Legends and schematics

Part No. 1268494 S-100 • S-105 • S-120 • S-125 iii

To August 31, 2016

1 Model 4 Sequence number

From September 1, 2016

1 Model 4 Serial label (located under cover)

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 1268494 S-100 • S-105 • S-120 • S-125 v

Be sure that your workshop or work area

Section 1 Safety Rules

Part No. 1268494 S-100 • S-105 • S-120 • S-125 vii

Section 3 Repair Procedures

Section 3 Repair Procedures, continued

Part No. 1268494 S-100 • S-105 • S-120 • S-125 ix

Section 3 Repair Procedures, continued

x S-100 • S-105 • S-120 • S-125 Part No. 1268494

Section 3 Repair Procedures, continued

Section 4 Diagnostic Codes

Part No. 1268494 S-100 • S-105 • S-120 • S-125 xi

Part No. 1268494 S-100 • S-105 • S-120 • S-125 xiii

Length, transport position 39 ft 11 in 39 ft 11 in Turning radius, inside, 8 ft 6 in 8 ft 6 in

Length, stowed 42 ft 8 in 46 ft 9 in Turntable rotation (degrees) 360° continuous

Wheelbase 12 ft 12 ft Lug nut torque, dry 420 ft-lbs

Turning radius, outside, 22 ft 2 in 22 ft 2 in Lug nut torque, lubricated 320 ft-lbs

Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-1

Fluid capacities Performance Specifications,

2 - 2 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Turntable rotate, 360°

Platform rotate, 160° 18 to 22 seconds Width, axles retracted 8 ft 2 in 8 ft 2 in

Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-3

Turning radius, outside, 19 ft 10 in 19 ft 10 in Fluid capacities

Platform dimensions Turntable rotation 93 oz

2 - 4 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Performance Specifications, Boom extend, boom fully raised

Boom extended to >80 ft / >24.4 m 50 to 55 seconds 110 ft / 33.5 m

Boom down 90 ft / 27.4 m

(time between fully raised and 70 ft / 21.3 m

(time between fully raised and 50 ft / 15.2 m

Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-5

Hydraulic Specifications Do not top off with incompatible

Optional fluids may not have the Ambient air temperature

2 - 6 S-100 • S-105 • S-120 • S-125 Part No. 1268494

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

Part No. 1268494 S-100 • S-105 • S-120 • S-125 2-7

Petro-Canada Environ MV 46 Hydraulic Component

UCON Hydrolube HP-5046 Fluid Displacement

Viscosity index 192 Charge pressure @ 2350 rpm 315 psi