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1. CR CONTROL RELAY WITH NUMBER AND FUNCTION PLUG JACK CONNECTOR DESCRIPTION AND OR LOCATION CR6 P6R CIRCUIT P1 Ji Black 23 Pin AMP Connector CR7 P7R CIRCUIT Platform Controls to Drive Chassis Harness FS FS1 FOOT SWITCH P2 J2 White 23 Pin AMP Connector H HORN OR ALARM Platform Controls to Drive Chassis Harness H3 ALARM AT PLATFORM CONTROLS P1 J1__ Platform Controls PC Board to Membrane Decal GND CHASSIS GROUND P2 J2 Platform Controls PC Board to Membrane Decal P1 J1 Black 23 Pin AMP connector SR JOYSTICK CONTROLLER Drive Chassis Controller to Drive Chassis Harness JCT BOOM UP DOWN amp TURNTABLE ROTATE P P2 J2 White 23 Pin AMP connector C2 SBOOM EXTEND RETRACT Drive Chassis Controller to Drive Chassis Harness ves DRIVE SFEERINGJOYSHICK P6 J6 3 Way Deutsch CAN Connector R POWER SWITCH Boom Harness to Electrical Rotary Coupler P2 PLATFORM CONTROLS EMERGENCY STOP BUTTON P7 J7 6 Way Deutsch Connector Drive Chassis Controller Safety ss STEER SENSOR Limit Switch to Electrical Rotary Coupler SS1 CIRCLE END YELLOW SIDE RIGHT REAR P8 J8 2 Way Deutsch Connector Drive Chassis Controller Power SS2 CIRCLE END BLUE SIDE LEFT REAR Limit Switch Harness to Electrical Rotary Coupler SS3 SQUARE END YELLOW SIDE RIGHT FRONT P
2. Deutz model a oil filler cap b ol filter c filter head d fuel filter Perkins model a oil filler cap b oil filter c filter head Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 5 Clean inside the filter head 6 Fill the filter with clean engine oil 7 Apply a thin layer of clean engine oil to the new filter gasket Install the filter and tighten it securely by hand 8 Clean up any oil that may have spilled during this procedure 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 10 Fill the engine with new oil per specifications and install the oil filler cap 11 Start the engine from the ground controls and allow the engine to run for 30 seconds Stop the engine 12 Check the oil filter and oil drain plug for leaks 13 Wait 15 minutes after stopping the engine and check the engine oil level on the dipstick Add oil if needed TABLE G PROCEDURES 14 Dispose of the used oil and filter properly Deutz F4L 913 Engine 14 3 quarts Oil capacity including filter 13 5 liters Deutz F4L 913 Engine Engine oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 20 C 15W 40 Engine oil should
3. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved 5 2 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Diagnostic code displayed AXLE EXT RET BUTTONS FAULT AXLE VALVE FAULT Condition Axles will not extend or retract Axle extend or axle retract inoperative Fault Code Chart Possible Causes Shorted axle extend or retract membrane on platform membrane panel Axle extend or axle retract valve coils circuits open or shorted to ground or the coils are bad Solution Consult Genie Industries Service Department The platform membrane panel may need to be replaced Refer to charts 33 and 34 to troubleshoot UP DOWN JOYSTICK NOT Up down functions inoperative from Up down joystick not calibrated Calibrate up down joystick refer to CALIBRATED platform repair section UP DOWN JOYSTICK SHORTED __ Up down functions inoperative from Open circuit between platform control Refer to charts 13 and 14 to TO 0V platform card and up down joystick roubleshoot UP DOWN JOYSTICK SHORTED Upidown functions inoperative from Shorted circuit between platform Refer to charts 13 and 14 to TO 5V platform control card and up down joystick troubleshoot UP DOWN JOYSTICK VALUE TOO Up down functions inoperative from Damaged circuit
4. 0sssecsnseessseeeeeeeenee 4 64 C 2 Clean the Fuel Pump Strainer Perkins Models n 4 64 C 3 Replace the Fuel Filter Element Perkins and Cummins Models 2 022 4 66 C 4 Replace the Engine Oil and Filter Deutz and Perkins Models 06 4 68 Ch Check the Specific Gravity of the Coolant Liquid Cooled Models 4 70 C 6 Inspect the Boom Extend Retract Cables cccccccceceesssteeeeeesssnneeeeeeneees 4 71 D 1 Check the Boom Wear Pads ccccceceeeeeeeeeeeceeeeeeneeeeeeeeeeesaaeeeeseeeeeeeaeeee 4 73 D 2 Check the Extendable Axle Wear Pads ssesseessseeeseieeernesrreserrsrrrensrrrssens 4 74 D 3 Checkthe Free wheel Configuration cc cccceeceeeeceeeeeeeeeeeeeaeeseeneeeeeeaeees 4 75 D 4 Check the Turntable Rotation Bearing Bolts 0 ccccceeeeeeeeeeeeeeeeeeeeeeneeeees 4 76 D 5 Check the Turntable Rotation Gear Backlash cccccsseceeseceeeeeeeeeeeeteeeees 4 77 D 6 Grease the Turntable Rotation Bearing and Rotate Gear seeeceeeeeeeees 4 78 D 7 Replace the Drive Hub Oil 0 cece ccceccceeeeceeeeeeeeeeeeeeeeeeeaaeeseceeeeeseaaeeeeiaaeeeee 4 78 D 8 Inspect the Engine Belt s Cummin Models cceeceeeeeeeeeeeeeteeeteeneeees 4 82 D 9 Replace the Fuel Filter Water Separator Deutz Models sseenseeeneeeeeen 4 84 D 10 Check the Engine Valve Clearances Perkins and Cummins Models 4 85 E 1 Testor Replace the
5. oV Continued on the next page 12V Check voltage on the TN wire at the ov Emergency Stop button contact 12V With the Emergency Stop button pulled out to the ON position check ON voltage on the PK wire at key switch contact AA pin 2 12V With the Emergency Stop button pulled out to the ON position and the ov key switch turned to platform controls check voltage on YL wire at key switch contact AA pin 1 12V Check the voltage on oV the P7 connector pin 4 12V Replace the ground control box TCON OR consult the Genie Industries Service Department Repair open in TN wire that runs from the P7 connector on circuit board to the Emergency Stop button contact OR replace the TN wire Repair or replace the Emergency Stop button contact AA OR repair or replace PK wire circuit that runs from the Emergency aop button to the key switch Make sure the key switch cam is releasing contact AA If not repair or replace the key switch head or replace contact AA Repair open in the YL wire that runs from the P7 connector on the circuit board to key switch contact AA pin 1 OR replace the YL wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 11 Section 5 Troubleshooting Flow Charts EE CHART 1 Continued from the previous page Check voltage on the 12V controller side of the 40A circuit breaker o
6. 2 Simultaneously push the LCD screen buttons se shown to activate status mode 3 Push one of the LCD screen buttons shown until BOOM ANGLE is 4 el displayed 4 Raise the boom and observe the LCD screen Result The LCD screen should display lt 10 gt 10 gt 50 gt 65 5 Push one of the LCD screen buttons shown until 4 BOOM LENGTH is e displayed 4 18 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures A 18 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures Deutz models A 3 A 19 B 3 B 5 B 8 B 13 C 1 C 6 D 4 D 9 B 15 CA Inspect for Damage and Loose or Missing Parts Check the Engine Fasteners Deutz Models Check the Engine Belt s Deutz and Perkins Models Replace the Air Filter Replace the Hydraulic Tank Return Filters Inspect the Tires and Wheels including lug nut torque Check the Engine Valve Clearances Deutz Models Inspect the Boom Extend Retract Cables Check the Turnable Rotation Bearing Bolts Replace the Fuel Filter Water Separator Deutz Model
7. Axle Extend With the key switch Press down the foot Continued to i turned to platform switch and activate the page 5 170 Function controls SEN axle extend button Is i Emergency Stop buttons there an audible beep Inoperative pulled out to the on position start the Be sure all other engine Press down the functions operate foot switch and activate normall the axle extend function Consult the Genie y Are there any diagnostic Industries Service codes present on the Department The Be sure the batteries display screen at the platform membrane are fully charged and ground controls decal may need to be properly connected replaced Continued on the next page 5 168 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from the previous page Is AXLE EXT RET BUTTON FAULT present on the yes display screen no Is AXLE VALVE FAULT yes present on the display screen no Consult the Genie Industries Service Department Section 5 Troubleshooting Flow Charts PE Consult the Genie Industries Service Department The platform membrane decal may need to be replaced Check for an open or short in the GR WH C60AXEX wire from pin 3 of the J2 connector at the drive chassis controller to pin 1 of the DIN connector at the axle extend retract valve coils item ES good Check for an open or short in the BR VLVRET1 wire fro
8. CHART 14 Is SAFETY SWITCH P9A FAULT present on the display Continued from the previous page Is BOOM ANGLE SWITCHES FAULT present on the display Is BOOM LENGTH SWITCHES FAULT present on the display Is BOOM UP DWN FLOW VALVE NOT CALIBRATED present on the display Is BOOM UP DWN FLOW VALVE FAULT present on the display no Continued on the next page yes yes yes yes yes Refer to Chart 18 or 19 Refer to Chart 12 Boom Angle Switch Fault Refer to Chart 15 Boom Length Switch Fault Calibrate boom up down joystick threshold See Repair Section Check for an open or shorted wire in RD WH CO3PBF wire circuit from pin 2 of the J4 connector on the ground control box to pin 1 of the DIN connector on the boom up down flow control valve item BF or item FF good Check for an open or shorted wire in BR VLVRET4 wire circuit from pin 1 of the J4 connector on the ground control box to pin 2 of the DIN connector on the boom up down flow control valve good Test the resistance of the boom up down flow control valve coil 0 or infinite ohms Replace the boom up down flow control valve coil 3 3 to 5 3 ohms bad Repair or replace the RD WH CO3PBF wire bad Repair or replace the BR VLVRET4 wire Consult the Genie Industries Service Department Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 Firs
9. Check for a short between pin 1 and pin 8 of the J20 connector Are the wires shorted together Continued from the previous page Check for a short between pin 2 of the J20 connector and pin 1 of the J21 connector Are the wires shorted together Consult the Genie Industries Service Department Visually trace the limit switch lower wire harness from the J20 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the RD WH P57PBD wire Visually trace the limit switch lower wire harnesses from the J20 connector to the ground controls TCON and the J21 connector to the ground controls checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the RD BK P58LS wire 5 112 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from page 5 104 Using auxiliary power retract the boom until the boom is extended less than 100 feet Start yes the engine Disconnect LSB2RS Does the engine stop no Disconnect LSB9AS Does the engine stop y s no Stop the engine Disconnect the J20 yes 12 pin and J21 8 pin Deutsch connectors inside the counterweight area of the machine Attempt to start the engine Does the engine start and does P9A P9B P10 P11 P1
10. Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE A PROCEDURES A 8 Drain the Inline Fuel Filter Water Separator Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage Explosion and fire hazard Engine ADANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Poor fuel quality or very wet conditions may necessitate performing this procedure more often Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the fuel filter water separator 2 CA A o gt Loosen the vent plug located on the fuel filter water separator head E head bolt vent plug drain plug filter bowl filter element separator head ep Oo o Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Do not completely drain the fuel bowl Tighten the vent plug Clean up any diesel fuel that may have spilled during the procedure
11. good Check for an open or short in the internal platform control box wire harness between the 2 1 2 2 and 2 3 connectors at the toggle switch and pins 3 5 and 7 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function manifold and start the engine At the ground controls activate the function enable high RPM button and the platform level up button and check the pressure 3000 PSI or more Are there mechanical restrictions keeping the platform level up function from operating yes Remove or repair the mechanical restrictions no bad bad less than 3000 PSI no Replace the ground controls membrane decal decal OR consult the Genie Industries Service Department Repair or replace the internal platform wire Replace the toggle switch harness Repair or replace the level up proportional valve item CH or item GH OR repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department Repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR consult the Genie Industries Service Department 5 140 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition
12. 12 Remove the key from the main key switch and insert the key into the service bypass recovery key switch The key switch should remain in the GROUND CONTROL position 13 Turn the service bypass recovery key switch to the SERVICE BYPASS position 14 Raise the boom Result The boom should raise 15 Remove the key from the service bypass recovery key switch and insert the key into the main key switch 16 Turn the main key switch to the orr position 17 Remove the key from the main key switch and insert the key into the service bypass recovery key switch 18 Turn and hold the service bypass recovery key switch to the Recovery position Result The boom should return to the stowed position 19 Turn the service bypass recovery key switch to the run position 20 Remove the key from the service bypass recovery key switch and insert the key into the main key switch 21 Turn the main key switch to the orr position 22 Close the turntable side cover Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 17 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for ground and platform person
13. Continued on page 5 84 5 78 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 19 Access the status Go to lift function ramp software version GE from screen and scroll down time Turn the key 1 01 Reset the ramp ee until the BOOM LENGTH an _ switch to the OFF time to 250 ms screen appears on the position Press and hold software version 1 06 the J button and turn or greater Reset the the key switch to ground ramp time to 500 ms controls display What boom length is shown on the display Press 1 4 and scroll down until boom EXTEND RETRACT RAMP DECEL appears on the display screen Is the ramp time shown 250 ms yes software version no Reset the boom speed 1 01 Go to the boom to 100 functions speeds screen Turn the key switch to the OFF position Press and hold the 1 button and turn the key switch to ground controls Press the buttons and scroll down until BOOM EXTEND SPEED is shown on the display screen Is the speed 100 50 software version 1 06 and greater Proceed to the next step yes Continued on Continued on the next page page 5 84 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 79 Section 5 Troubleshooting Flow Charts E CHART 19 Continued from the previous page 8 t Disco
14. Is DRIVE VALVE FAULT present on the display Continued from the previous page screen no Is BRAKE VALVE FAULT present on the display screen yes Continued on the next page CHART 40 Check for an open or bad Repair or replace the short in the WH BK WT BK V31REV wire V31REV wire circuit from pin 6 of the J3 connector at the ground controls to pin 1 of the Din connector on electronic proportional control EPC on the drive pump good Check for an open or bad Repair or replace the short in the BR BR VLVRET2 wire VLVRET2 wire circuit from pin 16 of the J3 connector at the ground controls to pin 2 of the Din connector at the electronic proportional control EPC good 4 8 to 6 8 ohms Consult the Genie Industries Service Check the resistance of the electronic proportional control EPC Department 0 or infinite ohms Replace the EPC If any other codes are present on the display screen refer to the fault code chart for more information PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 197 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 40 Check for a short or EE open in the WH RD P page V32BRK wire from pin 15 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the brake valve Repair or replace the WH RD V32BRK wire Check for a
15. Perkins models 62426 a Cummins models 62435 E SS Le fi A fe K P L SS ett E At ES Be ge Cummins model a fuel filter b lift pump Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 67 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE CG PROCEDURES C 4 Replace the Engine Oil and Filter Deutz and Perkins Models Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap 2 Remove the drain plug and sealing washer from the oil pan and allow all of the oil from the engine to drain into a suitable container See capacity specifications Be sure that the sealing washer is not damaged 3 Install the sealing washer onto the drain plug and tighten the drain plug 4 Use an oil filter wrench to remove the oil filter SV y
16. Replace oil pressure sensor Check for a short in the bad WH RD C26TSR wire from pin 13 of the J3 connector at the ground Repair or replace the WH RD C26TSR wire controls to the engine temperature sensor on engine good Replace the temperature sensor 5 26 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Is ENGINE SPEED NO Continued from the RESPONSE present on yes previous page the display screen no Is ENGINE SPEED a VALUE TOO HIGH yes present on the display screen no Consult the Genie Industries Service Department Section 5 Troubleshooting Flow Charts PE Check voltage on the ov Bat post on the alternator 12V While cranking the engine check the ov voltage at the alternator on the RD C107AF wire circuit from pin 19 of the J3 connector at the ground controls to the alternator 12V While the engine is less running check the than 4V voltage at the OR BK C41RPM wire on the alternator from pin 18 of the J3 connector at the ground controls to the alternator greater than AN Consult the Genie Industries Service Department Check high RPM setting and adjust throttle linkage See Maintenance Section CHART 4 Check for an open in the RD P114BAT wire that runs from the alternator to the battery separator and repair or replace the RD P114BAT wire OR co
17. safety switch GR 106 Spare OR BL 64 Power for operational switches RD 107 Alternator Field BL WH 65 Low fuel indication BK RD 108 Engine Status BL 66 Drive Enable GR WH 109 Sensor Pwr BL 67 Secondary boom not stowed BK 110 Sensor Return RD 68 Pri Boom lowered operational OR 111 Steer Signal BL 69 Pri boom 1 extended RD 112 Steer Signal to Solenoid Valve BL WH_ 70 Pri boom 2 retracted OR RD 113 Multi Function Valve BL BK 71 Pri boom 2 extended BK RD 114 Load Moment Overweight BL WH 72 Secondary boom extended RD BK 115 Load Moment Underweight BL RD 73 Secondary boom retracted GRN 116 AC Power Ground RD 74 Pri 1 Lockout WHT 117 AC Power Neutral Wire RD WH 75 Pri 2 Lockout BK 118 AC Power Hot Wire BL 76 Pri boom 3 extended BL 119 Hydraulic Pressure Sensor Output Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 7 Section pe Schematics First Edition First Printing Limit Switches Types of Limit Switches There are two types of limit switches which are found in various locations throughout the machine mechanical type operational or safety switches and magnetic proximity switches As in aircraft which features redundant safety systems each mechanical safety switch is backed up with an independently functioning proximity switch The mechanical type operational or safety switches are used to sense a positive displacement or movement of the limit switch actuator or arm as the machine moves through its
18. to secure it from moving could result in death or serious injury B 5 Replace the Air Filter Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Open the evacuator valve located on the air cleaner cap by squeezing the sides together with your fingers 2 Open the latches on the air cleaner cap Remove the end cap from the air cleaner canister Remove the filter element 4 Clean the inside of the air cleaner canister and end cap with a damp cloth 5 Install the new filter element 6 Replace the end cap on the canister Be sure the evacuator valve is pointing in the down direction Air filter Genie part number 62425 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 6 Inspect the Air Intake System Maintaining the air intake system in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Inspect the intake piping for cracked hoses loose clamps or punctures which can allow dirt and debris to enter the engine 2 Tighten or replace parts as necessary to make
19. CHART 39 At the ground controls Adjust engine high idle SEN display scroll until See Maintenance pale tse engine speed is present Section Is the engine high idle set to 2350 rpm Stop the engine Install Continued to two 0 to 5000 PSI 345 page 5 193 bar pressure gauges on the quick disconnects to the A amp B ports of the drive pump Start the engine ls the pressure 250 psi 17 2 bar or more Stop the engine Repair or replace the Disconnect the hoses drive pump from A amp B ports on drive pump and plug the ports Start the engine Is the pressure 250 psi 17 2 bar or more Press down the foot Repair or replace the switch and activate the drive pump drive forward function Is the pressure 4250 psi 293 bar or more Continued on the next page Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 193 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 39 Stop the engine and connect the A amp B hoses to the drive pump Disconnect the case drain hose from one drive motor Start the engine and activate the reverse function for one minute measuring the volume of oil Is the oil volume greater than 1 gallon 3 8 liters Repeat for each motor Repair or replace the bad drive motor Continued from the previous page Disconnect and plug the A amp B hoses at the drive manifold Start the engine and activate the drive forw
20. Check for a short between pin 1 of the P20 connector and pin 2 of the P21 connector Are the wires shorted together Continued from the previous page Check for a short between pin 2 of the P20 connector and pin 3 of the P21 connector Are the wires shorted together Consult the Genie Industries Service Department Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the WH BK P53LS wire Visually trace the limit switch lower wire harnesses from the P20 connector to the ground controls TCON and the P21 connector to the ground controls checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the BK WH P54ENG wire 5 114 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Disconnect LSB6S Start the engine and attempt to extend the boom Does the boom extend Continued from page 5 105 and is fault code P10 not on the display screen at the ground controls extends Disconnect the J26 cable break harness from the upper limit switch harness on the side of the boom tube at the platform end of the machine Attempt to extend the boom Does the boom extend and is fault code P10 no
21. Consult the Genie Industries Service Department 5 150 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Platform Rotate Clockwise Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position activate the function enable button and the platform rotate clockwise button Are there any diagnostic codes present on the display at the ground controls yes Continued on the next page no Activate the function enable and the platform rotate clockwise button Is there an audible beep yes At the platform controls test the platform rotate toggle switch for proper operation See Repair Section Is the switch faulty no Check for an open or short in the internal platform control box wire harness between the 1 1 1 2 and 1 3 connectors at the toggle switch and pins 4 6 and 8 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function manifold and start the engine At the ground controls activate the function enable high RPM button and the platform rotate clockwise
22. Continued on the next page no Activate the function enable high RPM button and the platform level down button Is there an audible beep yes From the platform controls test the platform level toggle switch for proper operation See Repair Section good Check for an open or short in the internal platform control box wire harness between the 2 1 2 2 and 2 3 connectors at the toggle switch and pins 3 5 and 7 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function manifold and start the engine At the ground controls activate the function enable high RPM button and activate the platform level down button and check the pressure 3000 PSI or more Are there mechanical restrictions keeping the platform level down function from operating yes Remove or repair the mechanical restrictions no bad bad less than 3000 PSI no Replace the ground controls membrane decal OR consult the Genie Industries Service Department Repair or replace the internal platform wire Replace the toggle switch harness Repair or replace the level down flow valve item CH or item GH OR repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR the platform function manifold could have an internal fault Consult the Genie I
23. Disconnect LSAX2ES and install a wire jumper between terminals 1 and 2 and install a wire jumper between terminals 3 and 4 on the connector Disconnect LSB3RS and LSB7DS from the wire harness Attempt to raise the boom and attempt to extend the boom Does the boom raise or extend NOTE IF THE BOOM RAISES OR EXTENDS IMMEDIATELY STOP Remove the wire jumper from the LSAX2ES connector and connect LSAX2ES to the wire harness Disconnect LSAX1ES and install a wire jumper between terminals 1 and 2 and between terminals 3 and 4 on the connector Attempt to raise the boom and attempt to extend the boom Does the boom raise or extend NOTE IF THE BOOM RAISES OR EXTENDS IMMEDIATELY STOP Continued on the next page yes Continued to page 5 98 Continued to page 5 99 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Continued to page 5 100 Fully retract the boom Remove the wire jumper from the LSAX1ES connector Connect LSB7DS to the wire harness Install a digital protractor onto the top of the boom Attempt to raise the boom Does the boom stop raising before 21 degrees NOTE IF THE BOOM RAISES TO MORE THAN 20 DEGREES IMMEDIATELY STOP Disconnect LSAX2ES from the wiring harness Fully lower the boom Attempt to extend the boom D
24. Genie Service Manual Part No Rev A1 Octobe S 100 S 105 S 120 S 125 d Introduction First Edition First Printing EEN Important Contact us Read understand and obey the safety rules and http www genielift com operating instructions inthe Genie S 100 and Genie e mail techpub genieind com S 105 Operator s Manualor the Genie S 120 and Genie S 125 Operator s Manualbefore attempting any maintenance or repair procedure This service manual covers the Genie S 100 and Genie S 105 and Genie S 120 and Genie S 125 models This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at a Genie dealer service center Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for f
25. Jagg 38 4 m 39 9 m Tire ply rating 18 Horizontal reach maximum 75 ft 80 ft Overall tire diameter 46 5 in 22 9 m 24 4 m 118 cm Maximum load capacity 750 Ib 500 Ib Wheel diameter 22 5 in 340 kg 227 kg 57 cm Turntable tailswing 66 in 66 in Wheel width 13 in axles retracted 168 cm 168 cm 33 cm Turntable tailswing 48 in 48 in Wheel lugs 10 3 4 16 axles extended 122 cm 122 cm Lug nut torque dry 420 ft lbs Wheelbase 12 ft 12 ft 569 5 Nm 366 cm 366 cM Lug nut torque lubricated 320 ft lbs Turning radius outside 24 ft4in 24 ft 4 in 433 9 Nm axles retracted 7 4m 7 4m Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 2 1 Section 2 e Specifications First Edition First Printing SPECIFICATIONS Fluid capacities Hydraulic tank capacity 55 gallons 208 liters Hydraulic system capacity 80 gallons including tank 303 liters Fuel tank capacity 40 gallons 151 liters Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Performance Specifications S 120 and S 125 Models Drive speeds maximum Drive speed stowed 3 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec Drive speed raised or extended 0 7 mph 1 1 km h 40 ft 40 sec 12 2 m 40 sec Drive speed fully extended 0 4 mph 0 6 km h 40 ft 70 sec 12 2 m 70 sec G
26. Part No 62401 First Edition First Printing Fully retract the boom Raise the boom until boom angle is greater than 10 degrees Does Continued from the previous page the low drive speed mode LED turn on yes Consult the Genie Industries Service Department Section 5 Troubleshooting Flow Charts PE Turn the key switch to ground conirols Using the display screen scroll to the boom angle status screen Is gt 10 degrees showing on the screen no Disconnect LSB1DO and check for proper operation good Reconnect LSB1DO and disconnect the J2 connector at ground no controls Check for continuity continuity between pin 17 of the J2 connector and pin 13 of the J2 connector continuity Check for proper installation and adjustment of Boom angle limit switches OR consult the Genie Industries Service Department CHART 42 Consult the Genie Industries Service Department a and adjust LSB1DO See Repair Section Check for proper adjustment of LSBiDO OR repair or replace the RD C68PBD wire from pin 17 of the J2 connector to pin 3 of the J2 connector at the ground controls OR repair or replace the OR BK C64LS wire at pin 4 of the duetch connector at LSB1DO Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 209 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 43 Engine Start Assist Inop
27. RD BK 2 Primary boom down drive RD WH 3 Primary boom up down FC proportional valve drive WH 4 Turntable rotate left valve drive WH BK 5 Turntable rotate right valve drive WH RD 6 Turntable rotate FC proportional valve drive BK 7 Primary boom extend BK WH 8 Primary boom retract BK RD 9 Primary boom Extend Retract proportional valve drive BL 10 Secondary boom up valve drive BL BK 11 Secondary boom down valve drive BL WH 12 Secondary boom up down FC proportional valve drive BL RD 13 Drive enable OR 14 Platform level up valve OR BK 15 Platform level down valve OR RD 16 Platform up down FC proportional valve drive GR RD 17 Platform rotate left valve driver GR BK 18 Platform rotate right valve driver GR WH 19 Jib select valve driver circuit RD 20 12 battery supply WH 21 12 ignition supply BK 22 Key switch power to platform Emergency Stop WH 23 Power to platform WH 24 Power to warning senders WH BK 25 Power to oil pressure sender WH RD 26 Power to temp sender RD 27 Auxiliary Power RD BK 28 Platform level alarm RD WH 29 Drive Motor shift speed WH 30 Forward WH BK 31 Reverse WH RD 32 Brake BK 33 Start BK WH 34 Start Aid glow plug or choke BK RD 35 Engine speed select BL 36 Steer clockwise 6 6 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 First Edition First Printing Ee ______ Section pe Schematics WIRE CIRCUIT LEGEND BL BK 37 Steer counterclockwise WH 77 Lower Angle
28. Repair or replace the rotator counterbalance valves OR repair or replace the rotator OR consult the Genie Industries Service Department 5 154 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is PLATFORM ROTATE TOGGLE SWITCHES Continued from the previous page FAULT present on the display screen CHART 29 Test the platform rotate yes Replace the toggle toggle switch at the platform controls for switch proper operation See Repair Section Is the switch faulty no Check for an open or short in the ch bad platform control box wire harness between the 1 1 1 2 and 1 3 connectors at the toggle switch and pins 4 6 and 8 of the P20 connector at the circuit board good Check for an open or short in the platform bad rotate counter clockwise membrane button at the ground controls between pin 1 of the J11 membrane decdal connector at the circuit board and pin 3 of the J11 membrane decal connector at the circuit board no good Check for an open or short in the platform bad rotate counter clockwise membrane button at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 8 of the J11 membrane decal connector at the circuit board good Consult the Genie Industries Service Department Continued on
29. Start the engine from the ground controls and check the fuel filter water separator for leaks If the engine will not start or runs erratically the fuel system may need to be bled Refer to B 4 Replace The Fuel Filter Water Separator 4 10 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section A Scheduled Maintenance Procedures TABLE A PROCEDURES A 9 3 Remove the filter element Inspect the Engine Air Filter 4 Clean the inside of the canister and the canister end cap with a damp cloth 5 Inspect the filter element If needed blow from the inside out using low pressure dry Maintaining the engine air filter in good condition is compressed air or tap out dust taking care not essential to good engine performance and service to damage the element life Failure to perform this procedure can lead to poor engine performance and component damage Install the filter element Perform this procedure with the 7 Install the end cap onto the canister Secure the engine off clamps 1 Open the engine side cover Empty the dust Air filter element discharge valve by pressing together the sides of the discharge slot Clean the discharge slot Genie part number 62425 as needed a camp b cannister end cap c dust discharge valve 2 Release the clamps from the end cap of the air filter canister Remove the end cap Part No 62401 Genie S 100 amp S 105 amp S 120
30. With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position press the foot switch and activate the function enable high RPM button and the turntable rotate clockwise button Are ther any fault codes present on the display at the ground controls yes Continued on the next page no Press down the foot switch and activate the turntable rotate no clockwise button Is there an audible beep yes Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine At the ground controls activate the function enable high RPM button and the turntable rotate clockwise button and check the pressure less than 2600 psi 2600 psi or more Are there mechanical yes restrictions keeping the turntable from rotating no less than Disconnect the turntable 2600 PSI rotate motor brake hose and install a 0 to 5000 PSI 345 bar pressure gauge into the hose Activate the function enable high RPM button and the turntable rotate clockwise button and check the pressure 2600 PSI or more Consult the Genie Industries Service Department Replace the ground control membrane decal OR consult the Genie Industries Service Department Repair or replace the turntable rotate proportional valve item BG or item FG OR repair or replace the turntable rotate directiona
31. present on the display yes Continued on the next page Disconnect and test bad LSB1DO See Repair Section Turn the machine off Connect LSB1DO and disconnect the J2 conector from the ground control box Check for continuity between the RD C68PBD wire and the OR BK C64LS wire at pin 17 and pin 13 of the J2 connector no continuit continuity Check for proper installation and adjustment of Boom angle limit switches See Repair Section OR consult the Genie Industries Service Department Confirm that the boom angle switches are properly adjusted See Repair Section OR consult the Genie Industries Service Department CHART 12 Replace LSB1DO Check for proper adjustment of LSBiDO See Repair Section OR repair or replace the RD C68PBD wire from pin 3 of the deutsch connector to pin 17 of the J2 connector on the ground control box OR repair or replace open in the OR BK C64LS wire to pin 4 of the deutsch connector at LSB1DO PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 43 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 12 Disconnect and test LSB1DO See Repair Section Continued from the previous page Turn the machine off Reconnect LSB1DO and disconnect the J2 connector from the ground control box Check for continuity between pin 17 RD C68PBD wire and pin 13 OR BK C64LS wire on the J2 conn
32. the next page Repair or replace the internal platiorm wire harness Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the ground control box membrane OR consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 155 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 29 Continued from the previous page Is PLATFORM ROTATE VALVE FAULT present on ge Check for an open or y short in the GR C17PRL wire from pin 3 of the J2 connector at the platform controls box to the display screen pin 1 of the Din connector at the platform rotate valve coil item CD or item GD good Check for an open or short in the BR VLVRET wire from pin 1 of the J2 connector at the platform controls to pin 2 of the Din connector at the platform rotate valve coil item CD or no item GD good Check the resistance of the platform rotate valve coil item CD or item GD 4 4 to 6 4 ohms bad _ Repair or replace the GR C17PRL wire bad __ Repair or replace the BR VLVRET wire Consult the Genie Industries Service Department 0 or infinite ohms Replace the valve coil If any other codes are on the display screen refer to the fault code chart for more information 5 156 Genie S 100 amp S 105 amp
33. yes no Check LSB13A0 for bad eee and adjust proper operation See LSB13A0 See Repair Repair Section Section Check for proper bad Adjust LSB13A0 See adjustment of Repair Section LSB13A0 yes Check for an open in the open _ Repair or replace the WH C77AS wire from WH C77AS wire pin 29 of the J2 connector at the ground controls to pin 3 of the duetsch connector at LSB13A0 Check for an open inthe open _ Repair or replace the OR BL C64LS wire from OR BL C64LS wire pin 13 of the J2 connector at ground controls to pin 4 of the duetsch connector at LSB13A0 OR consult the Genie Industries Service Department Continued on the next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 63 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 16 S 100 S 105 models Using the display scroll Proceed to the next to the options screen Is step the boom extend limit 120 S 125 models Option set to 100 feet Activate the high 35 5 m RPM function enable button and the boom extend button Will the boom extend to more than 100 feet 30 5 m Using the display scroll the boom angle status screen Raise the boom above 68 degrees Is gt 65 DEGREES present on the display screen Reset the boom extend Continued from the limit option to No LIMIT previous page yes See Repair Section yes A Continued on page 5 6
34. 1 of the Din connector at the circle end yellow side steer valve coil item EC good Check for an open or bad __ Repair or replace the short in the BL BK BL BK V37RRS wire V37RRS wire from pin 9 of the J2 connector at the drive chassis controller DCON to pin 1 of the Din connector at the circle end yellow side steer valve coil item EC good Check for an open or bad Repair or replace the short in the BR BR VLVRET2 wire VLVRET2 wire from pin 14 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the circle end yellow side steer valve coil item EC good 4 8 to 6 8 ohms Consult the Genie Industries Service Check the resistance of the circle end yellow side steer valve coil item EC Department 0 or infinite ohms Replace the valve coil PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 189 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 39 Drive Forward Function Inoperative Be sure all other functions operate normally Be sure the engine is running Be sure the drive hubs are not in the free wheel configuration Be sure the batteries are fully charged and With the key switch turned to platform controls and both Emergency stop buttons pulled out to the ON position start the engine Press down the foot switch and activate the drive forward function Are there
35. 1 operational BL WH 38 Gas WH BK 78 Upper Angle 2 operational BL RD 39 LP BK 79 power from TCON ESTOP OR 40 Limit switch signal stowed 80Can 2 0 J1939 Shield OR BK 41 RPM signal GR 81 Can 2 0 J1939 Low OR RD 42 Boom retracted signal YL 82 Can 2 0 J1939 High GR 43 Jib Up GR WH 83 Tilt signal x axis GR BK 44 Jib Down GR BK 84 Tilt signal y axis GR WH 45 AC Generator GR 85 Tilt sensor power WH 46 Drive Horn OR 86 Hydraulic Filter restricted WH BK 47 Output Power Enable RD 87 Platform Level Safety Power WH RD 48 Work Lamp RD BK 88 Platform Level Safety Output WH BK 49 Motion Lamp BR 89 Platform Level Safety Ground BL 50 Auxiliary Boom RD BK 90 Proximity Kill BL WH 51 Auxiliary Steer RD WH 91 Gate Interlock BL RD 52 Auxiliary Platform WH BK 92 Motor Speed LO HI WH BK_ 53 Boom envelope safety valve cutoff WH RD 93 Motor Bypass BK WH_ 54 Power to safety interlock WH 94 Load Sensor switches engine OR 95 Tether ESTOP return GR BK 55 Axle oscillation RD 96 Tether Power RD 56 Foot switch TCON BK 97 Tether ESTOP Power Emergency Stop power WH 98 J1708 high RD WH_ 57 Boom down safety interlock BK 99 J1708 low RD BK 58 Safety interlock to engine WH RD 100 Outrigger lowered GR WH 59 Chain break circuit WH BK 101 Outrigger raised GR WH 60 Axle extend OR 102 Pothole protector up GR 61 Axle retract OR RD 103 Pothole protector down OR 62 Boom stowed safety BK WH 104 Proprietary Data buss OR RD 63 Power to boom envelope BK RD 105 Proprietary Data buss
36. 50 to 55 seconds SPECIFICATIONS Boom extend boom fully raised 0 to 100 ft 0 to 30 5 m 120 to 140 seconds Boom retract boom fully raised 100 ft to 0 30 5 m to 0 120 to 140 seconds Turntable rotate 360 boom horizontal and fully retracted 170 to 190 seconds Turntable rotate 360 boom horizontal and extended gt 0 ft gt 0 m 285 to 315 seconds Turntable rotate 360 boom fully raised and extended gt 80 ft gt 24 4 m 490 to 540 seconds Platform rotate 160 18 to 22 seconds 120 ft 36 6 m 110 ft 33 5 m 100 ft 30 5 m 90 ft 27 4 m LSB13A0 LSB8AS 80 ft 24 4 m SCH BeA 70 ft 21 3 m LSB3EO x LSB4ES 60 ft 18 3 m 22 9 m 23 m e Q 50 ft 15 2 m 40 ft 12 2 m 30 ft 9 1 m LSB7DS LSB1D0 11 10 Q 20 ft 6 1m 10ft 3m f te T ES BR LSB3RO LSB3RS 3 ft 0 9m 3 5 ft 1 1m Oft 0m Ce Ce w g 4 0l w0 40 we wOL w p9 407 w y 6 40E wzZZL 4 Ok West HOS Weel 09 Wee U OL Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 IW Li o Section 2 e Specifications SPECIFICATIONS Hydraulic Specifications Hydraulic fluid Drive pump Dexron equivalent Type bi directional variable displacement piston pump Displacement 2350 rpm 28 gpm 106 L min Maximu
37. 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 75 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 18 Disconnect LSB13A0 deutsch connector Are Continued from the previous page the terminals inserted properly yes Test LSB13A0 See Repair Section good Check for an open or short in C77AS and C64LS wire circuits Trace the circuits back to the ground control box good Check pin 30 of the J2 connector at the ground control box to make sure that the terminal is inserted properly good Check pin 13 of the J2 connector at the ground control box to make sure that the terminal is inserted properly good Replace the ground control box OR consult the Genie Industries Service Department no bad bad bad bad Remove the orange secondary lock and reinsert the terminals Install the orange secondary lock oe and adjust LSB13A0 See Repair Section Repair or replace the C77AS and C64LS wire circuits Loosen the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Loosen the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place 5 76 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Boom Env
38. AWARNING as presented and scheduled could result in death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine H Keep records on all inspections for three years H Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection H Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable secured with the turntable rotation lock Key switch in the orr position with the key removed Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death a Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Se indi h AWARNING Orange used to indicate the presence of a potentially hazardous situation wh
39. Bolts Check the Engine Valve Clearances Cummins and Perkins Models Check and Adjust the Engine RPM Replace the Engine Oil and Filter Deutz and Perkins Models Deutz and A 19 Check the Engine Fasteners Deutz Models Engine specifications require that this procedure be performed after 40 hours of use Properly torqued engine fasteners are essential to good engine performance and operational safety Loose or improperly torqued fasteners can result in engine component damage and hazardous conditions 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine _ amp a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 2 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Tighten all valve cover retaining fasteners Torque to 108 in lbs 12 Nm 5 Tighten all air intake pipe clamps Torque to 108 in lbs 12 Nm 6 Tighten all intake manifold retaining fasteners Torque to 17 ft lbs 23 Nm 7 Tighten
40. Calibrate the turntable rotate joystick See Repair Section Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 129 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 22 Is TURNTABLE ROTATE Check for an open or bad 1 Repair or replace the Continued from the FLOW VALVE FAULT yes short in the WH RD WH RD CO6TRF wire previous page present on the display CO6TRF wire circuit screen from pin 4 of the J4 connector at the ground controls to pin 1 of the Din connector at the turntable rotate proportional valve coil item BG or item FG good Check for an open or bad_ Repair or replace the short in the BR BR VLVRET4 wire VLVRET4 wire from pin 1 of the J4 connector at the ground controls to pin 2 of the Din connector at the turntable rotate flow valve coil item BG or item FG good 4 3 to 6 3 ohms Consult the Genie Industries Service Check the resistance of the turntable rotate no proportional control Department valve coil item BG or item FG 0 or infinite ohms Replace the proportional valve coil Continued on the next page 5 130 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is BOOM DOWN Continued from the OVERLOAD FAULT yes previous page present on the display screen no Continued
41. DEE 4 TO ROTATE cow vaive COON 7 4OUT 2 IN2 N2 our 7 o fo Gj 2 E x o o 8 8 ae a a 8 E g y y CR10 5 3 8 8 Ed K6 87a P58LS lt conwar P_9B 4 PWR GND b goer i 1 C60AXEX C60AXEX hd Ooops re D13 7 SIAT OUT 1 r Wi i ST TCON J3 3 gt TO FUEL SOLENOID i l a IN2 ourzk hls A S62BSTO S62BSTO convent NFET EES P14 p11 PWR GND A A 4 STAT r e t LSB3RS is 4IN1 OUT 1 6 ate BOOM RETRACT B i 4IN2 out k TCONU47 23 TO BOOM UP VALVE a NFET K e P63LS kd conn P10 d PWR GND Zeg l gie STAT V fe sIN1 OUT ir Zi D d D Er LSB6S 4IN2 OUT2 TCON J4 9 TO BOOM EXTEND VAVLE t e CABLE TENSION NFET OK S59CNBK eons C61AXRT CON J2 10 MONITORED BY ECU P53LS conis Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 6 19
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43. First Printing Section 5 Troubleshooting Flow Charts Is PLATFORM LEVEL TOGGLE SWITCH S FAULT yes Continued from the previous page present on the display screen no Continued on the next page Test the platform level toggle switch at the platform controls for proper operation See Repair Section Is the switch faulty bad Check for an open or bad short in the internal platform control box wire harness between the 2 1 S2 2 and 2 3 connectors at the toggle switch and pins 3 5 and 7 of the P20 connector at the circuit board good Check for an open or short in the platform bad level membrane decal at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 5 of the J11 membrane decal connector at the circuit board good Check for an open or short in the platform bad level membrane switch at the ground controls between pin 1 of the J11 membrane connector at the circuit board and pin 6 of the J11 membrane connector at the circuit board good Consult the Genie Industries Service Department CHART 25 es__ Replace the toggle switch Repair or replace internal platform wire harness Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the ground control box membrane decal OR consult the Genie Industries Service D
44. Group 31 battery is used to power the three Electronic Control Modules ECM s which manage boom functions and engine controls The batteries are charged through a common engine driven alternator A battery separator is used to charge the smaller battery before charging the larger battery The control system is protected by two circuit breakers that may be manually reset Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 3 1 Section 3 Theory of Operation First Edition First Printing THEORY OF OPERATION Service Bypass Recovery Key Switch The Service Bypass Recovery key switch is only to be used by properly trained service personnel When the Service Bypass Recovery key switch is turned to the service bypass position the boom can be raised while the axles are retracted This feature of the machine is especially helpful for storage purposes or when loading the machine for transport When the boom is raised with the axles retracted the boom cannot be rotated past either circle end wheel When the Service Bypass Recovery key switch is turned and held to the recovery position the auxiliary power unit will turn on and fully retract the boom and then lower the boom to a stowed position This feature of the machine is especially helpful if the operator in the platform cannot lower the boom if the platform controls become inoperative or for returning the machine to a safe position when the safety switches h
45. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Ground control box harness connectors Turntable manifold wiring 2 Start the engine from the platform controls and extend the axles 3 Turn the key switch to ground control and raise the boom above the turntable covers 4 Install a safety chock Genie part number 75097 onto the hydraulic lift cylinder extension rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the boom The lift cylinder safety chock is available through Genie Genie part number 75097 5 Turn the engine off 6 Remove the boom storage area cover retaining fasteners and remove the boom storage area cover 7 Inspect the turntable area for burnt chafed and pinched cables 8 Install the boom storage area cover and install the boom storage area cover retaining fasteners 9 Raise the boom to a horizontal position 10 Remove the safet
46. P109ANG wire from pin A of the square end yellow side steer sensor connector to pin 20 of the J2 connector on the drive chassis controller DCON good Check for an open or short in the BK P110RT wire from pin C of the square end yellow side steer sensor connector to pin 19 of the J2 connector on the drive chassis controller DCON good Consult the Genie Industries Service Department First Edition First Printing Replace the steer bad sensor See Repair Section bad __ Repair or replace the OR C111RFS wire bad __ Repair or replace the GR WH P109ANG wire bad __ Repair or replace the BK P110RT wire 5 182 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts EE CHART 36 Is BLUE END YELLOW If any other codes are alta Lea the SIDE STEER VALVE present on the display H page FAULT present on the nO e screen refer to the fault code chart for more information display screen yes Check for an open or bad Repair or replace the short in the BL V36RFS BL V36RFS wire wire from pin 18 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the square end yellow side steer valve coil item EA good Check for an open or bad Repair or replace the short in the BL BK BL BK V37RFS wire V37RFS wire from pin 21 of the J2 connector at the dri
47. Schematics i ELECTRICAL COMPONENTS Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number Proximity switch Proximity switch 60987 Power Components EPR 20O00 10 Helzen Relay SPDT 12V DC Deutz models 000nnn 60521 aaan Potter Brumfield VF4 65F11 S01 4 Cummins and Perkins models 60521 eiras Potter Brumtield VF4 65F11 S01 3 Relays 22 pa Relay SPDT 12V DC Deutz models 0000 nn 6122 Brini s Potter Brumtield VF7 41F11 CO5 2 Cummins and Perkins models 61225 we Potter Brumfield 0 0 0 0 VF7 41F11 C05 1 SS1 through dk erdeelt Steer Sensor 0 0 eee 50159 oe Power Components HP NRPS noiaeo 4 TS1 TS2 TOS EE Toggle switch DPDT 3 position momentary 16397 oo Microswitch Control Inc IV KR aeons 3 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 6 3 Section pe Schematics Wire Circuit Legend Circuit numbering 1 Circuit numbers consist of three parts the circuit prefix circuit number and circuit suffix The circuit prefix indicates the type of circuit The circuit number describes the function of the circuit The circuit suffix provides an abbreviation for the number or may be used to further define the function of this portion of the circuit It also may be used to indicate the final end of the ci
48. See Repair Section Visually check LSB8AS bad good Adjust LSB4ES See Repair Section for damage See Repair Section Check for a short bad between pin 1 and pin 8 good Adjust LSB8AS See Repair Section of the J20 connector good Check for a short bad between pin 2 of the J20 connector and pin 1 of the J21 connector good Consult the Genie Industries Service Department CHART 20 Replace and adjust LSB4ES See Repair Section ie and adjust LS 8AS See Repair Section Repair the WH RD SJ1 wire OR repair the RD WH P57PBD wire Repair the BK RD SJ2 wire OR repair the RD BK P58LS wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 91 Section 5 Troubleshooting Flow Charts E CHART 20 Continued from the previous page Check for a short between pin 1 and pin 8 of the J20 connector Are the wires shorted together Check for a short between pin 2 of the J20 connector and pin 1 of the J21 connector Are the wires shorted together Consult the Genie Industries Service Department Visually trace the limit switch lower wire harness from the J20 connector to the ground controls checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the RD WH P57PBD wire Visually trace the limit switch lower wire harnesses from the J20 connector to the ground controls a
49. Stop the engine and Repair or replace the reconnect A amp B hoses faulty drive motor s to the drive pump Disconnect the motor case drain from one drive motor Start the engine and activate the reverse function for one minute measuring the volume of oil Is the oil volume greater than 1 gallon 3 8 liters Repeat for each motor Continued from the previous page Disconnect and plug A amp B hoses at the drive manifold Start the engine and activate the drive reverse function Is the pressure 4250 psi 293 bar or more Repair or replace the hydraulic swivel Consult the Genie Industries Service Department 5 200 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts EE CHART 40 Press down the foot Consult the Genie ER switch and activate the YES A Industries Service page i drive reverse function Is Department the pressure 4250 psi 293 bar or more no Disconnect the hoses no Repair or replace the from A amp B ports on drive pump drive pump and plug the ports Start the engine Is the pressure 250 psi 17 2 bar or more yes Press down the foot no Repair or replace the switch and activate the drive pump drive forward function Is the pressure 4250 psi 293 bar or more yes Stop the engine and es Repair or replace the reconnect A amp B hoses faulty drive motor s to the
50. T4 Foot Switch ati haoi paeran anaa aa a aia aa aaa aE aaa aea aA E 7 10 1 5 Toggle Switches AA 7 10 Platform Components KN te 7 12 2 2 Platform Leveling Cylinder cccccecceseeeeeeeeeeeeeeececaeeeeeeeeeeseaaeeseeeeeeeaeeeneas 7 12 23 Platform Rotator c cccccctecnit nist Wins eae eodine dates 7 14 xii Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing KE TABLE OF CONTENTS Section Seven Repair Procedures continued Jib Boom Components S 105 and S 125 Models 3 1 Jib Boom S 105 and S 125 Models ccesceescceeseceeeeeeeeeeeeeeeeeeeeeeeesseeeaaes 7 18 3 2 Jib Boom Lift Cylinder S 105 and S 125 Models cccecceceeesseeeeeeseteeeeees 7 20 Boom Components kl Cable Nrack corrain ede es aad eee ede dees 7 23 d2 TEE 7 26 4 3 Boom Lift Cylinder 2 0 eee cceceeeeeneeeeeeeeeeeeeaaeeseeeeeeeaaeeeseaaeeeseeeeessiaaeeseas 7 37 4 4 Extension Cylinders AA 7 39 Ab Boom Extend Retract Cables 0 ccccccccceeeceeceeeseeeeeeeeeeeesecueeeeeeeeesstaeeeseaes 7 43 Turntable Covers 5 1 Turntable Covers ssssssssssseessessssessssssrenssosnsetnnsrsnnnssnnstnnnstenssttnscnnnsonnnonnnnnt 7 47 Engines ECH RPM Adjustment eu ccd enceeniidceedidceenvenienraienniennel 7 49 oa Flex Plate EE 7 49 6 3 Oil Pressure and Coolant Temperature Sending Units Cummins and Perkins Models ssssessssseeeeseesesesirrssrrnsstnnssrnnsrnsssrnnssrnnsnn 7 50 6 4 Oil Pressure and T
51. V36LFS BL 22 UNUSED 23 PIN 23 V37LFS BL BK 23 P61LS A GR CONNECTORS Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 11 Section Ge Schematics First Edition First Printing Platform Controller Pin Legend J1 BLACK 23 PIN CONNECTOR PCON PLATFORM CONTROLLER J2 1 VLVRET BR 2 UNUSED 3 C17PRL GR 4 C18PRR GR BK 5 C43JU GR 6 C44JD GR BK 7 C14PLU OR 8 C15PLD OR BK 9 UNUSED 10 R90PXS RD BK 11 C90PXS RD BK 12 RET94LDS WH 13 C94LDS WH 14 R94LDS WH 15 C88PTS RD BK 16 R56PTS RD 17 C56PTS RD 18 UNUSED 19 PLATRET BR 20 C84TAY GR BK 21 P85PTS GR 22 PTSRET BR 23 P87PTS RD PCON PLATFORM CONTROLLER J1 1 GNDPCON BR 2 P52PCON BL RD 3 UNUSED 4 S56PRV RD 5 UNUSED 6 UNUSED 7 P56PRV RD 8 UNUSED 9 UNUSED 10 D80SHLD 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 C470UT WH BK 16 C46HN WH 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 UNUSED 21 UNUSED 22 UNUSED 23 P23PCON BK J2 WHITE 23 PIN CONNECTOR f E co OD CC e CH me OOOC N el Gel Se PIN NUMBERING FOR 23 PIN CONNECTORS 6 12 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 First Edition First P
52. screen Turn the key switch to the OFF position Press and hold the 1 button and turn the key switch to ground controls Press the buttons and scroll down until BOOM EXTEND SPEED is shown on the display screen Is the speed is 100 precent software version 1 06 and later Proceed to the next step yes Test LSB13A0 for proper operation See Repair Section bad Continued on page 5 75 CHART 18 software version 1 01 Reset the ramp time to 250 ms software version 1 06 Reset the ramp time to 500 ms no Reset the boom speed to 100 good Recheck the operation of the boom Retract the boom 3 feet then extend the boom If the boom fails this test begin troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 73 Section 5 Troubleshooting Flow Charts EE CHART 18 Continued from the previous page Disconnect LSB3EO Are the terminals no properly inserted into the deutsch connector yes Test LSB3EO for proper operation See Repair Section bad good Check for an open or short in C71PBE and C64LS wire circuits bad Trace the circuits back to the ground control box Check the wiring at the connector between the upper and lower limt switch harness Make sure that terminal 10 on J20 is properly inserted A
53. the boom if the platform controls become ke Too rpi inoperative or for returning the machine to a safe High idle 2350 rpm position when the safety switches have been tripped Perform this procedure with the axles retracted 1 Open the ground controls side turntable side cover 4 44 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section A Scheduled Maintenance Procedures SEH TABLE B PROCEDURES 2 Pull out the Emergency Stop button to the on position at both the ground and platform controls 3 At the ground controls turn the service bypass recovery key switch to the RuN position 4 Turn the main key switch to ground control start the engine and then turn the key switch to platform control 5 Check any machine function from the ground controls Result The machine functions should not operate 6 Turn the main key switch to ground control 7 Check any machine function from the platform controls Result The machine functions should not operate 8 Turn the main key switch to the orF position Result The engine should stop and no functions should operate 9 Open the ground controls side turntable side cover 10 Turn the main key switch to ground control and start the engine 11 Raise the boom Result The boom should raise to 10 above horizontal and then stop The boom should not raise above the limit switch unless both axles are extended
54. vertical 120 ft to 0 36 6 mto0 170 to 190 seconds Length transport position 39ft11in 39 ft 11 in 12 17 m 12 17 m Turntable rotate 360 F boom horizontal and Length stowed 42 ft 8 in 46 ft fully retracted 170 to 190 seconds 13 m 14m Turntable rotate 360 Width axles retracted 8 ft 6 in 8 ft 6 in boom horizontal and 259 cm 259 cm extended gt 0 ft gt 0 m 285 to 315 seconds Width axles extended 11 ft6in 11 ft6in Turntable rotate 360 351 cm 351 cm boom horizontal and e s Height stowed maximum 10 ft 1 in 10 ft 1 in extended gt 80 ft gt 24 4 m 490 to 540 seconds g 308 cm 308 cm Platform rotate 160 18 to 22 seconds Weight 39 700 Ibs 40 000 Ibs 18 007 kg 18 143 kg Ground clearance 151 2 in 151 2 in 120 ft 36 6 m 39 cm 39 cm TOMES a M seen Operational dimensions e NODE ESOS Un E LSB2RS Platform height maximum 100 ft 105 ft T 101 ft 30 8 m 30 5 m 32 m 90ft 27 4m 8 f LSB4E0 80 ft 24 4 m oot edam Working height maximum 106 ft 111 ft LSB13A0 LSB8AS 32 3 m 33 8 m 70 ft 21 3 m 53s SH SS Horizontal reach maximum 75 ft 80 ft 60 ft 18 3 m 75 5 ft 22 9 m 24 4 m 23 m g 50 ft 15 2 m SR Maximum load capacity 750 Ib 500 Ib aa 340 kg 227 kg 40 ft 12 2 m Turntable tailswing 66 in
55. 4 Raise the boom until the engine rom switches to low speed 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 7 Continue at full speed and note the time when the machine reference point crosses the finish line 40 ft 40 sec 12 2 m 40 sec Drive speed raised position 8 Lower the boom below horizontal 9 Extend the boom approximately 4 feet 1 2 m 10 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 11 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 12 Continue at full speed and note the time when the machine reference point crosses the finish line 40 ft 40 sec 12 2 m 40 sec Drive speed extended position 13 Raise the boom to a horizontal position 14 Extend the boom until the raise boom LED and envelope alarm are activated 15 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start
56. 66 in SBS axles retracted 168 cm 168 cm Se Turntable tailswing 48 in 48 in an E axles extended 122 cm 122 cm SE OEC oam sekaan Wheelbase 12 ft 12 ft 2 366 cm 366 cm 2 B 8 a g ss Turning radius outside 24 ft 4 in 24 ft 4 in gt S e 2 e axles retracted 7 4m 7 4m 3 3 3 ba ka bo to _ gt ee Turning radius inside 16 ft 4 in 16 ft 4 in axles retracted 4 9m 4 9m Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 2 3 Section 2 e Specifications First Edition First Printing SPECIFICATIONS Turning radius outside 20 ft 8 in 20 ft 8 in Fluid capacities axles extended 6 3 m 6 3 m Hydraulic tank capacity 55 gallons Turning radius inside 10 ft 1 in 10 ft 1 in 208 liters axles extended 3 1m 3 1m Hydraulic system capacity 80 gallons Turntable rotation degrees 360 continuous including tank 303 liters Platform rotation 160 Fuel tank capacity 40 gallons 151 liters Maximum allowable 150 Ibs side force ANSI and CSA 667 N Airborne noise emissions 80 dB Maximum sound level at normal operating workstations Maximum allowable 90 DS A weighted side force CE 400 N Controls Platform dimensions 12V DC proportional Length 96 in 244 cm Width 36 in 91 cm Tires and wheels Tire size 15 x 22 5 18 pr FF Tire ply rating 18 Overall tire diameter 43 1 in 109 5 cm Wheel diameter 22 5 in 57 cm Wheel width 11 75 in 30
57. Battery System diesel number 2 D 63A 12V Type Quantity AH rating Cold cranking ampere Reserve capacity 25A rate 12V Group 27TM 1 109AH 630A 160 minutes Battery Engine starting Type Quantity AH rating Cold cranking ampere Reserve capacity 25A rate Cooling system Engine capacity System capacity 12V Group 4D 1 190AH 1020A 325 minutes 8 8 quarts 8 3 liters 20 quarts 18 9 liters 2 8 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 2 Specifications PH SPECIFICATIONS Deutz Engine F4L 913 Injection system Displacement 249 3 cu in Injection pump make IMSA 4 086 liters Injection pump pressure 8702 psi Number of cylinders 4 600 bar Bore and stroke 4 02 x 4 92 inches Injector opening pressure E Ge 102 x 125 mm Fuel requirement diesel number 2 D Horsepower 77 2200 rpm Firing order 1 3 4 2 Alternator output 55A 12V Compression ratio 18 1 Battery System Compression pressure Type 12V Group es pressure psi or bar of the lowest cylinder must be at a 109AH least 75 of the highest cylinder Se Bee Cold cranking ampere 630A Low idle no load 1300 rom Reserve capacity 25A rate 160 minutes High idle no load 2350 rom Battery Engine starting Valve clearance cold Type 12V Group 4D Quantity 1 Intake 0 006 in AH rating 190AH 0 15mm Cold c
58. C61AXRT GR 11 S62BSTO OR 12 P63LS OR RD 13 C64LS OR BL 14 C65LOFL BL WH 15 C66DREN BL 16 UNUSED 17 C68PBD RD 18 C69PBE BK 19 C70PBE BL WH 20 C71PBE BL BK 21 UNUSED 22 UNUSED 23 V74PRLO RD 24 V75PRLO RD WH 25 SNSR GND BR 26 UNUSED 27 G119SR BL 28 C76PBE BL 29 C77AS WH 30 C78PS WH BK 31 UNUSED 32 UNUSED 33 UNUSED 34 UNUSED 35 VLVRET1 BR S 100 amp S 105 MODELS 1 GNDDCON BR 2 P21DCON RD 3 P53LS WH BK 4 P54ENG BK WH 5 P56PRV RD 6 P57PBD RD WH 7 P58LS RD BK 8 SS9CNBK GR WH 9 C60AXEX GR WH 10 C61AXRT GR 11 S62BSTO OR 12 P63LS OR RD 13 C64LS OR BL 14 C65LOFL BL WH 15 C66DREN BL 16 UNUSED 17 C68PBD RD 18 C69PBE BK 19 C70PBE BL WH 20 C71PBE BL BK 21 UNUSED 22 UNUSED 23 V74PRLO RD 24 V75PRLO RD WH 25 SNSR GND BR 26 UNUSED 27 G119SR BL 28 UNUSED 29 C77AS WH 30 UNUSED 31 UNUSED 32 UNUSED 33 UNUSED 34 UNUSED 35 VLVRET1 BR 1 VLVRET1 BR 2 C35RPM BK RD 3 C21IGN WH 4 C34SA BK WH 5 V3OFWD WH 6 V31REV WH BK 7 C46HRN WH 8 UNUSED 9 C33STR BK 10 UNUSED 11 UNUSED 12 C25PSR WH BK 13 C26TSR WH RD 14 RET85TTSR GR 15 P85TTSR GR 16 VLVRET2 BR 17 UNUSED 18 C41RPM OR BK 1
59. Continued on the next page yes Chart 44 Is AUX PROPEL VALVE o If any other codes are FAULT present on the on the display screen display screen refer to the fault code chart for more information yes Check for an open or bad __ Repair or replace the short in the BL RD BL RD V52AFV wire V52AFV wire from pin 6 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the forward valve coil item JA good Check for an open or bad_ Repair or replace the short in the BL RD BL RD V52AFV wire V52REV wire from pin 7 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the reverse valve coil item JB good Check for an open or bad Repair or replace the short in the BR VLVRET BR VLVRET wire wire from pin 1 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the reverse and forward valve coils items JA and JB good Check the resistance of Ge 10 4 Consult the Genie the forward and reverse Industries Service valve coils items JA and JB Department 0 or infinite ohms Replace the valve coil PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 213 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 44 Activate the auxiliary pump and an auxiliary drive function Does the auxiliary pump turn on Continued from the pr
60. FAULT present on the display screen but SAFETY SWITCH P14 FAULT is NOT present no Is SAFETY SWITCH P12 FAULT and SAFETY SWITCH P14 FAULT present on the display screen no If any other codes are on the display screen refer to the fault code chart for more information yes yes Continued to page 5 176 Disconnect LSB7DS bad and check for proper in installation and operation See Repair Section good Check for an open or bad short in the RD SS6PRV wire from pin 5 of the J2 connector at the ground controls to pin 3 of the deutsch connector to LSB7DS good Check for an open or bad short in the OR S62BSTO wire from pin 4 of the deutsch connector to LSB7DS to pin 11 of the J2 connector at the ground controls to pin 3 of the deutsch connector to LSB3RS CHART 34 Replace and adjust LSB7DS See Repair Section Repair or replace the RD S56PRV wire Repair or replace the OR S62BST0 wire PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 175 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 34 Disconnect LSB3RS and check for proper operation and installation See Repair Section Continued from page 5 175 Check for an open or short in the GR C61AXRT wire from pin 4 of the deutsch connector to LSB3RS to pin 7 of the 12 pin deutsch connector on the turntable to the upper
61. FD good Check for an open or short in the BR VLVRET7 wire from pin 27 of the J4 connector at the ground controls to pin 2 of the DIN connector at the boom down valve coil item BD or item FD no good Test the resistance of the boom down valve coil 0 or infinite ohms Replace the boom down valve coil If any other fault codes are present refer to the fault code chart at the beginning of this section for more information 3 3 to 5 3 ohms bad _ Repair or replace the RD BK C02PBD wire bad __ Repair or replace the BR VLVRET7 wire Consult the Genie Industries Service Department 5 52 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Are there mechanical restrictions keeping the boom from raising Continued from page 5 49 Activate the function enable high RPM button and the boom down button Manually override the boom down directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold Start the engine and activate the function enable high RPM button and the boom down buttonand check the pressure Exchange boom up down flow control valve item BF or item FF with the boom extend retract flow control valve
62. Hydraulic OH 4 86 E 2 Change or Recondition the Engine Coolant Liquid Cooled Models 4 89 E 3 Change the Fuel Hoses ossesseeessseeseenssesrnesrrnernnttneessttnssrnnetnnnsrnnnnsrenssenn 4 90 EA Check the Engine Valve Clearances Cummins Models 4 92 E 5 Check the Fuel Injectors Deutz Models ccceceeeeeeeeeeeeeeeeeeeeeeeteeeeees 4 92 EG Remove and Inspect the Boom Extend Retract Cables s s s 4 93 viii Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing KE Section Five TABLE OF CONTENTS Troubleshooting Flow Charts tt tee e EE 5 1 Fault Code Chatt ses eaves ceed d e seet beta stewnere lava aaaea Ea dadevaecns teedecta eile 5 3 1 Display NOL ACUVG EE 5 11 2 Engine Will Not Crank Over 0 cceceeceeeeceeececeeeeeeeeeeeeaaaeeeeneeeeeeaaeesesaeeeeeeneees 5 16 3 Engine Cranks Over But Will Not Start cceecceeeseeeeeeeeeeeeeeeeeeseneeeeeneees 5 22 4 Engine Starts and Runs for 3 Seconds and Dies senene 5 25 5 Engine High Idle Inoperative eesseeesssrneesserrreeernnnensrnennnnnnrnnnnnntnnnnnnennnnnnnne 5 28 6 Engine Low Idle inoperative rreran nran ee RRRA 5 30 7 All Functions Inoperative Engine Starts and Runs s s s 5 31 8 Boom Up Down Extend Retract Turntable Rotate and Platform Functions Inoperative Drive Steer and Axle Extend Retract Functions Operationa 5 32 9 All Platform Steering and Axle Functions Inoperative All
63. J2 harness to the lower J2 harness Check for an open or short in the GR C61AXRT wire from pin 7 of the 12 pin deutsch connector on the turntable to the lower J2 harness to the upper J2 harness to pin 3 of the 6 pin deutsch connector at the electric swivel Check for an open or short in the BR wire from from pin 3 of the 6 pin deutsch connector on the turntable side of electric swivel to pin 3 of the 6 pin deutsch connector on the drive chassis side of electric swivel Continued on the next page Replace and adjust LSB3RS See Repair Section Repair or replace GR C61AXRT wire Repair or replace the GR C61AXRT wire Replace the electric swivel OR consult the Genie Industries Service Department 5 176 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Check for an open or short in the GR C61AXRT wire from pin 6 of the J1 connector at the drive chassis controller DCON to pin 3 of the 6 pin deutsch connector at the electric swivel Repair or replace the GR C61AXRT wire Check for an open or short in the OR S62BSTO wire from pin 3 of the deutsch connector to LSB3RS to pin 6 of the 12 pin deutsch connector at the ground controls to the upper J2 harness to the lower J2 harness Repair or replace the OR S62BST0 wire Check for an
64. J3 connector at the ground controls to pin 2 of the Din connector on the electronic proportional control EPC at the drive pump good 4 8 to 6 8 ohms Consult the Genie Industries Service Check the resistance of the electronic proportional control EPC on the drive pump Department 0 or infinite ohms Replace the EPC If any other codes are present on the display screen refer to the fault code chart for more information PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 191 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 39 Check for a short or open in the WH RD V32BRK wire from pin 15 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the brake valve coil item DO Repair or replace the WH RD V32BRK wire Continued from the previous page Check for a short or open in the BR VLVRET1 wire from pin 1 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the brake valve coil item DO Repair or replace the BR VLVRET1 wire Check the resistance of Consult the Genie the brake valve coil Industries Service item DO Department 0 or infinite ohms Replace the coil 5 192 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE
65. Key switch contact legend With the ground controls Emergency Stop button pulled out to theon position check the voltage on the PK wire at terminal 3 of key switch contact AB the pink wire checked should originate at the Emergency Stop button With the key switch turned to ground controls and the Emergency Stop button pulled out to theon position check the voltage on the OR wire at terminal 4 of key switch contact AB With the ground control Emergency Stop button pulled out to theon position check the voltage on the GR wire at terminal 3 of key switch contact BB the green wire checked should originate at pin 3 of the J7 connector Continued on the next page Repair open in PK wire from the Emergency Stop button to the key switch Check to see if the key switch internal cam is activating key switch contact AB Replace key switch contact AB Replace the key switch Repair open in GR wire Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 10 With the key switch Check to see if the key turned to ground switch internal cam is controls and the activating key switch Emergency Stop button contact BB pulled out to the ON position check the voltage at purple wire at terminal 4 of key switch contact BB Replace key switch contact BB Continued from th
66. OR consult the Genie Industries Service Department 5 18 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 2 Disconnect LSB7DS Check LSB7DS by Please begin Continued from the continuity GE and check for voltage at measuring for continuity troubleshooting from the H page pin 3 at the deutsch between pin 1 and pin 2 beginning of the chart connector Is there and between pin 3 and voltage present pin 4 no continuity Check the main key SE Make sure cam on the Key switch switch Contact BA iq key switch is not contact legend should be OPEN in the Ge A damaged or stripped ae eeh 7 p repair or iers Sc when the key neccessary Inspec is turned to platform and repair contact block controls or ground BA as required yes controls switch OK Replace the ground control box OR consult the Genie Industries Service Department NO AJ Replace LSB1DO Connect LSB7DS Disconnect LSBiDO and check for voltage on pin 3 of the deutsch connector Is there voltage present yes Connect L B1DO NO AJ Replace LSB3RO Disconnect LSB3RO and check for voltage on pin 3 of the deutsch connector Is there voltage present yes Continued on the next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 19 Section 5 Troubleshooting Flow Charts First Edition First Print
67. OR repair or replace the steer cylinder OR repair or replace the pilot operated check valves items EM and EBB OR consult the Genie Industries Service Department Replace the faulty steer valve PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 181 Section 5 Troubleshooting Flow Charts EE CHART 36 Continued from the previous page Is STEERING JOYSTICK SHORTED TO 0 VOLTS or STEERING JOYSTICK SHORTED TO 5 VOLTS or STEERING JOYSTICK VALUE TOO HIGH or STEERING JOYSTICK VALUE TOO Low present on the display screen yes Is BLUE END YELLOW SIDE STEER SENSOR SHORTED TO 0 VOLTS or yes BLUE END YELLOW SIDE STEER SENSOR SHORTED To 5 VOLTS or BLUE END YELLOW SIDE STEER SENSOR VALUE TOO HIGH or BLUE END YELLOW SIDE STEER SENSOR VALUE TOO LOW present on the display screen no Continued on the next page Check for damaged wires in internal platform controls wire harness between steer joystick connector P4 and and circuit board connector P20 OR consult the Genie Industries Service Department Check square end blue end yellow side steer sensor for proper installation and Operation see Repair Section good Check for an open or short in the OR C111RFS wire from pin B of the square end yellow side steer sensor connector to pin 12 of the J2 connector on the drive chassis controller DCON good Check for an open or short in the GR WH
68. Oil capacity including filter 8 4 liters Perkins 1004 42 Engine Engine oil viscosity requirements below 32 F 0 C ow 13 F to 68 F 25 C to 20 C 5W 20 10 F to 104 F 12 C to 40 C 10W 30 14 F to 122 F 10 C to 50 C 15W 40 above 23 F 5 C 20W 50 Engine oil should have properties of API classification CF4 grade OR ACEA classification E3 TABLE A PROCEDURES A 5 Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and can damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be in the NORMAL range Bodily injury hazard Fluids in the AWARNING radiator are under pressure and extremely hot Use caution when removing cap and adding fluids Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE A PROCEDURES A 6 Check the Engine Belt s Cummins Models Maintaining the engine belt s is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt s and continued use may cause
69. Other Functions Operation 5 33 10 Ground Controls Inoperative Platform Controls Operate Normally 0 5 38 11 Platform Controls Inoperative Ground Controls Operate Normally 2 5 40 12 Boom Angle Switch Fault 0 cccececcecceseeeeeeeeeeeeeeececeeeeeeeeeeesaaeeseeeeeesenaaeeee 5 42 138 Boom Up Function Inoperative 20 0 cee eeeeeeeeeeeeeneeeeeeeeaaeeeeeeeeaaeeeeeeeeaas 5 45 14 Boom Down Function Inoperative sisissssissi ressas iaaa aa 5 49 15 Boom Length Switch Faute 5 54 16 Boom Extend Function Inoperative ec ceceeee centers eeeenneeeeeeeenaeeeeeeeeaes 5 58 17 Boom Retract Function Inoperative sasssa 5 67 18 Boom Envelope Operational Switch Failure S 100 and S 105 Models 5 72 19 Boom Envelope Operational Switch Failure S 120 and S 125 Models 5 77 20 Boom Envelope Safety Switch Failure S 100 and S 105 Models 00 5 86 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 ix First Edition First Printing a ________________ TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 21 Boom Envelope Safety Switch Failure S 120 and S 125 Models 0 5 104 22 Turntable Rotate Clockwise Function Inoperative cccccseeeeeeeesteeeees 5 128 23 Turntable Rotate Counter Clockwise Function Inoperative cceeeeeeee 5 133 24 Platform Level Function Inoperative cc ceceeeeeeeeee
70. S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Jib Up Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position activate the function enable high RPM button and the jib up button Are there any diagnostic codes present on the display at the ground controls yes Continued on the next page no Activate the function enable and the jib boom up button Is there an audible beep yes Test the jib boom up down toggle switch at the platform controls for proper operation See Repair Section Is the switch faulty no Check for an open or short in the internal platform control box wire harness between the 3 1 3 2 and 3 3 connectors at the toggle switch and pins 10 9 and 12 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function manifold and start the engine At the ground controls press and hold the function enable button and activate the jib boom up button and check the pressure 3000 PSI or more Are there mechanical restrictions keeping the jib boom up function from
71. SIDE If any other codes are alta Lea the STEER VALVE FAULT present on the display H page present on the display nO l screen refer to the fault code chart for more information screen yes Check for an open or bad Repair or replace the short in the BL V36LFS BL V36LFS wire wire from pin 22 of the J2 connector at the drive chassis controller DCON to pin 1 of the Din connector at the square end blue side steer valve coil item EB or item HQ good Check for an open or bad Repair or replace the short in the BL BK BL BK V37LFS wire V37LFS wire from pin 23 of the J2 connector at the drive chassis controller DCON to pin 1 of the Din connector at the square end blue side steer valve coil item EB or item HQ good Check for an open or bad __ Repair or replace the short in the BR BR VLVRET2 wire VLVRET2 wire from pin 14 of the J2 connector at the drive chassis controller DCON to pin 2 of the Din connector at the square end blue side steer valve coil item EB good Check the resistance of 4 8 to 6 8 Consult the Genie the square end blue ohms Industries Service side steer valve coil item EB Department 0 or infinite ohms Replace the valve coil 5 180 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Blue End Yellow Side Steering Function Inoperative Be sure all o
72. Section Check for proper installation of LSB3EO OR consult the Genie Industries Service Department Repair or replace BL BK C71PBE wire circuit from pin 10 of the 12 pin deutsch connector on turntable that joins lower J2 harness to the upper J2 harness to pin 20 of the J2 connector on the ground control box PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 57 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 16 Boom Extend Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the boom is within the operation envelope zone Be sure the batteries are fully charged and properly connected With the key switch turned to ground no controls and both Emergency Stop buttons pulled out to theon position activate the high RPM function enable button and the boom extend button Are there any fault codes present on the display screen yes Is BOOM EXT RET JOYSTICK NOT yes CALIBRATED present on the display screen Is BOOM EXT RET JOYSTICK SHORTED TO 0 VOLTS BOOM EXT RET JOYSTICK SHORTED TO 5 VOLTS BOOM EXT RET yes JOYSTICK VALUE TOO HIGH or BOOM EXT RET JOYSTICK VALUE TOO Low present on the display screen no Is SAFETY SWITCH PQA FAULT present on the display screen Continued on the next page Press the boom extend button Is
73. Section good Continued on the next page Check LST10 for proper operation and installation See Repair Section good Check for short on BL C66DREN wire from pin 3 of the deutsch connector to LST10 to pin 15 on the J2 connector at the ground controls good Consult the Genie Industries Service Department Push the drive enable button Do you hear an audible beep when button is activated no Consult the Genie Industries Service Department Replace and adjust LST10 See Repair Section Replace and adjust bag LST10 See Repair Section bad __ Repair or replace the BL C66DREN wire Consult the Genie Industries Service Department 5 202 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 41 Check for an open in the BL C66DREN wire from pin 3 of the deutsch connector at LST10 to pin 15 of the J2 connector at the ground controls Repair or replace the BL C66DREN wire Continued from the previous page Check for an open or Repair or re short in the OR BK OR BK C64 C64LS wire from pin 4 of the deutsch connector at LST10 to pin 13 of the J2 connector at the ground controls oe the S wire Contact the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 203 Section 5 Tro
74. between platform Refer to charts 13 and 14 to HIGH platform control card and up down joystick or troubleshoot Joystick may need to be replaced UP DOWN JOYSTICK VALUE TOO Up down functions inoperative from Damaged circuit between platform Refer to charts 13 and 14 to LOW platform control card and up down joystick or troubleshoot Joystick may need to be replaced UP DOWN BUTTONS FAULT Up down functions inoperative from Shorted boom up down membrane _ Consult Genie Industries Service turntable on turntable membrane panel Department The turntable membrane panel may need to be replaced BOOM UP DOWN SPEED NOT Up down function speeds to fast or to Up down speed calibration set from Calibrate Boom up down speed refer CALIBRATED slow display or Reset Boom up down flow valve defaults set from display Refer to Display module section to repair section BOOM UP DOWN FLOW VALVE NOT CALIBRATED BOOM UP DOWN FLOW VALVE FAULT BOOM UP VALVE FAULT BOOM DOWN VALVE FAULT BOOM ANGLE SWITCHES FAULT No movement on up down functions until joystick is moved past half stroke Up down functions inoperative Up function inoperative Down function inoperative Extend and up functions inoperative and boom down function operative only when boom is fully retracted Reset Boom up down flow valve defaults set from display Refer to Display module section Boom up down flow valve coil circuit op
75. boom Attempt to raise the boom Does the boom stop raising before 21 degrees NOTE IF THE BOOM RAISES TO MORE THAN 20 DEGREES IMMEDIATELY STOP Disconnect LSAX2ES from the wiring harness Fully lower the boom Attempt to extend the boom Does the boom stop extending at 3 5 feet 1 1 m NOTE IF THE BOOM EXTENDS TO MORE THAN 4 FEET 1 3 M IMMEDIATELY STOP Continued to page 5 125 Continued on the next page 5 108 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Connect LSB3EO Continued from the LSAX1EO LSAX2EO previous page LSAX1ES LSAX2ES LSB3RS LSB7DS to the wiring harness Extend the boom to approximately 5 feet 1 5 m Disconnect LSAX1ES Attempt to retract the axles Do the axles retract Continued to page 5 126 Connect LSAX1ES LSAX2ES LSB3RS LSB7DS to the wiring harness Extend the boom to approximately 5 feet 1 5 m Disconnect LSAX1ES Attempt to retract the axles Do the axles retract Continued to page 5 127 Continued on the next page CHART 21 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 109 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 21 Fully extend the axles no Visually check LSB3RS Disconnect LSB3RS from the wiring harness Replace and adjust for damage and che
76. button and check the pressure 3000 PSI or more Are there mechanical restrictions keeping the platform rotate clockwise function from operating yes Remove or repair the mechanical restrictions less than 3000 psi Chart 28 Replace the ground control membrane decal no OR consult the Genie Industries Service Department bad _ Repair or replace the yes Replace the toggle switch internal platform wire harness Repair or replace the platform rotate valve item CD or item GD OR repair or replace the rotator counterbalance valves OR repair or replace the platform rotator OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department Repair or replace the rotator counterbalance valves OR repair or replace the rotator OR no consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 151 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 28 Is PLATFORM ROTATE Test the platform rotate yes Continued from the previous page TOGGLE SWITCHES yes toggle switch at the FAULT present on the display screen platform controls for proper operation See Repair Section Is the switch faulty no Check for an open or bad short in the internal platform control box wire harness between the 1 1 S1 2 and 1 3
77. by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbol is selected then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line 40 ft 9 1 sec 12 2 m 9 1 sec Drive speed stowed position B 27 Test the Drive Speed Raised or Extended Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart and two lines on the ground 10 feet 3 m apart 2 Start the engine from the platform controls 3 Press the engine idle select button until the foot switch activated high idle rabbit and foot switch symbol is selected
78. charge pump and the high pressure filters are for the drive circuit Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the three filters mounted to the bulkhead TABLE B PROCEDURES 2 Place a suitable container under the filters 3 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 4 Remove the filter element from the housing 5 Inspect the housing seal and replace it if necessary 6 Install the new medium pressure filter element into the housing Genie part number 60858 and tighten it securely 7 Install the new high pressure filter elements into the housings Genie part number 60857 and tighten them securely 8 Clean up any oil that may have spilled during the installation procedure 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 10 Start the engine from the ground controls 11 Inspect the filter housings and related components to be sure that there are no leaks Medium and high pressure filters Genie part numbers eres E Medium pressure filter 60858 High pressure filter 60857 a high pressure filters b medium pressure filter Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 37 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 11 Inspect the Electrical Wiring
79. circle end of the machine to prevent the machine from rolling 2 Center a lifting jack of ample capacity 30 000 lbs 15000 kg under the drive chassis between the wheels at the square end of the machine 3 Lift the wheels off the ground and place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the square end of the machine disengage position engage position TABLE D PROCEDURES 5 Manually rotate each wheel at the square end of the machine Result Each wheel at the square end of the machine should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks Lower the machine lisi Fai AWARNING C llision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage 7 Chock both of the wheels at the square end of the machine to prevent the machine from rolling 8 Center a lifting jack of ample capacity 30 000 lbs 15000 kg under the drive chassis between the wheels at the circle end of the machine 9 Lift the wheels off the ground and place jack stands under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the circle end of the machine 11 Manually rotate each wheel at the circle
80. cm Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 433 9 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 2 e Specifications Performance Specifications S 100 and S 105 Models Drive speeds maximum Drive speed stowed 3 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec Drive speed raised or extended 0 7 mph 1 1 km h 40 ft 40 sec 12 2 m 40 sec Drive speed fully extended 0 4 mph 0 6 km h 40 ft 70 sec 12 2 m 70 sec Gradeability boom stowed 42 Boom function speeds maximum from platform controls Jib boom up S 105 models 28 to 32 seconds Jib boom down S 105 models 28 to 32 seconds Boom up 80 to 88 seconds 100 to 110 seconds Boom fully retracted Boom extended to gt 4 ft gt 1 2 m time between fully lowered and a fully raised position Boom extended to gt 80 ft gt 24 4 m time between 53 envelope limit and a fully raised position 50 to 55 seconds Boom down 80 to 88 seconds 100 to 110 seconds Boom fully retracted Boom extended to gt 4 ft gt 1 2 m time between fully raised and a fully lowered position Boom extended to gt 80 ft gt 24 4 m time between fully raised and the 50 envelope limit
81. code chart for more information CHART 25 Check for an open or bad Repair or replace the short in the OR C14PLU wire from pin 7 of the J2 connector at the platform control box to OR C14PLU wire pin 1 of the Din connector at the platform level valve coil item CH or item Gh good Check for an open or bad Repair or replace the short in the BR VLVRET BR VLVRET wire wire from pin 1 of the J2 connector at the platform control box to pin 2 of the Din connector at the platform level valve coil item CH or item GH good 4 4 to 6 4 ohms Consult the Genie Industries Service Check the resistance of the platform rotate valve Department coil item CH or item GH 0 or infinite ohms Replace the valve coil PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 143 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 26 Platform Level Down Function Inoperative Be sure all other functions operate normally Be sure the platform out of level LED and ICON are not flashing at the ground control box Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position activate the function enable high RPM button and the platform level down button Are there any fault codes present on the display screen yes
82. component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 2 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Inspect the engine belt for Cracking Glazing Separation Breaks 5 Replace the belt if any damage is found See D 8 Inspect the Engine Belt s 6 Inspect the generator belt if equipped for Cracking Glazing Separation Breaks a generator option b generator belt 4 8 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 7 Replace the belt if any damage is found See D 8 Inspect the Engine Belt s Cummins engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensione
83. connector and pin 3 of the P21 connector Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the WH BK P53LS wire Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the WH P54ENG wire 5 118 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from page 5 106 Using auxiliary power raise the boom to greater than 68 degrees and fully extend the yes boom Start the engine and disconnect LSB9AS Does the engine stop no Disconnect LSB2RS Does the engine stop SS no Disconnect the J20 12 pin and J21 8 pin yes deutsch connectors inside the counterweight area of the machine Does the engine stop and does P9A P9B P10 P11 P12 P14 P18 and boom length fault appear on the display screen at the ground controls no Continued on the next page Visually check LSB9AS bad for damage See Repair Section good Adjust
84. controls side of the machine The cover has to be removed before the following procedure can be completed 1 Remove the power to platform plug panel upper retaining fasteners and loosen the lower 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 retaining fasteners Remove the cover from the machine Crushing hazard The turntable AWARNING cover may become unbalanced and fall when it is removed from the machine if it is not properly supported Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 1 Section A Scheduled Maintenance Procedures First Edition First Printing 4 Remove the plug located on the top of the drive brake and check the oil level Result The oil level should be even with the bottom of the plug hole plug turntable rotate drive hub c drive brake oo 5 If necessary add oil until the oil level is even with the bottom of the plug hole 6 Install the plug into the drive hub Turntable rotate drive hub oil 92 fl oz 2 7 liters Capacity approximately Type SAE 80W 90 EP multipurpose gear oil TABLE B PROCEDURES B 15 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly
85. drive functions simultaneously though at reduced speed This setting maintains a consistent low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground controls 2 Pull out the Emergency Stop button to the ON position at both the ground and platform controls 3 Start the engine from the ground controls 4 Push and hold the high speed function enable speed select button rabbit symbol Result The engine should change to high idle 5 Release the high speed function enable speed select button Result The engine should return to low idle TABLE B PROCEDURES 6 Turn the key switch to platform controls 7 Atthe platform controls press the engine idle select button until high idle rabbit symbol is selected Result The engine should change to high idle a foot switch activated high idle indicator light b low idle indicator light c high idle indicator light d engine rpm select button 8 Press the engine idle select button until low idle turtle symbol is selected Result The engine should change to low idle 9 Press the engine idle select button until the foot swit
86. error messages The beacon if equipped should flash In cold climates the LCD readout screen will need to warm up before the display appears 2 Start the engine oon o TABLE A PROCEDURES Push and hold a function enable speed select button and push the boom up button Result The boom should raise to 10 above horizontal and then stop The boom should not raise above the limit switch unless both axles are extended Push and hold a function enable speed select button and push the boom down button Result The boom should lower and return to the stowed position Push and hold a function enable speed select button and press the boom extend button Result The boom will extend approximately 3 feet 1 m and stop The boom should not extend further unless both axles are extended Push and hold a function enable speed select button and push the boom retract button Result The boom should retract Turn the key switch to platform controls Press down the foot switch Move the drive control handle in the forward direction and push the extend axle button Result The machine should drive and the axles should extend The indicator light will flash while the axles are moving and stay on when the axles are fully extended The extend axle function will only work while the machine is moving Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edit
87. example 75 5 80 5 feet Greater than or equal to is indicated by gt on the display A digital protractor will be needed to properly troubleshoot the machine Be sure the batteries are fully charged and properly connected The ground control box display reads SAFETY SWITCH PQA FAULT and SAFETY SWITCH P9B FAULT or SAFETY yes el Continued on page 5 73 SWITCH P9B FAULT Did the engine shut off while the boom was extending no Did the engine shut off while the boom was being lowered Continued on page 5 75 Unable to determine from the operator when the safety switch was tripped Using auxiliary power retract the boom to less than 75 80 feet and lower the boom to a horizontal position on the engine _ the status screen an i scroll down until the engne boom length screen appears Extend the boom while observing the display screen Does the engine stop OR does the boom stop at 75 80 feet and is the raise boom arrow flashing boom Start the engine and raise the boom to greater than 53 degrees and extend the boom to more than 75 80 feet Activate the function enable high RPM button yes and the boom down button and lower the boom Does the engine stop with the boom at 50 degrees no Begin troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department Safety switch LSB4ES has tripped software version 1 0
88. for 3 Seconds and Dies Be sure to check the engine oil level and fill as needed Be sure to check fuel level and fill as needed Be sure to check coolant level and fill as needed Be sure fuel system is properly bled Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position check for diagnostic codes on the display screen at the ground controls Are codes present Is ENGINE OIL PRESSURE VALUE TOO LOW present on the display screen Is ENGINE OIL yes PRESSURE SENSOR VALUE TOO HIGH or ENGINE OIL PRESSURE SENSOR VALUE TOO LOW present on the display screen no Is ENGINE OIL PRESSURE SENSOR SHORT TO 5V present on the display screen no Is ENGINE OIL PRESSURE SENSOR SHORT TO OV present on the display screen Continued on the next page Chart 4 Consult the Genie Industries Service Department Replace oil pressure sending unit OR refer to the engine manual for troubleshooting low oil pressure Replace the oil pressure sensor Check for an open in the WT BK C25PSR wire from pin 2 of the J3 connector at the ground controls to the engine oil pressure sensor on engine bad_ Repair or replace the WT BK C25PSR wire good Replace the oil pressure sensor Check for a short in the WH BK C25PSR wire from pin 12 of the J3 conne
89. from 2 speed solenoid to fuel injection system is not binding or is defective Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position start the engine and select low RPM mode Does the 2 speed solenoid pull in Does the 2 speed solenoid move in and out without binding Check adjustment of the linkage and low idle adjustment See Maintenance Section Refer to the engine manual for troubleshooting the fuel injection system OR consult the Genie Industries Service Department Check for a short to battery positive in the BK RD C35RPM wire from pin 2 of the J3 connector at the ground controls to the 2 speed solenoid OR replace the K7 relay inside the ground control box Check the linkage or replace the solenoid Adjust the linkage or adjust the low idle See Maintenance Section Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts All Functions Inoperative Engine Starts and Runs Be sure the hydraulic suction line shutoff valves for the pumps are in the open position Be sure the hydraulic tank is filled to the correct level Be sure the batteries are fully charged and properly connected Check the pump suction line shutoff valves In the open position the valve handles s
90. from the RD P87PTS wire previous page display screen Check for an open or bad Repair or replace the short in the RD BK C88PTS wire from pin 15 of the J2 connector RD BK C88PTS wire at the platform controls to pin 6 of the deutsch connector at the platform level sensor Check for an open or bad_ Repair or replace the short in the BR PTSRET BR PTSRET wire wire from pin 22 of the J2 connector at the platform controls to pin 4 of the deutsch connector no at the platform level sensor ok Is SAFETY SWITCH P7R FAULT present on the display screen Replace the K2 relay inside the platform control box OR consult yes the Genie Industries Service Department no Consult the Genie Industries Service Department Continued on the next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 149 Section 5 Troubleshooting Flow Charts First Edition First Printing E CHART 27 Is SAFETY SWITCH P22R Check for an open or Rpair or replace the RD FAULT present on the short in the RD P56PRV P56PRV wire OR display screen wire from pin 7 of the J1 replace the main cable connector at the OR consult the Genie platform controls to pin 7 Industries Service of the J1 connector at Department the ground controls Continued from the previous page Replace the K1 relay inside the ground control box OR consult the Genie Industries Service Department
91. good Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department bad bad bad bad bad Remove the obstruction Remove the debris OR replace and adjust LSB20LO See Repair Section Replace and adjust LSB20LO See Repair Section Adjust LSB20LO See Repair Section Check the connectors for any metal particles good that might be shorting the terminals together bad Clean the connectors CHART 21 Visually trace the wiring harness from the deutsch connector to the ground control box checking for pinch points and chafed or shorted wiring and repair the BR VLVRET5 wire OR repair the RD BK C115LS wire PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 121 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21 Continued from page 5 107 Disconnect LSAX1ES from the wiring harness Attempt to raise and extend the boom Does the boom raise or extend yes Check for continuity between the BL RD J2 and RD P53LS wires if the boom raises and check for continuity between the OR BL J3 and RD WH P57PBD wires if the boom extends no continuity Check for continuity between terminals 1 and 2 of the connector to LSB7DS no continuity Consult the Genie Industries Service Department no continuity continuity Visually che
92. half stroke Turntable rotate functions inoperative Turntable rotate CW function inoperative Turntable rotate CCW function inoperative Section 5 Troubleshooting Flow Charts S Possible Causes Turntable rotate speed calibration set from display or Reset turntable rotate flow valve defaults set from display Refer to Display module section Reset turntable rotate flow valve defaults set from display Refer to Display module section Turntable rotate flow valve coil circuit open or shorted to ground or the coil itself is bad Turntable rotate CW valve coil circuit open or shorted to ground or the coil itself is bad Turntable rotate CCW valve coil circuit open or shorted to ground or the coil itself is bad FAULT CODE CHART Solution Calibrate Turntable rotate speed refer to repair section Calibrate turntable rotate Thresholds refer to repair section Refer to charts 22 and 23 to troubleshoot Refer to chart 22 to troubleshoot Refer to chart 23 to troubleshoot MULTI FUNCTION VALVE FAULT STEERING JOYSTICK NOT Multiple functions inoperative Boom up dwn ext ret and turntable rotate auxiliary functions inoperative Steering functions inoperative Multi function valve coil circuit open or shorted to ground or coil may be bad Steering joystick not calibrated Refer to chart 32 to troubleshoot Calibrate steering joystick refer to CALIBRATED repair section S
93. have properties of API classification CC SE or CC SF grades OR ACEA classification E1 96 Oil filter Genie part number 62430 Perkins 1004 42 Engine 8 9 quarts Oil capacity including filter 8 4 liters Perkins 1004 42 Engine Engine oil viscosity requirements below 32 F 0 C OW 13 F to 68 F 25 C to 20 C 5W 20 10 F to 104 F 12 C to 40 C 10W 30 14 F to 122 F 10 C to 50 C 15W 40 above 23 F 5 C 20W 50 Engine oil should have properties of API classification CF4 grade OR ACEA classification E3 Oil filter Genie part number 62427 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE CG PROCEDURES C 5 Check the Specific Gravity of the Coolant Liquid Cooled Models The quality of the coolant which is used can have a great effect on the efficiency and life of the cooling system Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Burn injury hazard Beware of hot ACAUTION engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns Perform this procedure with the machine on level ground Perform this procedure with the engine off 1 Put on protective clothing and eyewear 2 Operate the engine until it is warm enough to open the thermostat Continue to run the engine until the c
94. icon and alarm active Unit out of level LED icon and alarm active damaged or sensor may need to be replaced Open circuit in turntable level sensor X direction wiring Short in turntable level sensor X direction circuit wiring Damaged circuit in turntable level sensor X direction wiring or turntable level sensor may need to be replaced Damaged circuit in turntable level sensor X direction wiring or turntable level sensor may need to be replaced Open circuit in turntable level sensor Y direction wiring Repair open in circuit Refer to electrical schematic to troubleshoot Repair short in circuit Refer to electrical schematic to troubleshoot Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department to determine if turntable level sensor needs to be replaced Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department to determine if turntable level sensor needs to be replaced Repair open in circuit Refer to electrical schematic to troubleshoot Continued on next page Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Diagnostic code displayed TURNTABLE LEVEL SENSOR Y DIRECTION SHORTED TO 5V TURNTABLE LEVEL SENSOR Y DIRECTION VALUE TOO HIGH TURNTABLE LEVEL SENSOR Y DIRECT
95. if the rpm is incorrect and continued use may cause component damage Deutz models 1 Start the engine from the ground controls 2 Push one of the LCD screen buttons shown until 4 el engine rpm is displayed Result Low idle should be 1300 rpm Skip to step 11 if the low idle rpm is correct 3 Remove the secondary idle adjustment screw cap from the secondary idle adjustment screw on the injection pump Loosen the locknut SS L ST 2 H 1 d kel L geld RS il ah is I E eg Deutz engine a primary idle adjustment screw b secondary idle adjustment screw Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 4 Turn the secondary adjustment screw counterclockwise until the adjustment screw is loose Tighten the locknut Be sure the adjustment screw is loosened until there is no spring tension felt 5 Remove the primary idle adjustment screw cap from the primary idle adjustment screw on the injection pump Loosen the locknut 6 Adjust the primary idle adjustment screw until low idle is 1250 rpm Tighten the locknut 7 Install the primary idle adjustment screw cap and tighten Do not over tighten 8 Loosen the secondary idle adjustment screw locknut 9 Adjust the secondary adjustment sc
96. inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Checklist C First Edition First Printing Checklist E Refer to Table C Refer to Table E C 1 Valves Deutz models E 1 Hydraulic oil C 2 Fuel pump strainer Perkins models E 2 Engine coolant Liquid cooled models C 3 Fuel filter element Perkins and Cummins E 3 Fuel hoses C 4 Engine oil and filter Deutz and Perkins E 4 Valves Cummins models C 5 Check the coolant Liquid cooled models Perform every 3000 hours C 6 Boom extend retract cables Checklist D E 5 Fuel injectors Deutz models Perform every 5 years E 6 Remove and inspect boom extend retract cables Refer to Table D D 1 Boom wear pads D 2 Axle wear pads D 3 Free wheel configuration D 4 Turntable bearing bolts D 5 Turntable gear backlash D 6 Grease rotation bearing D 7 Drive hub oil D 8 Engine Belt s Cummins models D 9 Fuel filter Deutz models D 10 Valves Cummins and Perkins Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 F
97. item BB or item FB Check the boom down function Does the function operate Repair or replace the boom lift cylinder or cylinder counterbalance valves OR boom function manifold could have an internal fault Consult the Genie Industries Service Department Remove or repair the mechanical restrictions Replace the boom up down directional valve item BD or item FD Check for mechanical restrictions keeping the boom from moving OR repair or replace boom lift cylinder or cylinder counterbalance valve OR consult the Genie Industries Service Department Replace the faulty flow control valve CHART 14 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 15 Boom Length Switch Fault Be sure all other functions operate normally Be sure the boom length limit switches are properly connected to the correct wiring harness leads Be sure the batteries are fully charged and properly connected With the boom fully E retracted and boom angle less than 10 degrees is BOOM LENGTH SWITCHES FAULT present on the display yes Disconnect and test bad LSB3EO See Repair Section good With LSB3EO disconnected check for voltage on the BL BK C71PBE wire at pin 3 of yes the deutsch connector that was connected to LSB3EO Is there voltage present no S 100 and S 105
98. m without stopping the engine DANGER IF THE BOOM EXTENDS THE BOOM EXTEND TO MORE THAN 101 FEET 30 8 M WITHOUT STOPPING THE ENGINE STOP IMMEDIATELY Continued on the next page 5 104 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 21 Continued to page 5 115 Retract the boom to within 2 inches of full retraction and fully lower the boom Remove the boom end cover from the pivot end of the boom and remove the arm from the cable tension limit switch LSB6S Using the arm just removed from LSB6S rotate the head of the switch 45 degrees clockwise and attempt to extend the boom Does the boom extend and does P10 not appear on the display screen at ground controls DANGER IF THE BOOM EXTENDS STOP IMMEDIATELY Continued from the previous page Continued to page 5 115 Using the arm removed from LSB6S rotate the head of the switch 90 degrees counter clockwise and attempt to extend the boom Does the boom extend and does P10 not appear on the display screen at ground controls DANGER IF THE BOOM EXTENDS STOP IMMEDIATELY Continued on the next page Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 105 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21 Continued to page 5 117 Install the arm ont
99. machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Locate the fuel filter Thoroughly clean the outside surfaces of the fuel filter assembly TABLE CG PROCEDURES 6 Remove the fuel filter element and dispose of properly 7 Clean the inside surfaces of the filter head Fill the new fuel filter element with clean diesel fuel Lightly lubricate the O ring with clean diesel fuel and install the element into the filter head Failure to fill the fuel filter element with clean diesel fuel before installation will require bleeding the fuel system 9 Clean up any fuel that may have spilled during this procedure 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 11 Install the fuel tank line onto the inline fuel filter water separator head Tighten the hose clamp 12 Bleed the fuel system See Maintenance Procedure B 4 Replace the Inline Fuel Filter Water Separator Element Before bleeding the system fill the fuel tank Fuel filter elements Genie part numbers
100. moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions Be sure that the axles are fully extended before attempting this procedure 1 Start the engine from the platform controls and extend the axles 2 Measure each wear pad Ze inch 11 1 mm Extendable axle wear pad specifications Minimum thickness 3 Replace any wear pad if it is less than specification If a wear pad is not less than specification shim as necessary to obtain zero clearance and zero drag If the wear pads are still within specification refer to Repair Section 15 1 How to Shim the Extendable Axles 4 Extend and retract the axles through the entire range of motion to check for tight spots that may cause binding or scraping of the axle tubes Always maintain squareness between the outer and inner axle tubes Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures D 3 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage Collision hazard Select a work AWARNING site that is firm and level 1 Chock both of the wheels at the
101. nia n E ETRE 5 202 42 Drive Mode Select Inoperative ccceeeceeeeeeeeeeceeeeeeeeeeeeseaaeeeeeeeeeesaeeeeeas 5 204 43 Engine Start Assist Inoperative ecceeeecceeeeeeeeeeceeeeeeeeeeesaaeeseeeeeeeesaeeseeas 5 210 44 Auxiliary Drive Function Inoperative 20 0 0 ceeeeeeeeeeeeeennaeeeeeeeeaeeeeeeeeaaees 5 213 x Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing eee TABLE OF CONTENTS Section Six Schematics tte e e EE 6 1 Electrical GOMPONEMS sisata inna aa ene a a a 6 2 Wire Circuit Legend 6 4 Bulle ENEE 6 8 Delage deeg ee 6 10 Drive Chassis Controller Pin Legend ssssssssseessseessseessiresrrrsssrrssrnnsrnnnsennsssrnnnsrnnsnnn 6 11 Platform Controller Pin Legend 6 12 Turntable Controller Pin Legend ecccccceeeeceeeeceeeeeeeeeeeeeseaeeseeeeeeesaaeeseeeeeessaaeeseaes 6 13 Electrical Schematic Legend Drive Chassis DCON and Platform Controls PCON 0 eeeceeeeeeeeeeeteeeeeeeeees 6 14 Electrical Schematic Legend Ground Controls TCON cceceeeeeseeeseteeeeeeeeeees 6 15 Electric Symbols Legend scrsuisiireiriiaireiaia aaia aa 6 16 Electrical Schematic Drive Chassis and Platform Controls Sheet 1 of 2 located at end of manual Electrical Schematic Ground Controls Sheet 2 Of 21 located at end of manual Limit Switch Harness Schematic S 100 amp S 105 Model 6 17 Limit Switch Harness Schematic S 120 amp S 125 Model 6 18 Safety C
102. perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Tag disconnect and plug the fuel line from the fuel tank at the inline fuel filter water separator head Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 2 Loosen the vent plug located on the inline fuel filter water separator head T Vth G CH head bolt vent plug drain plug filter bowl filter element fuel filter water separator head wO Oo 0 o Place a suitable container under the filter bowl 4 Loosen the drain plug located at the bottom of the bowl Completely drain the fuel from the bowl 5 Loosen the head bolt Rotate the filter bowl counterclockwise and remove it from the element 6 Install the bowl onto the new inline filter element Genie part number 62433 Tighten the drain plug 7 Fill the element and bowl with clean diesel fuel 8 Apply a thin layer of oil onto the element gasket 9 Install the filter oowl assembly onto the filter head
103. range of operational functions Included in this group are envelope limit switches which sense the extended length and angle of the boom position of the axles and rotational position of the turntable For example when the 53 operational switch is activated by achieving a 53 boom angle the boom may then be extended beyond 75 feet 22 9 m Another example is the drive enable limit switch which disables the drive function anytime the boom is rotated past the rear axles indicated by the square end of the drive chassis In some cases the engine will be stopped if safety parameters are exceeded Magnetic proximity switches are used to sense very specific positions of a part of the machine in relation to the remainder of the machine Proximity switches must be correctly aligned for the machine functions to operate Proximity switches are found at the front and rear axle the turntable and several locations on the boom Limit Switch Numbering LSAX1RO LSAX2RO LSAX1EO LSAX2EO LSAX1ES LSAX2ES LSB6S LSB7DS LSB3RS LSB2RS LSB9AS LSB8AS LSB4ES LST10 LSB1DO LSB2RO LSB3RO LSB3EO LSB4EO LSB13A0 LSB14A0 LSB19LO LSB20LO Front axle retract proximity Rear axle retract proximity Front axle extend proximity Rear axle extend proximity Front axle extend safety Rear axle extend safety Cable tension safety Boom 11 angle safety Boom 3 foot 0 9 m extend safety Boom 101 feet 80 8 m ex
104. s Cummins Models Maintaining the engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Body injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine engine pivot plate anchor hole engine pivot plate retaining fastener o o 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 2 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate anchor hole to secure it from moving could result in death or serious injury If the machine is not equipped with the generator option proceed to step 7 4 Loosen the generator and remove the generator belt 5 Inspect the generator belt for Cracking Glazing Separation Breaks a generator option b generator belt Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 6 Replace the
105. stop immediately and retract the boom until the boom is extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury 31 Activate the function enable high RPM button and attempt to retract the boom Result The boom retract function should be disabled Result If the boom retracts the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired See Repair Section 32 Rotate the head of the switch 45 degrees clockwise and install the arm onto LSB6S Axle Extend Safety Switch LSAX1ES and LSAX2ES and 3 feet 0 9 m Safety Switch LSB3RS and 11 Angle Safety Switch LSB7DS 33 Fully retract and lower the boom to the stowed position 34 Retract both axles approximately 1 foot 0 3 m 35 Remove the access cover from each axle 36 Disconnect the square end axle extend safety switch LSAX1ES and install a wire jumper between pin 3 and pin 4 of the deutsch connector 37 Place a metal washer over the target area of the axle extend proximity switch LSAX1EO and place a metal washer over the target area of the axle extend proximity switch LSAX2EO to close the contacts Result The axle extend indicator light at the ground and platform controls should be illuminated P Proximity switch a target area Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Proce
106. that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 21 Check the coolant level in the coolant recovery tank Add coolant if needed Coolant capacity 20 quarts 18 9 liters E 3 Change the Fuel Hoses Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsafe operating condition Explosion and fire hazard Engine INYO S fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Bodily injury hazard Fuel may be ADANGER expelled under pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them Immediately clean up any fuel that may have spilled during this procedure Perform this procedure with the engine off Deutz models 1 Remove the engine side turntable fixed side cover Refer to Repair Section 5 1 How to Remove a Fixed Turntable Cover Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 2 Tag disconnect and plug the fuel line from the fuel tank
107. the K7 relay oV Has the 40A circuit breaker been tripped CH yes Check for a short in the BK RD C35RPM wire circuit from pin 2 of the J3 connector on ground control box to 2 speed solenoid Repair or replace the RD BK C35RPM wire Replace the ground control box OR consult the Genie Industries Service Department Replace the ground control box OR consult the Genie Industries Service Department Check the voltage at terminal 87 of the K7 relay Replace the K7 relay Replace the ground control box OR consult the Genie Industries Service Department 5 28 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 5 Continued from the BRN VLE ote ge previous page circuit from pin 1 of the J3 connector at the ground control box to the 2 speed solenoid Repair or replace the BRN VLVRET wire Does the 2 speed solenoid move in and out without binding Check the linkage for inding Repair or replace the linkage lo a Replace the solenoid Replace 2 speed solenoid OR consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 29 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 6 Engine Low Idle Inoperative Be sure that mechanical linkage
108. the boom end cover from the pivot end of the boom a boom end cover b side access covers c cable ends located underneath the boom TABLE CG PROCEDURES Remove the retaining fasteners from the access covers located on the side of the boom at the platform end of the machine Remove the covers Visually inspect the cables and components through both inspection holes for the following Frayed or broken wire strands Kinks or crushed cables Corrosion Paint or foreign materials on the cables Split or cracked cable ends Cables are on all pulleys Cables have equal tension Cables at end of adjustment range No Broken or damaged pulleys No Unusual or excessive pulley wear All fasteners in place and secure A flashlight and inspection mirror may be necessary to thoroughly inspect the above items A pulley groove gauge should be used to check the condition of the pulleys Replace the cables if any damage is found At the pivot end of the boom visually inspect for the following The red locking bracket is securely installed over the cable adjustment bolts Install the plastic cover at the pivot end of the boom and access panels on the sides of the boom Start the engine from the platform controls Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 71 Section 4 Scheduled Maintenance Procedures First Ed
109. the diesel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Explosion and fire hazard Engine ADANGER 7 S fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Tag disconnect and plug the fuel hose from the fuel tank at the inline fuel filter water separator head 2 Place a suitable container beneath the fuel filter a overflow valve b fuel lift pump priming lever c oil filter d filter head e fuel filter 3 Loosen the fuel filter with a filter wrench and drain the fuel into a suitable container Remove the fuel filter from the machine when the fuel flow has slowed or stopped 4 Apply a thin layer of clean diesel fuel to the new fuel filter gasket Genie part number 29560 5 Install the new filter and tighten it securely by hand 6 Clean up any diesel fuel that might have spilled during the procedure 7 Use a permanent ink marker to write the date and number of hours from the h
110. the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING Bodiv injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine ee N 2a a engine pivot plate anchor hole b engine pivot plate retaining fastener Table B Procedures 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Inspect the radiator for leaks and physical damage 5 Clean the radiator fins of debris and foreign materials 6 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 7 Swing the engine pivot plate in towards the machine 8 Install the bolt that was just removed into the original hole to se
111. threads of the hydraulic tank filter mount 29 Install a new tank breather filter Genie part number 60559 onto the filter mount and tighten it securely by hand 30 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 31 Install a new tank case drain return filter Genie part number 44207 onto the filter mount and tighten it securely by hand 32 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 33 Install a new tank return filter Genie part number 61326 onto the filter mount and tighten it securely by hand 34 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 35 Clean up any oil that may have spilled during the procedure 36 Open the hydraulic tank shutoff valves CAUTION Component damage hazard Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Refer to Repair Section 10 2 How to Prime the Pump Use only Dexron equivalent hydraulic fluid 37 Install the turntable side cover Hydraulic system Hydraulic tank capacity 55 gallons 208 liters Hydraulic system 80 gallons capacity including tank 303 liters Hydraulic fluid Dexron equivalent Hydraulic tank return filters Genie part numbers Hydraulic tank breather filter 60559 System return filter 61326 Drive motor case drain retur
112. to the electric swivel and electric swivel case or to return the faulty electric the BLK wire of pin 2 of swivel to Genie either of the P8 Industries connectors at the electric swivel Not shorted Check for a short in the If circuit breaker trips RD S56PRV wire circuit when the engine is from pin 2 of the J8 Not started refer to Chart 3 connector at the electric shorted Engine Cranks Over But swivel to pin 5 of the J1 Will Not Start connector at the drive If the circuit breaker chassis controller trips when high rpm is DCON activated refer to Chart 5 Engine High Idle Inoperative If the circuit breaker trips when start assist is activated refer to Chart 43 If the circuit breaker still trips replace the circuit breaker OR consult the Repair or replace the RD S56PRV wire Genie Industries Service Department CHART 1 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 15 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 2 Engine Will Not Crank Over Be sure to check fuel level Be sure the key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the on position Be sure the circuit breakers are not tripped Be sure the batteries are fully charged and properly connected Key switch contact legend With the key switch yes turned to ground controls and both Emergency St
113. under platform has run into an obstruction or is out of adjustment Load in platform is above rated load or load sensor is out of adjustment Refer to chart 27 to troubleshoot Refer to chart 27 to troubleshoot Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department Activate spare membrane and carefully move away from obstruction or readjust proximity kill limit switch Unload excessive weight out of platform or readjust load sensor BOOM UP OVERLOAD FAULT All functions except Boom retract Load in platform is above rated load Unload excessive weight out of inoperative or boom has run into an obstruction platform or readjust limit switch or or boom up overload switch is out of move away from obstruction adjustment BOOM DOWN OVERLOAD FAULT All functions except Boom up and Boom has been lowered into an Refer to chart 14 to troubleshoot PRESS PLATFORM ESTOP retract inoperative Code displayed whenever engine is running and controller is waiting for engine to be shut off to save calibrations or any parameter changes made with the display to memory obstruction with boom extended or boom down overload switch is out of adjustment or there is an open in boom down overload circuit Just finished a speed calibration for boom up dwn ext ret or turntable rotate or Joysticks were calibrated with engine running or a function paramete
114. up es Replace the toggle down toggle switch at the platform controls for proper operation See Continued from the previous page switch present on the display screen no Continued on the next page Repair Section Is the switch faulty Check for an open or short in the internal platform control box wire harness between the 3 1 3 2 and 3 3 connectors at the toggle switch and pins 10 9 and 12 of the P20 connector at the circuit board good Check for an open or short in the jib boom up membrane button at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 7 of the J11 membrane decal connector at the circuit board good Check for an open or short in the jib boom down membrane button at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 4 of the J11 membrane decal connector at the circuit board good Consult the Genie Industries Service Department bad bad bad Repair or replace the internal platform wire harness Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the ground control box membrane decal OR consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 161 Section 5 Troubleshooting Flow Charts First Edi
115. yes Test LSB14A0 for bad oe and adjust proper operation See LSB14A0 See Repair Repair Section Section good damaged Check for an open or varing shortin C78AS and found C64LS wire circuits Trace the circuits back to the ground control control box or use an ohmmeter to check for continuity Repair or replace the C78AS or the C64LS wire circuits wires are OK Check pin 30 at the J2 nel jy Loosen but do not connector on the ground Geer remove the red control box to make sure secondary lock and re that the terminal is insert the terminal inserted properly Install the secondary lock in to secure the terminal in place properly inserted not properly inserted Check pin 13 at the J2connector on the ground control boxto make sure the terminal is inserted properly Loosen but do not remove the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place roperly neetiee Replace the ground control box OR consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 83 Section 5 Troubleshooting Flow Charts CHART 19 Press amp keys together to access the status screen Scroll down until BOOM ANGLE Continued from pages 5 77 5 78 and 5 79 is present on the display screen What boom angle is shown on the display gt 50 degrees Cont
116. 0 amp S 105 amp S 120 amp S 125 5 45 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 13 Is SAFETY SWITCH P11 FAULT present on the display Continued from the previous page Is BOOM ANGLE SWITCHES FAULT present on the display Is BOOM LENGTH SWITCHES FAULT present on the display Is BOOM UP DWN FLOW VALVE NOT CALIBRATED present on the display Is BOOM UP DWN FLOW VALVE FAULT present on the display no Continued on the next page yes yes yes yes yes Refer to Chart 20 OR Chart 21 Boom Envelope Safety Switch Failure Refer to Chart 12 Boom Angle Switch Fault Refer to Chart 15 Boom Length Switch Fault Calibrate boom up down joystick threshold See Repair Section Check for an open or short in the RD WH CO3PBF wire circuit from pin 2 of the J4 connector at the ground controls to pin 1 of the DIN connector on the boom up down flow control valve item BF or item FF good Check for an open or short in the BR VLVRET4 wire from pin 1 of the J4 connector at the ground controls to pin 2 of the DIN connector at the boom up down flow control valve good Test the resistance of the boom up down flow control valve 0 or infinite ohms Replace the boom up down flow control valve 3 3 to 5 3 ohms bad Repair or replace the RD WH CO3PBF wire bad __ Repair or replace the BR VLVRET4
117. 0 9m C O ptiom 3 ft 0 9m jf 3 5 ft 1 1m J S 100 amp S 105 Models S 120 amp S 125 Models S 100 shown S 120 shown LSAX1RO LSAX2RO A SE T Era 3 Ier LSAX1E0 LST10 LSAX2ES LSAX2E0 i Z LSAX1ES li z TE TEE TT Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 9 Section 6 e Schematics First Edition First Printing Relay Layout Fuel solenoid relay Deutz models only Oil cooler relay Deutz models only Engine cold start relay Starter relay Horn relay Flashing beacon relay CR17 relay K7 powers C35RPM circuit Hi low solenoid CR16 relay K8 powers C34SA circuit Engine cold start CR12 relay K4 powers primary valves 1 and 2 ignition glow plug starter relay generator and the boom retract multifunction and platform rotate valve coils CR14 relay K2 powers P7R or SS6PRV circuit including the auxiliary valve boom extend retract and turntable rotate valve coils CR10 relay K6 powers C21IGN and C107AF circuits Fue
118. 000 psi 207 bar less than 3000 psi Test the auxiliary pump bad __ Replace the auxiliary yos See Repair Section pump good Replace the auxiliary pump relief valve OR consult the Genie Industries Service Department Continued on the next page Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 165 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 32 Press and hold the auxiliary power button at the ground controls and hold the platform rotate button Does the platform rotate Continued the previous page yes Continued on the next page ec 2500 psi dere may be dirty OR repair disconnect the hose from port P2A IN of the distribution manifold and install a 0 to 5000 psi 345 bar pressure gauge into the pressure port of the pump Press and hold the auxiliary power button and press the platform rotate button and note the pressure or more or replace the battery cables less than 2500 psi Adjust the auxiliary Press and hold the pump 2500 psi relief auxiliary power button ae all the way in f pel SE press the cl Ee SC i de platform rotate button and hold the auxiliary power button and press the platform rotate button and note the pressure and adjust the relief valve pressure to 2500 psi 172 bar less than 2500 psi Test the auxiliary pump bad _ Replace the auxiliary See Repair Section
119. 01 First Edition First Printing Section 5 Troubleshooting Flow Charts Is PLATFORM LEVEL Continued from the DOWN VALVE FAULT previous page present on the display screen no If any other codes are on the display screen refer to the fault code chart for more information CHART 26 Check for an open or bad Repair or replace the short in the OR BK C15PLD wire from pin 8 of the J2 connector at the platform control box OR BK C15PLD wire to pin 1 of the Din connector at the platform level valve coil item CH or item GH good Check for an open or bad Repair or replace the short in the BR VLVRET BR VLVRET wire wire from pin 1 of the J2 connector on the platform control box to pin 2 of the Din connector at the platform level valve coil item CH or item GH good 4 4 to 6 4 ohms Consult the Genie Industries Service Check the resistance of the platform level valve coil Department item CH or item GH 0 or infinite ohms Replace the valve coil Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 147 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 27 Platform Level Safety Fault SAFETY SWITCH P22 FAULT SAFETY SWITCH P22R FAULT Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to g
120. 0AH 57160 Allied iiia Group 4D nsaisssssssnnen 1 BS EE Battery separator 61343 oe Surepower Industries T lee es 1 CBT EEN Circuit breaker 40A 61188 Klooien an 7851 37 40 l 1 CBZ e Circuit breaker 20A 61187 KIIXON ni 7851 37 20 l 000000 1 CR6 CR7 CR10 through E AR Relay SPDT 12V DC 24057 Potter Brumfield VF4 15F11 CO5 10 FA EE Fuse 20A Maxi Deutz models ee 75433 wee Bussmann MAX 20 1 SE Fuse 70A Maxi 61116 BUSSMAN 0c0ccceeee MAX 20 1 FB te ggen Seet Flashing beacon e 20189 aaaea ECCO Electronic Controls 6400A GEN osansa 2 FST ee a aas Foot switch ece EIERE Linemaster Switch Corp EE 1 H1 H Alarm Audio D32 0 Sauer Danfoss ENEE E 2 e EE Horn 12V DC 112 dB 0 54506 Wolo Industries B00LJ 12 eee 1 IGT JCI ket Joystick controller Dual axis ee 62390 osien Sauer Danfoss K26519 1090332 2 e Joystick controller Single axis eee 62391 oe Sauer Danfoss K26520 1090333 1 KS1 KS2 Contact NO 45081 Telemecanique ZB2 BE101 5 Contact N C oo 29732 eiis Telemecanique ZB2 BE102 6 6 2 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 6
121. 1 Engine stops and fault message scrolls across the screen version 1 04 and greater Engine stops and the retract boom LED amp LCD flash along with the auxiliary power button at the platform controls and the battery icon at the ground controls Safety switch LSB8AS has tripped software version 1 01 Engine stops and fault message scrolls across the screen software version 1 04 and greater Engine stops and the retract boom LED amp LCD flash along with the auxiliary power button at the platform controls and the battery icon at the ground controls Continued on page 5 73 Continued on page 5 75 5 72 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from page 5 72 Access the status screen and scroll down until the BOOM LENGTH screen appears on the display What boom length is shown on the display gt 0 Continued on the next page gt 80 Section 5 Troubleshooting Flow Charts PE Go to lift function ramp time Turn the key switch to the OFF position Press and hold the button and turn the key switch to ground controls Press J J and scroll down until boom EXTEND RETRACT RAMP DECEL appears on the display screen software version 1 01 Is the ramp time shown 250 ms software version 1 06 Is the ramp time shown 500 ms yes software version 1 01 Go to the boom functions speeds
122. 13AO mounting fasteners and adjust the switch so it closes when the boom angle reaches 53 degrees Loosen the LSB8AS mounting fasteners and adjust the switch so the contacts of the switch open when the boom angle reaches 50 degrees 5 84 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Disconnect LSB13A0 Are the terminals no inserted properly yes Test LSB13A0 See bad Repair Section good damaged Check for an open or wiring short in C77AS and Hound C64LS wire circuits Trace the circuits back to the ground control box wires are OK not Check pin 30 at the J2 connector on the ground poet control box to make sure that the terminal is properly inserted properly inserted not Check pin 13 at the J2 connector on the ground properly control box to make sure that the terminal is properly inserted roperly need Replace the ground control box OR consult the Genie Industries Service Department CHART 19 Remove the orange secondary lock and reinsert the terminals Install the orange secondary lock oe and adjust LSB13A0 See Repair Section Repair or replace the C77AS and C64LS wire circuits Loosen but do not remove the red secondary lock and re insert the terminal Install the secondary lock in to secure the termi
123. 16 J16 3 Way Deutsch CAN Connector SS4 SQUARE END BLUE SIDE LEFT FRONT Electrical Rotary Coupler to Drive Chassis Controller Harness P17 J17 6 Way Deutsch Connector Drive Chassis Controller Electrical TS TOGGLE SWITCH Rotary Coupler to DCON Harness TS tS RLATFORMRO TATE P17 J17 6 Way Deutsch Connector Drive Chassis Controller Electrical TS2 PLATFORM LEVEL Rotary Coupler to DCON Harness TS3 JIB BOOM UP DOWN P18 J18 2 Way Deutsch Connector y VALVE COIL Electrical Rotary Coupler to Drive Chassis Controller Harness Y1 AXLE RETRACT P33 J33 Platform Manifold Tilt Sensor Y2 AXLE EXTEND Y3 MOTOR SPEED Y4 AUXILIARY FORWARD Y5 AUXILIARY REVERSE Y6 BRAKE Y7 RR STEER RIGHT Y8 RR STEER LEFT Y9 LR STEER RIGHT Y10 LA STEER LEFT Y11 RF STEER RIGHT Y12 RF STEER LEFT Y13 LF STEER RIGHT Y14 LF STEER LEFT Y15 PLATFORM ROTATE CCW Y16 PLATFORM ROTATE CW Y17 JIB BOOM UP Y18 JIB BOOM DOWN Y19 PLATFORM LEVEL UP Y20 PLATFORM LEVEL DOWN A L B Cc I D I E I E I G I H I I J I K ji L I M ji N D I q oZ o p rm rm rn re rn 1 2 2 3 he 9 ti ia Hio AI Nt j REFER TO THE DRIVE CHASSIS AND PLATFORM CONTROLS SCHEMATIC SHEET 1 OF 2 IN THE BACK OF THE MANUAL 8 9 A I B o I D I E I E I G H I I J I K I L I mM N I o T E 6 14 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 First Edition First Printing Section 6 Schematics EE Electrical Schematic Legend Ground Contro
124. 2 P14 P18 and BOOM LENGTH FAULT appear on the display screen at the ground controls Continued on the next page Visually check LSB2RS bad for damage See Repair Section good Adjust LSB2RS See Repair Section Visually check LSB9AS bad for damage See Repair Section good Adjust LSB9AS See Repair Section Check for a short between pin 1 of the J20 _ bad connector and pin 2 of the J21 connector good Check for a short between pin 2 of the J20 connector and pin 3 of bad the J21 connector Consult the Genie Industries Service Department CHART 21 Replace and adjust LSB2RS See Repair Section eae and adjust LS 9AS See Repair Section Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the WH BK P53LS wire Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the BK WH P54ENG wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 113 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21
125. 2 and 3 3 connectors at the toggle switch and pins 10 9 and 12 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function manifold and start the engine At the ground controls activate the function enable high RPM button and the jib boom down membrane button and check the pressure 3000 PSI or more Are there mechanical restrictions keeping the jib boom down function from operating yes Remove or repair the mechanical restrictions no yes bad less than 3000 psi no Replace the ground control membrane decal OR consult the Genie Industries Service Department Repair or replace the internal platform wire Replace the toggle switch harness Repair or replace the jib boom down valve item CL OR repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department Repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR consult the Genie Industries Service Department 5 160 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 31 Is JIB UP DOWN TOGGLE SWITCHES FAULT yes Test the jib boom
126. 20 amp S 125 5 171 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 33 Check for a mechanical obstruction blocking the axle from full extension Is there an obstruction Remove or repair the mechanical obstruction Continued from page 5 170 Stop the engine 2200 PSI Repair or replace the Disconnect LSAX1EO or or more _ cylinder OR consult the LSAX2E0 from the wire Genie Industries Service harness and install a 0 Department to 5000 PSI 345 bar ee gauge at port AE or RAE on the steer axle manifold Start the engine and activate the axle extend function Adjust the axle extend oe Adjust the axle extend relief valve item EQQ a ae en EQQ in the steer axle ee Repair Section manifold all the way in clockwise counting the number of turns Activate the axle extend function and check the pressure Stop the engine 2500 PSI Repair or replace the Disconnect the hydraulic or more _ cylinder OR consult the hose from the P port of Genie Industries Service the steer axle manifold Department Plug the port and connect the hydraulic hose into a 0 to 5000 PSI 345 bar gauge Do NOT start the engine damage could result Activate the auxiliary hydraulic pump and the axle extend function and check the pressure Continued on the next page 5 172 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Editio
127. 5 Bl lt O O O c islsis 2 18 40 St99 k DIS 2 2 2 8 a E 3 5 5 5 9 9 Sone OLLST B S a 8 3 eee S18VN3 INYA z gt gt gt zs HHOO 78 N340990 z la S 2 O 00 cu a o lt Siglaigials 35 qos lt EN BUS EE zB HIWT8 1407880 OF namon SE z Zsisglisls W e o lt JAAA a ka D UI z ES m Klees KT 52 OASE 930 0L e A Ei ut RS oatast oa 78 0894899 ka NYO OLS8z9S Ki YA HM STESd sE 934 Ih x Hwaoxaxyoso lt lt 5 sacas du Aud9ss 2 oiken ee geen EI 9ga s saj 2a wen s ovetast Qanz gt z et bb T eg Ke KH 930 89 je a oo z YA HM SY8L9 SV Ovrissi a2 5 oun LPs au ZS x Fa a Omg ze A 3 93099 2 T 2 Hung ENN sSveas ASIA HWOH 08dSd lt lt 3 SE Ye LLSYATA EES 7 3 Saad os a HO S1r99 VE Ou zre svsas1 HEI 1X3 5 ll egen EEZdC t Gu HM IPS au Aud9ss EZE e HMV 18 4ad029 leza H g HAOH OI lt Eg E a e 1 gea J8 HM SY89 22 w M90 SIS A KE 62 2d HM SWZLO SEElOEE auma ers lt lt SSES Nedc nasc SC 718 384929 Qarjyosar Ouere lt lt Lezd q8 4S6119 Y9 LHXY199 x 9Z Zd HMW GY dad2sd Ce Ixage SES Y8 0N9 YSNS au O sTe9d puegs vezd HWAY OTHdSZA Ko yo oLsgz9s lt lt ees OO e EAZA x X8 40 S71p99 Tt 1X4 SZ eed o EWEN Oapas7 Oz zd y8 18 38d149 n SS HM 18 38d029 8 HO S199 S 1X300 o OargsT DE ya 3ad690 a 18 3894919 Lid au agd890 S DES 78 N340990 DES HM 18 1401S80 o EL ue Ve aa YOSE E OO EIER lt g
128. 6 no Check LSB14A0 for bad _ Replace and adjust proper operation See LSB14A0 See Repair Repair Section Section Check for proper bad Adjust LSB14A0 See adjustment of Repair Section LSB14A0 Check for an open in the ope _ Repair or replace the WH BK C78AS wire WH BK C78AS wire from pin 30 of the J2 yes connector at the ground controls to pin 3 of the duetsch connector at LSB14A0 Check for an open in the ope _ Repair or replace or bl OR BL C64LS wire from C64LS wire pin 13 of the J2 connector at ground controls to pin 4 of the duetsch connector at LSB14A0 OR consult the Genie Industries Service Department Continued on the next page 5 64 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 16 Install a 0 to 5000 PSI Check for mechanical Repair the cylinder OR 345 bar pressure restrictions preventing repair the cylinder gauge at the quick the boom from counterbalance valve disconnect coupling on extending OR consult the Genie the boom function Industries Service manifold Start the Department engine Activate the high RPM function enable button and the boom Remove the obstruction extend button and check the pressure Continued from the previous page less than 1800 PSI Exchange the boom Replace the faulty flow extend retract flow valve valve item BB o
129. 8 degrees and extend the boom past 101 106 feet yes Press the boom down button and lower the boom Does the engine stop when the boom is at 65 degrees and is the boom retract light not flashing Press the boom down button and lower the boom Does the engine stop with the boom at 50 degrees yes no Begin troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department Safety switch LSB2RS has tripped software version 1 01 Engine stops and fault message scrolls across the screen software version 1 04 and greater Engine stops and the retract boom LED amp LCD flash along with the auxiliary power button at the platform controls and the battery icon at the ground controls Safety switch LSB9AS has tripped software version 1 01 Engine stops and fault message scrolls across the screen software version 1 04 and greater Engine stops and the retract boom LED amp LCD flash along with the auxiliary power button at the platform controls and the battery icon at the ground controls Safety switch LSB8AS has tripped software version 1 01 Engine stops and fault message scrolls across the screen software version 1 04 and greater Engine stops and the retract boom LED amp LCD flash along with the auxiliary power button at the platform controls and the battery icon at the ground controls Continued on page 5 81 Continued on page 5 82
130. 9 C107AF RD 20 C83TAX GR WH 21 C84TAY GR BK 22 C45GEN GR WH 23 VLVRETS BR TCON TURNTABLE CONTROLLER J5 1 BATVLV RD 2 BATGND BR 3 BATGND BR 4 BATECU RD 1 VLVRET4 BR 2 CO3PBF RD WH 3 CO9PERF BK RD 4 CO6TRF WH RD 5 UNUSED 6 UNUSED 7 CO1PBU RD 8 CO2PBD RD BK 9 CO7PBE BK 10 CO8PBR BK WH 11 UNUSED 12 UNUSED 13 UNUSED 14 VLVRETS BR 15 UNUSED 16 UNUSED 17 C15LS RD BK 18 C14LS BK RD 19 UNUSED 20 UNUSED 21 UNUSED 22 UNUSED 23 C113MFV OR RD 24 UNUSED 25 CO4TRL WH 26 COSTRR WH BK 27 VLVRTN7 BR 28 UNUSED 29 UNUSED 30 VLVRET6 BR 31 UNUSED 32 C27AUX RD 33 UNUSED 34 UNUSED 35 DRIVE LAMP Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 13 Section 6 e Schematics E Electrical Schematic Legend Drive Chassis DCON and Platform Controls PCON First Edition First Printing
131. 9PBE wire from pin 3 of the deutsch connector at LSB2RO to pin 4 of the J21 connector on turntable OR check for an open in the OR BK C64LS wire circuit PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts CHART 15 Extend the boom to greater than 80 feet Is BOOM LENGTH Continued from page 5 54 SWITCHES FAULT present on the display no Continued on the next page First Edition First Printing SSS ovo eee Disconnect and test bad LSB3RO See Repair Section With LSB3RO no disconnected but continuity installed on machine check for continuity between pins 3 and 4 on the deutsch connector that is connected to LSB3RO continuity Connect LSB3RO to the upper J2 harness and disconnect the J20 connector Check for continuity between the BL WH C70PBE wire and the OR BK C64LS wire from pin 4 of the J20 connector to pin 9 of the J20 connector continuity no continuity Repair or replace the BL WH C70PBE wire from pin 3 of the deutsch connector at LSB3RO to pin 4 of the J20 connector on turntable OR check for an open in the OR BK C64LS wire circuit Replace and adjust LSB3RO See Repair Section Check for proper installation of LSB3RO OR consult the Genie Industries Service Department Repair or replace the BL WH C70PBE wire from pin 4 of the P20 connector on turntable to pin 19 of the J2 conne
132. Angle Safety Switch LSB8AS 14 Raise the boom to approximately 60 15 Extend the boom to approximately 95 feet 24 4 m 16 Disconnect the 53 proximity switch LSB13AO and install a wire jumper between pin 3 and pin 4 of the deutsch connector 17 Activate the function enable high RPM button and lower the boom to 50 Result The engine should stop and the boom down function should be disabled Result If the engine does not stop and the boom continues to lower to less than 50 the LSB8AS switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING lowers to less than 50 without stopping the engine stop immediately and raise the boom until the boom is elevated to greater than 53 Failure to raise the boom could result in death or serious injury 18 Measure the angle of the boom Result the angle of the boom should be greater than 50 19 Using auxiliary power raise the boom until the boom angle is greater than 53 20 Remove the wire jumper installed in step 16 and connect the deutsch connector to LSB13A0O Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 76 feet 30 8 m Length Safety Switch LSB4ES 21 Disconnect the 75 feet 22 9 m proximity switch LSB3EO and install a wire jumper bet
133. BOOM DOWN Y26 BOOM EXTEND Y27 BOOM RETRACT Y28 MULTIFUNCTION VALVE Y29 TURNTABLE ROTATE CW Y30 TURNTABLE ROTATE CW REFER TO THE GROUND CONTROLS SCHEMATIC SHEET 2 OF 2 IN THE BACK OF THE MANUAL mE p Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 15 Section 6 e Schematics First Edition First Printing Electrical Symbols Legend tt Ce A A aad am MN AA 28 3 Bott Coil St l Battery Sending unit Foot switch Fuel solenoid wo Aai e e A B C aa a ai Se a oo Chassis ground Diode obz aed oa 234 Fan belt 8 gt break switch EZ Eet HIGH LOW SPEED Steer sensor F1 SOLENOID 20A FUSE NN Fuse se with amperage 7 on eae emperature switc hs Current limiting H h device hs l shy CB1 C 40A gt Circuit breaker le with amperage 5 a Service bypass recovery Relay Toggle switch
134. Charts Raise the boom enough to clear the rest pad Visually check that the Continued from page 5 87 load moment weldment freely rotates around the pivot good Visually check LSB20LO for damage and metallic debris good Test LSB20LO for proper operation See Repair Section good Check for proper adjustment of LSB20LO See Repair Section good Disconnect the J4 white 35 pin connector from the ground control box TCON and disconnect LSB20LO Check for a short between the BR VLVRET5 wire and the RD BK C115LS wire at pin 3 and pin 4 of the deutsch connector at LSB20LO good Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department bad bad bad bad bad Remove the obstruction Remove the debris OR replace and adjust LSB20LO See Repair Section Replace and adjust LSB20LO See Repair Section Adjust LSB20LO See Repair Section Check the connectors for any metal particles good that might be shorting the terminals together bad Clean the connectors CHART 20 Visually trace the wiring harness from the deutsch connector to the ground control box checking for pinch points and chafed or shorted wiring and repair the BR VLVRET5 wire OR repair the RD BK C115LS wire PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 97 Section 5 Troubleshooting F
135. Check for an open or short in the OR C111RRS wire from pin B of the circle end yellow side steer sensor connector to pin 10 of the J2 connector on the drive chassis controller good Check for an open or short in the GR WH P109ANG wire from pin A of the circle end yellow side steer sensor connector to pin 20 of the J2 connector at the drive chassis controller good Check for an open or short in the BK P110RT wire that runs from pin C of the circle end yellow side steer sensor connector to pin 19 of the J2 connector at the drive chassis controller good Consult the Genie Industries Service Department bad bad bad bad First Edition First Printing Replace the steer sensor See Repair Section Repair or replace the OR C111RRS wire Repair or replace the GR WH P109ANG wire Repair or replace the BK P110RT wire 5 188 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts EE CHART 38 Is YELLOW END YELLOW If any other codes are Continued from the previous page SIDE STEER VALVE FAULT no present on the display screen refer to the fault present on the display screen code chart for more information yes Check for an open or bad Repair or replace the short in the BL V36RRS BL V36RRS wire wire from pin 8 of the J2 connector at the drive chassis controller to pin
136. Continued on the next page no no no properly inserted Continued to page 5 172 Adjust the proximity switch s to the proper distance from the target See Repair Section Replace and adjust LSAX1EO See Repair Section Replace and adjust LSAX2E0 See Repair Section Loosen but do not remove the red secondary lock and re insert the terminal until it locks into place Push in the secondary lock to lock the terminal into place 5 170 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 33 Check the GR C61LS A Repair the GR ala CH the wire for continuity from C61LS A wire P page pin 15 of the J1 connector to pin 3 of the deutsch connector to LSAX1EO Is there continuity Check for continuity in Repair the GR BK J4 from pin 3 of the wire from pin 3 of the deutsch connector at deutsch connector at LSAX2E0 to pin 4 of the LSAX2E0 to pin 4 of the deutsch connector at deutsch connector at LSAX1EO LSAX1EO Is there continuity Check for continuity in Repair the GR the GR P61LS A wire P61LS A wire from pin from pin 23 of the J1 23 of the J1 connector connector to pin 4 of the to pin 4 of the deutsch deutsch connector at connector at LSAX2EO LSAX2EO Is there continuity Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 1
137. Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 195 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 40 Drive Reverse Function Inoperative Be sure all other functions operate normally Be sure the engine is running Be sure the drive hubs are not in the free wheel configuration Be sure the batteries are fully charged and With the key switch turned to platform controls and both Emergency stop buttons pulled out to the ON position start the engine Press down the foot switch and activate the drive reverse function Are there any diagnostic codes present on the display at ground controls Is DRIVE JOYSTICK NOT CALIBRATED on the display screen Continued on page 5 199 Calibrate the drive joystick See Repair Section properly connected Is DRIVE JOYSTICK Check for damaged SHORTED TO 0 VOLTS or wires in the internal DRIVE JOYSTICK platform control box wire SHORTED TO 5 VOLTS or harness between the DRIVE JOYSTICK VALUE drive joystick connector TOHIGH or DRIVE P4 and board connector JOYSTICK VALUE TO LOW P20 OR Drive joystick on the display screen may need to be replaced OR consult the Genie Industries Service Department Continued on the next page 5 196 Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts
138. FQ 0 or infinite ohms Replace the boom retract valve coil If any other codes are present on the display refer to the fault code chart for more information PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 69 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 17 Check for an open or Continued from the shortin the AD previous page V74PRLO wire from pin 23 of the J2 connector at the ground controls to pin 1 of the DIN connector at the boom retract sequence valve coil item BN Repair or replace the RD V74PRLO wire Check for an open or short in the BR VLVRET1 wire from pin 35 of the J2 connector at the ground controls to pin 2 of the DIN connector at the boom retract sequence valve coil item BN Repair or replace the BR VLVRET1 wire Check the resistance of Consult the Genie the boom retract Industries Service sequence valve coil Department item BN 0 or infinite ohms Replace the boom retract sequence valve coil 5 70 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts EE CHART 17 Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping the gauge to the quick boom from moving OR disconnect coupling on replace the boom retract the function manifold sequence valve Start the engi
139. First Printing Continued from the previous page Press the engine start ov assist button and check the voltage at terminal 30 12V Press the engine start assist button and check oV the voltage at terminal 86 12V Continued on the next page Section 5 Troubleshooting Flow Charts PE Troubleshoot the RD BAT CBL A circuit from terminal 30 at the engine start assist relay to the 70A fuse to the battery separator to the battery and repair the wire circuit from terminal 30 at the start assist relay to the 70A fuse OR replace the 70A fuse OR repair the cable from the 70A fuse to the battery separator OR repair the cable from the battery separator to the battery Check the voltage at pin 4 of the J3 connector at the ground controls Locate the K8 relay inside the ground control box Pull out the K8 relay just enough to expose the terminals for testing and check the voltage at terminal 87 Do not completely remove the relay oV Check the voltage at terminal 30 of the K8 relay 12V Check for voltage of the K8 relay with the black lead of the volt meter on terminal 86 and the red lead on terminal 85 12V Replace the K8 relay OR consult the Genie Industries Service Department 12V 12V CHART 43 Repair or replace the BK WH C34SA wire from pin 4 of the J3 connector to terminal 86 of the the engine start assist relay Consult the Genie Indust
140. ION VALUE TOO LOW DCON CAN NO RESPONSE CAN BUS NO RESPONSE Condition Unit out of level LED icon and alarm active Unit out of level LED icon and alarm active Unit out of level LED icon and alarm active All drive chassis functions inoperative No functions from platform control box and all platform functions inoperative when using turntable controls Section 5 Troubleshooting Flow Charts PE Possible Causes Short in turntable level sensor Y direction circuit wiring Damaged circuit in turntable level sensor Y direction wiring or turntable level sensor may need to be replaced Damaged circuit in turntable level sensor Y direction wiring or turntable level sensor may need to be replaced Open or shorted wires in CAN bus circuits between DCON and TCON control box s Open or shorted wires in CAN bus circuits between PCON and TCON control box s FAULT CODE CHART Solution Repair short in circuit Refer to electrical schematic to troubleshoot Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department to determine if turntable level sensor needs to be replaced Repair damage in circuit wiring Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department to determine if turntable level sensor needs to be replaced Repair damage in circuit wiring Refer o electrical schematic to trouble
141. LSB9AS See Repair Section Visually check LSB2RS bad for damage See Repair Section good Adjust LSB2RS See Repair Section Check for a short between pin 1 of the J20 bad connector and pin 2 of the J21 connector good Check for a short between pin 2 of the J20 connector and pin 3 of bad the J21 connector good Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department CHART 21 Replace and adjust LSB9AS See Repair Section Replace and adjust LSB2RS See Repair Section Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the WH BK P53LS wire Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the BK WH P54ENG wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 119 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21 Check for a short between pin 1 of the P20 connector and pin 2 of the P21 connector Continued from the previous page Check for
142. ND BLUE SIDE STEER SENSOR yes SHORTED TO 0 VOLTS or YELLOW END BLUE SIDE STEER SENSOR SHORTED TO 5 VOLTS or YELLOW END BLUE SIDE STEER SENSOR VALUE TOO HIGH or YELLOW END BLUE SIDE STEER SENSOR VALUE TOO LOW present on the display screen no Continued on the next page Section 5 Troubleshooting Flow Charts PE Check for damaged wires in internal platform controls wire harness between steer joystick connector P4 and and circuit board connector P20 OR consult the Genie Industries Service Department Check circle end yellow end blue side steer sensor for proper installation and Operation see Repair Section good Check for an open or short in the OR C111LRS wire from pin B of the circle end blue side steer sensor connector to pin 11 of the J2 connector on the drive chassis controller DCON good Check for an open or short in the GR WH P109ANG wire from pin A of the circle end blue side steer sensor connector to pin 20 of the J2 connector on the drive chassis controller DCON good Check for an open or short in the BK P110RT wire from pin C of the circle end blue side steer sensor connector to pin 19 of the J2 connector on the drive chassis controller DCON good Consult the Genie Industries Service Department CHART 37 Replace the steer bad sensor See Repair Section bad __ Repair or replace the OR C111LRS wire bad __ Repair or re
143. Parker l a l Seal Lok fittings and hose ends 5 Tighten the nut or fitting to the appropriate are custom size O rings They are torque per given size as shown in the table not standard SAE size O rings above They are available in the O ring 6 Operate all machine functions and inspect the field service kit hoses and fittings and related components to Genie part number 49612 be sure that there are no leaks 2 Lubricate the O ring before installation 2 10 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 3 Theory of Operation Power Source The Genie S 100 S 105 S 120 and S 125 are powered by one of three diesel engines the Cummins B3 9L the Deutz F4L 913 and the Perkins 1004 42 Auxiliary power is supplied by a hydraulic pump powered by a 12V battery Hydraulic System All machine functions are performed by the hydraulic system The hydraulic system can be divided into two groups Boom and Steer Axle functions and Drive functions Boom and Sieer Axle functions are powered by two section gear pumps rated at 17 gpm 64 4 L min and 10 gpm 37 9 L min When the engine is running these pumps supply hydraulic fluid under pressure to function manifolds where the directional and flow control valves are located To protect from over pressurization of the systems each manifold is provided with a pressure relief valve The Steer and Axle extend retract manifo
144. PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 207 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 42 Extend the boom to greater than 3 0 9 m Is the low speed drive mode LED on Continued from the previous page yes Continued on the next page Turn the key switch to ground conirols Using the display screen scroll to the Boom length status screen Is gt 0 showing on the screen no Disconnect limit switch LSB3RO and check for proper operation See the Repair Section good With LSB3RO disconnected but still installed on machine check for continuity between pin 3 amp pin 4 of the duetsch connector to LSB3RO no continuity Connect LSB3RO Disconnect the J20 12 pin connector and check for continuity between pin 4 and pin 9 of the J20 connector no continuity Repair or replace BL WH C70PBE wire from pin 3 of the duetsch connector at LSB3RO to pin 4 of the J20 connector OR check for an open in the OR BK C64LS wire Consult the Genie Industries Service Department Replace and adjust LSB3RO See Repair Section Check for proper installation of LSB3RO OR consult the Genie Industries Service Department Repair or replace the BL WH C70PBE wire from pin 4 of the P20 connector to pin 19 of the J2 connector at the ground controls 5 208 Genie S 100 amp S 105 amp S 120 amp S 125
145. Platform level and boom up down Shorted circuit between platform level Refer to chart 24 to troubleshoot DEGREES SHORTED TO 5V unctions inoperative sensor and platform control box PLATFORM LEVEL SENSOR Platform level and boom up down Damaged circuit between platform Refer to chart 24 to troubleshoot DEGREES VALUE TOO HIGH unctions inoperative level sensor and platform control box or platform level sensor may need to be replaced PLATFORM LEVEL SENSOR Platform level and boom up down Damaged circuit between platform Refer to chart 24 to troubleshoot DEGREES VALUE TOO LOW unctions inoperative level sensor and platform control box or platform level sensor may need to be replaced PLATFORM LEVEL VALVE FAULT Platform level up or platform level Platform level up or platform level Refer to charts 25 and 26 to down function inoperative down coils circuits open or shorted to troubleshoot ground or the coils are bad PLATFORM ROTATE TOGGLE Platform rotate functions inoperative Shorted platform rotate toggle switch Refer to charts 28 and 29 to SWITCHES FAULT from platform or turntable controls Ion the platform control box or shorted troubleshoot PLATFORM ROTATE VALVE FAULT Platform rotate CW or CCW inoperative platform rotate CW or CCW membrane switch on the turntable membrane panel Platform rotate cw or ccw coils circuits open or shorted to ground or the coils are bad Refer to charts 28 and 29 to troub
146. Proportional Valves Platform Manifolds sseeeeeeeeeeeeeseeeeeenereesresernnnn 7 86 10 12 Platform Rotate Counterbalance Valve Manifold sseeseeesseeeseeeeeeeerneennn 7 86 10 13 Turntable Rotation Manifold Components 7 87 10 14 Steer and Axle Extend Retract Manifold Components View 7 88 10 15 Steer and Axle Extend Retract Manifold Components View 3 7 92 10 16 Valve Adjustments Steer and Axle Extend Retract Manifold 8 7 96 10 17 Drive Manifold Components 7 98 10 18 Valve Adjustments Drive Manifold cccceeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeees 7 102 xiv Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing TABLE OF CONTENTS Section Seven Repair Procedures continued Fuel and Hydraulic Tanks TI Fuel Tankas naaa anaedai pataa ahaaa Ra aaa 7 103 NS Aydraulie El 7 104 Turntable Rotation Components 12 1 Turntable Rotation Hydraulic Motor and Drive Hub 7 106 Axle Components 13 1 EE 7 110 1322 YOK and AUD EE 7 112 13 3 Dive let EE 7 114 13 4 Drive HUD eodogeeggertegteerSderdeER Seege na a aA a D EE 7 115 13 5 Steering Cylinders AAA 7 116 13 6 Extendable Axles ceccccccce cece cece rrna NANE ERRE AAEE 7 117 Appendix Electrical Schematic Genie part number 62304 Drive Chassis and Platform Control Sheet 1 of 2 Ground Controls gedeelt ed Jee lat eesti EE Sheet 2 of 2 PartNo 62401 Genie S 100 amp S 105 amp S 120
147. RD J2 wire or the GR WH C60AXEX wire if the boom raises OR and check for continuity between the OR BL J3 and OR RD P63LS wires if the boom no damage repair or replace the OR BL J3 or OR RD P63LS wires if the boom extends extends Consult the Genie Industries Service Department no continuity Check for continuity Visually inspect the dim Consult the Genie between terminals 1 and continuity wiring looking for pinch Industries Service 2 of the connector to points and chafed or Department LSB7DS broken wires damage found Repair or replace the WH BL P53LS wire circuit OR repair or no continuity replace the GR WH C60AXEX wire circuit Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 123 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21 Lower the boom to Replace and adjust approximately 10 LSB7DS See Repair degrees Disconnect Section LSB7DS and attempt to raise the boom Does the boom raise Continued from page 5 108 Disconnect the J2 black Visually inspect the Consult the Genie 35 pin connector from siy lower limit switch wiring Industries Service the ground control box harness looking for Department TCON Check for a pinch points and chafed short between the GR or broken wires WH C60AXEX wire and the WH BK P53LS wire at pin 1 and pin 2 of the conne
148. Repair or replace the BL C76PBE wire yes bad bad bad good Repair or replace the boom extend sequence control valve item BO OR consult the Genie Industries Service Department Adjust the cable tension See Repair Section Replace and adjust LSB4EO See Repair Section Repair or replace the OR BK C64LS wire Repair or replace the OR BK C64LS wire Consult the Genie Industries Service Department Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Boom Retract Function Inoperative Make sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected With the key switch turned to ground no controls and both Emergency Stop buttons pulled out to theon position activate the function enable high RPM button and the boom retract button Are there any fault codes present on the display screen at the ground controls yes Is BOOM EXT RET JOYSTICK NOT yes CALIBRATED present on the display Is BOOM EXT RET JOYSTICK SHORTED TO 0 VOLTS OR BOOM EXT RET JOYSTICK yes SHORTED TO 5 VOLTS BOOM EXT RET JOYSTICK VALUE TOO HIGH BOOM EXT RET JOYSTICK VALUE TOO LOW present on the display no Is BOOM EXT RET FLOW VALVE NOT CALIBRATED present on the di
149. SENSOR DEGREES at the platform control SHORTED TO 5 VOLTS box and pins 1 2 and 3 OR PLATFORM LEVEL of the deutsch connector SENSOR DEGREES VALUE at the platform tilt TOO HIGH OR sensor PLATFORM LEVEL SENSOR DEGREES VALUE TOO LOW present on the display screen Repair the wire circuit Is SAFETY SWITCH P22 Refer to the appropriate FAULT OR SAFETY platform level SWITCH P22R FAULT inoperative chart to present on the display continue screen troubleshooting Refer to Chart 27 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 139 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 25 Platform Level Up Function Inoperative Be sure all other functions operate normally Be sure the platform out of level LED and ICON are not flashingat the ground control box Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position activate the function enable high RPM button and the platform level up button Are there any fault codes present on the display screen yes Continued on the next page no Activate the function enable high RPM button and the platform level up button Is there an audible beep yes At the platform controls test the platform level toggle switch for proper operation See Repair Section
150. TEERING JOYSTICK SHORTED Steering functions inoperative from Open circuit between platform control Refer to charts 35 36 37 and 38 to TOO0V platform card and steering joystick troubleshoot STEERING JOYSTICK SHORTED Steering functions inoperative from Shorted circuit between platform Refer to charts 35 36 37 and 38 to TO 5V platform control card and steering joystick troubleshoot STEERING JOYSTICK VALUE TOO steering functions inoperative from Damaged circuit between platform Refer to charts 35 36 37 and 38 to HIGH platform control card and steering joystick or troubleshoot Joystick may need to be replaced STEERING JOYSTICK VALUE TOO Steering functions inoperative from Damaged circuit between platform Refer to charts 35 36 37 and 38 to LOW platform control card and steering joystick or troubleshoot Joystick may need to be replaced BLUE END BLUE SIDE STEER Blue end blue side steering functions Open circuit between blue end blue Refer to chart 35 to troubleshoot SENSOR SHORTED TO 0V inoperative side steering sensor and DCON box BLUE END BLUE SIDE STEER Blue end blue side steering functions Shorted circuit between blue end blue Refer to chart 35 to troubleshoot SENSOR SHORTED TO 5V inoperative side steering sensor and DCON box BLUE END BLUE SIDE STEER Blue end blue side steering functions Damaged circuit between blue end Peter to chart 35 to troubleshoot SENSOR VALUE TOO HIGH inoperative blue side steering sensor and DCON bo
151. TI CR16 sIN2 OUT k Tonne gt To AUXILIARY RELAY a z K8 87a s 5 t POA PWR GND ol ee PWR GND ka 2 T T STAT 30 Foai STAT V Sc gt JINI OUT1 TcoNv4s gt gt Parm IN 1 OUT 1 I TO TURNTABLE FLOW CONTROL N2 OUT2 TCON J4 8 TO BOOM DOWN VALVE le ROTATE VALVE 4 IN2 OUT2P TCON J2 5 TCON J2 4 TCONN2 3 Y TCON J2 6 See ae LY 85 P57PBD P57PBD CHOKE PWR GND P53LS P53LS P53LS A gr ouT1 N conta CR FORWARD VALVE P54ENG CAI GE NS OUT zip TO REVERSE VALVE NFET D MEET PWR GND b 2 3 4 STAT b 30 e Tconwa2 TO HI LO SOLENOID ai OUT1 gt Ln 7 A sIN2 OUT2P zN SS S S LSB2RS a LSB9AS KS NFET NFET E 4 LSB7DS a Py s 101 30 8 m 8 Es v 65 DEGREES SEHR a a GND PWR b 4 PWR GND b Hro BOOM DOWN gt d STAT d STAT HR TO DRIVE LP RELAY CON J4 35 A OUT1 IN1 gt 4IN1 OUT 1 e Tconnz23 ES TO PRIMARY 1 LOCKOUT VALVE t Si 7 D D Ee R3 To STARTER RELAY CC TCONM99 4OUT2 IN2 p NZ OUT2P ebe A MEET NFET Si AXIE EXTEND Loi AGND PWR 4PWR GND b 4 a STAT p STAT k ij To ROTATE COW vaLVE CCTCONW4 10 AOUT1 IN1 4 IN1 OUT 1 TcoNu2 24 gt TO PRIMARY 2 LOCKOUT VALVE MN LSB8AS LSB4ES OUT 2 IN2 N2 OUT DH E D E SODEGREES g R D K SEA of e ds LSAX2 ES NEET d i NFET j sba AXLE EXTEND GND PWR 4 PWR GND b St 4 STAT STAT k H a a TO ROTATE CW VALVE Sg a OUT 1 N1 gt a jN1 OUT 1 j __TCON J4 23 gt TO MULTIFUNCTION VALVE
152. V Check voltage on the 12V battery side of the 40A circuit breaker oV Continued on the next page First Edition First Printing Repair open in the RD BATVLYV wire that runs from 40A circuit breaker to pin 1 of the J5 connector inside the ground control box OR repair open in the BR BATGND1 wire from the system battery negative post to pin 2 of the J5 connector not Check if the 40A circuit tripped breaker is tripped tripped not Reset circuit breaker tripped and check if it continues to trip tripped Check for a short on RD shorted BATVLYV wire that runs from the 40A circuit breaker to pin 1 of the J5 connector at the ground control box not shorted Check for a short inthe shorted S56PRV RD wire circuit that runs from pin 6 of the J1 connector at the ground control box to pin 4 of the J1 connector at the platform control box not shorted Check for a short in the BL RD P52PCON wire 1 shorted circuit that runs from pin 2 of the J1 connector at the ground control box to pin 2 of the J1 connector at the platform control box Not shorted Continued on page 5 14 Replace the 40A circuit breaker Begin troubleshooting from beginning of the chart OR consult the Genie Industries Service Department Repair or replace RD BATVLV wire Repair or replace ground control box J1 Main Cable Harness Repair or replace the ground control bo
153. W END YELLOW SIDE Yellow end yellow side steering Damaged circuit between yellow end Refer to chart 38 to troubleshoot STEER SENSOR VALUE TOO HIGH functions inoperative yellow side steering sensor and DCON box or steering sensor may need to be replaced YELLOW END YELLOW SIDE Yellow end yellow side steering Damaged circuit between yellow end Refer to chart 38 to troubleshoot STEER SENSOR VALUE TOO LOW functions inoperative yellow side steering sensor and DCON box or steering sensor may need to be replaced BLUE END BLUE SIDE STEER Blue end blue side CW or blue end Blue end blue side CW or CCW valve Refer to charts 35 to troubleshoot VALVE FAULT blue side CCW functions inoperative coils circuits open or shorted to ground or the coils are bad BLUE END YELLOW SIDE STEER Blue end yellow side CW or blue end Blue end yellow side CW or CCW Refer to charts 36 to troubleshoot VALVE FAULT yellow side CCW functions valve coils circuits open or shorted to inoperative ground or the coils are bad YELLOW END BLUE SIDE STEER Yellow end blue side CW or yellow __ Yellow end blue side CW or CCW Refer to charts 37 to troubleshoot VALVE FAULT end blue side CCW functions valve coils circuits open or shorted to inoperative ground or the coils are bad YELLOW END YELLOW SIDE Yellow end yellow side CW or yellow Yellow end yellow side CW or CCW Refer to charts 38 to troubleshoot STEER VALVE FAULT DRIVE JOYSTICK NOT CALIBRATED end yellow side CCW
154. a NOOGEND a Zon e To S EE z PEJ S 35 S ER E a E 2 5 g z d SEKR ne eg fe58e Nz 8 S6agE90 a Qax ax eB al oe amp 3 ek Ess sg ES B36 f 2 e26 6 E nz S EN 2 D bal a Sa oo on E 89 oOo fe T OEE 2ogo e E of Do JAAA 1X3 DC ECH Spe 1X3 SE SH 1X3 SZ oaegsI 6 17 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 Section Ge Schematics First Edition First Printing t Switch Harness Schemati imi L S 120 amp S 125 Models LO OO kel D B o glo Elo g E E ZI g 2 5 SISE z S SS EJES 8 2 Y8g LLIHATA Ia Ea nworowan JI o7z Id BEIER u OTHdbZA ti 5 5 5 8 S O7 t lid 2 Si J e 9 83 BIZ g 8 5 amp 3 S e38 Q zITIsS 3 z 8 s 2 2 2 O 3 S s 6 EISE EK Z 2 2 2 EJO S IS 8 2 Elei PAIE SERRE 3 3 8 oO ee Sej ol S s elel 3 ti O s 8 8
155. a short between pin 2 of the P20 connector and pin 3 of the P21 connector Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the WH BK P53LS wire Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the BK WH P54ENG wire 5 120 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Raise the boom enough to clear the rest pad Visually check that the Continued from page 5 107 load moment weldment freely rotates around the pivot good Visually check LSB20LO for damage and metallic debris good Test LSB20LO for proper operation See Repair Section good Check for proper adjustment of LSB20LO See Repair Section good Disconnect the J4 white 35 pin connector from the ground control box TCON and disconnect LSB20LO Check for a short between the BR VLVRET5 wire and the RD BK C115LS wire at pin 3 and pin 4 of the deutsch connector at LSB20LO
156. all exhaust manifold retaining fasteners Torque to 30 ft lbs 40 Nm 8 Tighten all engine mounting fasteners Torque engine to bracket mounting fasteners to 54 ft lbs 73 Nm and bracket to engine pivot plate mounting fasteners to 175 ft lbs 237 Nm 9 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 10 Swing the engine pivot plate in towards the machine 11 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury TABLE A PROCEDURES A 20 Check the Batteries Genie specifications require that this procedure be performed every 125 hours Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions There are 2 batteries on the machine One is used for starting the engine and the other is used to power the control system The two batteries are charged by the alternator through a battery separator Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoi
157. amp Genie S 105 Operator s Manual or the Genie S 120 amp Genie S 125 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 5 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE A PROCEDURES A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Visually inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom and axle wear pads Dents or damage to machine Tires and wheels Engine and related components Limit switches and horn Alarms and beacon if equipped Nuts bolts and other fasteners Platform entry mid rail or gate Cracks in welds or structural components Compartment covers and latches A 4 Ch
158. amp S 125 4 11 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE A PROCEDURES A 10 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire could result in death or serious injury Explosion and fire hazard Engine ADANGER kee i fuels are combustible Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Perform a visual inspection around the following areas Fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately A 11 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems Perform this procedure with the boom in the stowed position and the axles extended 1 Visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be 3 4 inch 19 mm from the t
159. amp S 125 XV First Edition First Printing KH TABLE OF CONTENTS This page intentionally left blank Xvi Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing Section 2 Specifications Specifications Machine Specifications Turning radius inside 16ft4in 16 ft4in S 120 and S 1 25 Models axles retracted 4 9m 4 9m SS Turning radius outside 20 ft 8 in 20 ft 8 in Stowed dimensions S 120 S 125 axles extended 6 3 m 6 3 m Length transport position 39 ft 11 in 39 ft 11 in Turning radius inside 10 ft 1 in 10 ft 1 in 12 17 m 12 17m axles extended 3 1m 3 1m Length stowed 42 ft 8 in 46 ft Turntable rotation degrees 360 continuous 13m 14m Platform rotation 160 Width axles retracted 8 ft 6 in 8 ft 6 in 259 cm 259 cm Maximum allowable 150 Ibs side force ANSI and CSA 667 N Width axles extended 11 ft 6 in 11 ft 6 in 351 cm 351 cm Maximum allowable 90 Ibs side force CE 400 N Height stowed maximum 10 ft 1 in 10 ft 1 in 308 cm 308 cm Controls 12V DC proportional Weight 44 340 Ibs 44 640 Ibs Platform dimensions 20 112 k 20 248 k Length 96 in Ground clearance 153 4 in 153 4 in 244 cm 40 cm 40 cm Width 36 in Operational dimensions 91 cm Platform height maximum 120 ft 125ft Tires and wheels 36 6 m 38 1 m Tire size 18 x 22 5 18 pr FF Working height maximum 126 ft 131 ft
160. and finish lines TABLE B PROCEDURES 16 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 17 Continue at full speed and note the time when the machine reference point crosses the finish line Drive speed 10 ft 18 sec fully extended position 3 m 18 sec Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 28 Test the Alarm Package if equipped The alarm package includes Travel alarm Descent alarm Travel and descent alarm Motion alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine running or not running 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls Result The flashing beacon should be on and flashing 2 Push and hold a function enable speed select button and the boom down button Hold for a moment and then release them Result The descent alarm should sound when the boom down button is pressed Turn the key switch to platform control Result The flashing beacon should be on and flashing P
161. and tighten it securely by hand The filter oowl assembly must be full of fuel when it is installed onto the filter head or the fuel system will have to be bled TABLE B PROCEDURES 10 Tighten the head bolt to 65 in lbs 7 3 Nm 11 Tighten the vent plug 12 Clean up any diesel fuel that may have spilled during the procedure 13 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 14 Install the fuel tank line onto the inline fuel filter water separator head Tighten the hose clamp Inline fuel filter water separator element Genie part number 62433 Bleed the fuel system Before bleeding the fuel system be sure the fuel tank is full Deutz models 1 Loosen the overflow valve at the injector pump a overflow valve b fuel lift pump priming lever c oil filter d filter head e fuel filter Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures a la n TABLE B PROCEDURES 2 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent 3 While continuing to operate the priming lever tighten the overflow valve 4 Clean up any diesel fuel that might have spilled during the procedure 5 Start the engine and inspect for leaks ADANGER CAUTION CAUTION Explosion and fire hazard If a fuel leak is discovered kee
162. any diagnostic codes present on the display at ground controls Is DRIVE JOYSTICK NOT CALIBRATED on the display screen Continued to page 5 193 Calibrate the drive joystick See Repair Section properly connected Is DRIVE JOYSTICK Check for damaged SHORTED TO 0 VOLTS or wires in internal platform DRIVE JOYSTICK control wire harness SHORTED TO 5 VOLTS or between the drive DRIVE JOYSTICK VALUE joystick connector P4 TO HIGH Or DRIVE and and circuit board JOYSTICK VALUE TO LOW connector P20 OR the present on the display drive joystick may need screen to be replaced see Repair Section OR consult the Genie Industries Service Department Continued on the next page 5 190 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is DRIVE VALVE FAULT present on the display Continued from the previous page screen no Is BRAKE VALVE FAULT present on the display screen yes Continued on the next page CHART 39 Check for a short or bad _ Repair or replace the open in the WH WH V30FWD wire V30FWD wire from pin 5 of the J3 connector at the ground controls to pin 1 of the Din connector on the electronic proportional control EPC at the drive pump good Check for a short or bad _ Repair or replace BR open in the BR VLVRET2 wire VLVRET2 wire from pin 16 of the
163. ar Yearly application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Remove the turntable rotation gear cover retaining fasteners and remove the gear cover from the machine 2 Open the ground controls side turntable side cover 3 Locate the grease fitting below the ground control box 4 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 5 Apply grease to each tooth of the drive gear located under the turntable 6 Install the turntable rotation gear cover and retaining fasteners onto the machine AWARNING Bodily injury hazard Contact with the turntable rotation gear could result in serious injury Do not operate the machine if the turntable rotation gear cover is not installed Grease type Multi purpose grease TABLE D PROCEDURES D 7 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two drain plugs is at the lowest point 2 Re
164. arator cccceeseeeseceeeeeeneeeeseaeeeeeaes 4 10 A 9 Inspect the Engine Air Filter necerais a 4 11 A 10 Check for Fuel Leaks ceccecececcceeeeeeeeeeeeeeeeceaaeeeeeneeeeeaaaeeenaeeeeeaaeeessaaeeteaees 4 12 A 11 Check the Hydraulic Oil Level ecceeecceeeeeeeeeeeceeeeeeeeeeseaaeeeeneeeeeeaeeeees 4 12 A 12 Check for Hydraulic Leaks 4 13 A 13 Check the Hydraulic Filter Condition Indicators cccccccceeeeeeeeteeeeeteeeeees 4 13 A 14 Test the Platform and Ground Controls c cccccceeeeeeeeeeeneeeeecaeeeeeeeeeesaeeneaes 4 15 A 15 Test the Auxiliary Power Operation ccccceceeeeeeceeeeeeeeeeeeaeeseeeeeeessaeeeeaas 4 16 A 16 Test the Tilt Sensor and Alarm ccccceceeceeeeeeeeeeeceeeeeeeeeeeseaeeeeeaeeeeesaaeeneaes 4 17 A 17 Test the Operating Envelope ccccceeeeeeeeeeeeeeeeeeeeeeeseaeesseaeeeeeeeeeessaaeeneaes 4 18 A 18 Perform 30 Day Service 0 0 ceccececceeeeceeeeeeeeeeeeaaeeeeeaeeeeeeaeeeseaaeeseeneeeeseaeeeneas 4 19 A 19 Check the Engine Fasteners Deutz Models sseessseeeseeeeeeesrreerr rererere 4 20 A 20 Check the Batteries 20 0 2 cecceceeecceeeeeeeeeeeeeaeeeeeaaeeeeeeeeeeeaaaeesecaeeeseaaeeessaeesseaes 4 21 B 1 Check the Radiator Liquid Cooled Models ccceeeeeeeeeeeteeeeeteeeeesaeeees 4 23 B 2 Check the Oil Cooler and Cooling Fins Deutz Models eeeceeeeeeees 4 24 B 3 Check the Engine Belt s Deutz and Perkins Model 4 25 BA Rep
165. ard function Is the pressure 4250 psi 293 bar or more Repair or replace hydraulic swivel Consult the Genie Industries Service Department 5 194 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 39 Press down the foot Consult the Genie Continued from switch and activate the yes Industries Service age 5 193 pag drive forward function Is Department the pressure 4250 psi 293 bar or more no Disconnect hoses from no Repair or replace drive the A amp B ports on the pump drive pump and plug the ports Start the engine Is the pressure 250 psi 17 2 bar or more yes Press down the foot no Repair or replace drive switch and activate the pump drive forward function Is the pressure 4250 psi 293 bar or more yes Stop the engine and es Repair or replace the connect the A amp B hoses bad drive motor to the drive pump Disconnect the case drain from one drive motor Start the engine and activate the drive forward function for one minute measuring the volume of oil Is the oil volume greater than 1 gallon 3 8 liters Repeat for each motor Disconnect and plug A amp no Repair or replace B hoses at the drive hydraulic swivel manifold Start the engine and activate the drive forward function Is the pressure 4250 psi 293 bar or more yes Consult the Genie Industries Service
166. art Consult the Genie Industries Service Department The ground control box may be faulty 12V 12V circuit open or shorted 12V Section 5 Troubleshooting Flow Charts PE Turn the machine off and isolate the fuel solenoid Check the resistance of the solenoid 0 or infinite ohms Replace the fuel solenoid Replace the emission control element Repair or replace wire circuit C21IGN WH wire from the J3 connector terminal 3 at the ground controls to the fuel solenoid Consult the Genie Industries Service Department If problem still occurs please begin troubleshooting from the beginning of chart CHART 3 See Cummins or Perkins service manual for troubleshooting fuel system PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 3 Continued from page 5 22 Disable the starter by removing the starter relay Disconnect the 12V deutsch connector going to the fuel solenoid Press the engine start button on the ground control box and check the voltage at pin B of the deutsch connector oV Disconnect the fuel solenoid relay Press the ov engine start button and check the voltage at pin 1 terminal 30 12V Trace the BK RD E35SPD wire circuit bad checking for a break in the wire or a short to ground Check for proper pin ins
167. at the inline fuel filter water separator head 3 Remove and replace the following fuel line hoses and clamps Hose from the fuel tank to the inline fuel filter water separator Hose from the inline fuel filter water separator to the fuel lift pump Hose from the fuel lift pump to the fuel filter Hose from the fuel filter to the fuel injector pump Hose from the fuel injectors to the fuel tank 3 Clean up any fuel that may have spilled during this procedure 4 Install the fuel tank line onto the inline fuel filter water separator head Tighten the hose clamp 5 Install the ground control side fixed turntable cover onto the machine and tighten the retaining fasteners 6 Bleed the fuel system See B 4 Replace the Inline Fuel Filter Water Separator Element Before bleeding the system fill the fuel tank Perkins and Cummins models 1 Remove the engine side turntable fixed side cover Refer to Repair Section 5 1 How to Remove a Fixed Turntable Cover TABLE E PROCEDURES 2 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine nS W dp SC e H a engine pivot plate anchor hole b engine pivot plate retaining fastener 3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to insta
168. ate are fully charged and properly connected Continued on the next page Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 163 Section 5 Troubleshooting Flow Charts CHART 32 With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position press the auxiliary power button and a boom function button and check the voltage at the red cable on the auxiliary power unit Continued from the previous page more Press the auxiliary power button and a boom function button Check the voltage of the RD C27AUX wire at the small terminal of power relay PR1 on the auxiliary power unit more oV Turn the key switch to the OFF position not Disconnect the J2 black properly 35 pin connector from inserted the ground control box and check to make sure that pin 32 is properly inserted properly inserted Visually trace the manifold harness from the ground controls to the auxiliary pump and check for damage to the harness Is there damage to the harness no Consult the Genie Industries Service Department 12V or 12V or yes First Edition First Printing KH Check continuity in the ground wire cable circuit bad from the auxiliary pump motor mounting bolt to ground good Replace the auxiliary pump motor Test power relay PR1 good See Repair Section bad Replace PHI Loosen but do not r
169. atform controls 2 Push one ofthe LCD screen buttons shown until 4 i TURNTABLE LEVEL X AXIS appears Result The LCD screen should display the angle in degrees 3 Push one of the LCD screen buttons shown until 4 el TURNTABLE LEVEL Y AXIS appears Result The LCD screen should display the angle in degrees TABLE A PROCEDURES Push one of the LCD screen buttons shown until 4 gell PLATFORM LEVEL appears Result The LCD screen should display the angle in degrees Turn the key switch to platform controls Push a button such as the engine RPM button or the fuel select button Result The alarm should sound at the platform controls Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 17 Section 4 Scheduled Maintenance Procedures First Edition First Printing SS TABLE A PROCEDURES A 17 6 Extend the boom and observe the LCD screen Test the Operating Envelope Result The LCD screen should display at 0 Testing the machine operating envelope is critical gt 0 to safe machine operation If the boom is allowed gt 80 to operate outside of the operating envelope the 100 machine stability is compromised and may tip over gt 100 1 Turn the key switch to ground controls and pull 7 Retract the boom out the Emergency Stop buttons out to the on position at both the ground and platform controls 8 Lower the boom
170. ation and Maintenance Manual Cummins part number 3810205 Genie part number 62448 E 5 Check the Fuel Injectors Deutz Models Engine specifications require that this procedure be performed at 3000 hours Complete information to perform this procedure is available in the Deutz Workshop Manual Deutz part number 297 7293 Genie part number 62434 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures E 6 5 Remove and Inspect the Boom Extend Retract Cables Genie specifications require that this procedure be performed at 5 years or 5000 hours whichever comes first and every 2 years thereafter until the cables are replaced 6 The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Removal and inspection of the boom extend retract cables at specified intervals is essential to good machine performance and safe machine operation The boom extend retract functions should operate smoothlyand be free of hesitation jerking and unusual noise 1 Remove the boom extend cylinder from the machine See Repair Procedure 4 4 How to Remove the Primary Boom Extension Cylinder 2 Remove the extend cables from the boom 9 extension cylinder assembly and lay them flat on the ground Attach a rope to the boom retract cables at the pivot end of the boom At the platform end of the
171. ave been tripped Machine Controls Three ECMs manage the boom functions They are located at the turntable ground controls or TCON the platform platform controls or PCON and the drive chassis drive chassis controller or DCON Communication between the controllers is maintained via a high speed data bus CAN bus For example steering inputs from PCON are sent to DCON via the high speed data bus using multiplexed signals A series of proximity switches and mechanical limit switches provide information to the controllers These proximity and mechanical switches maintain and define the safe operating parameters of the machine In addition there is a back up safety system using mechanical limit switches which will cut power to selected portions of the controllers should the operational system fail to operate properly The ground controls TCON have membrane operated switches They are non tactile touch switches for greater durability When one button is pressed there is an audible beep indicating operation In addition there is a display on the ground control box that is used to show fault codes engine condition machine status and setup and the display language selected Boom speeds turntable rotation and ramp rates are adjustable Also various options and operating limitations can be programmed For example the boom extension can be limited to 80 ft 24 4 m or 100 ft 30 5 m The platform controls PCON has three
172. belt if any damage is found 7 Lift the belt tensioner and remove the engine belt 8 Inspect the engine belt for Cracking Glazing Separation Breaks 9 Replace the belt if any damage is found 10 Check the torque of the belt tensioner retaining fastener Torque to 32 ft lbs 43 Nm 11 Lift the belt tensioner and install the engine belt Cummins engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required If the machine is not equipped with the generator option proceed to step 13 12 Install the generator belt 13 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 14 Swing the engine pivot plate in towards the machine TABLE D PROCEDURES 15 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Belts Genie part numbers 62437 60725 Cummins Engine Belt Cummins Generator Belt 3 8 inch to 1 2 inch 9mmto12mm Generator belt deflection Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE D PROCEDURES D 9 Replace the Fuel Filter Deutz Models Replacing
173. ble beep from all buttons the horn button will activate the horn yes Consult Genie Industries Service Department Check for an open or short in the ESTOP 2 wire from the Emergency Stop button contact to pin 30 of the J20 connector bad Repair or replace the ESTOP 2 wire from the Emergency Stop button contact to pin 30 of the J20 connector CHART 11 Consult the Genie Industries Service Department The platform control box membrane decal may need to be replaced Replace the platform Emergency Stop contact Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 41 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 12 Boom Angle Switch Fault Be sure the machine is on level ground With the boom fully retracted and the boom angle at less than 10 degrees is BOOM yes ANGLE SWITCHES FAULT present on the display screen at the ground Be sure the boom controls angle limit switches are properly connected to the correct wiring harness leads Be sure the batteries are fully charged and properly connected no Continued on the next page Disconnect and test LSB13A0 See Repair Section ok With LSB13AO disconnected check for voltage on the WH C77AS wire at pin 3 of the deutsch connector that was connected to LSB13A0 no voltage present Disconnect and test LSB14A0 See Repair Secti
174. boom pull the boom retract cables out of the boom assembly and lay them on the ground Using a flashlight visually inspect the boom retract cables and components inside the boom assembly for the following Frayed or broken wire strands Kinks in the cables Corrosion Paint or foreign materials on the cable Split or cracked cable ends Cables at end of adjustment range Replace the cables if there is any damage to the cables The retract cables must be replaced in pairs If the cables are replaced the cable sheaves or pulleys should also be replaced At the pivot end of the boom pull the boom retract cables into the boom assembly using the rope 3 Visually inspect the boom extend cables and 10 Install the boom extension cylinder assembly components for the following into the boom Frayed or broken wire strands 11 Adjust the boom extend retract cables See Kinks in the cables Corrosion Paint or foreign materials on the cable Split or cracked cable ends Cables at end of adjustment range 4 Replace the boom extend cables if there is any damage to the cables The extend cables must be replaced in pairs If the cables are replaced the cable sheaves or pulleys should also be replaced Repair Procedure 4 5 How to Adjust the Boom Extend Retract Cables Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 93 First Edition First Printing Section 5 Troublesho
175. ch activated high idle rabbit and foot switch symbol is selected Result The engine should not change to high idle 10 Press down the foot switch Result The engine should change to high idle Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 55 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 24 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation An improperly functioning drive enable system may allow the machine to be moved into an unsafe position When the boom is rotated past one of the circle end wheels while the machine is moving the indicator light will illuminate and the drive function will continue to operate until the drive control joystick is returned to neutral The drive enable button must be pressed to reactivate the drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved When the boom is rotated past one of the circle end wheels and the machine is not moving the indicator light will illuminate and the drive function is turned off 1 Start the engine from the platform controls 2 Press down the foot switch and lower the boom to the stowed position 3 Rotate the turntable until the boom moves past one of the circle end tires Result The drive enable indicator light should
176. chock and lower the boom to the stowed position Be sure that each turntable rotation bearing mounting bolt under the drive chassis is torqued in sequence to 190 ft lbs 258 Nm The turntable rotation bearing bolt torque sequence is the same from above the turntable and below the drive chassis 4 76 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures D 5 Check the Turntable Rotation Gear Backlash Properly adjusted turntable rotation gear backlash is essential for good machine performance and service life Improperly adjusted turntable rotation gear backlash will cause the machine to perform poorly and continued use will cause component damage The turntable rotation drive hub is mounted on the swing chassis behind the fixed side cover at the ground controls side Be sure to check the backlash with the machine fully stowed and the counterweight at the square end of the machine Select a test area that is firm level and free of obstructions This procedure may require two people ech Rotate the turntable in a clockwise direction until the turntable rotation motor pinion gear is directly over the 3 red painted gear teeth on the TABLE D PROCEDURES Mark a test line approximately two feet long 0 6 m perpendicular to the length to the boom on the gro
177. circuits battery voltage on the OR check battery cables small upper battery OR replace the battery 9V or more Disconnect the J3 m Loosen but do not tor from th properly the red around contol box and DEER secondary lock and re check that terminal insert the terminal until it number 3 circuit locks into place Push in C21GN is properly the secondary lock to inserted secure the terminal terminal is properly inserted e Deutz or Deutz Continued on page 5 24 erkins engine Cummins or Perkins Continued on the next page 5 22 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from the previous page Disable the starter by removing the starter relay Push the engine start button on the ground control box and check the voltage at positive terminal on fuel solenoid Perkins models Disconnect the WH C21IGN wire from the emission control Press the engine start button and check the voltage on the wire that was disconnected Deutz and Cummins models Proceed to the next step oV Perkins models Connect the wire to the emission control Check circuit C21IGN for broken wires or shorted circuits Deutz and Cummins models Check circuit C21IGN for broken wires or shorted circuits wire circuit OK Press the engine start button and check voltage at the fuel solenoid oV Replace relay K6 inside the ground control box engine won t st
178. ck LSAX1ES for damage good Adjust LSAX1ES See Repair Section Visually inspect the wiring looking for pinch points and chafed or broken wires no damage Consult the Genie Industries Service Department Visually inspect the wiring looking for pinch points and chafed or broken wires damage found Repair or replace the WH BL P53LS wire circuit OR repair or replace the GR WH C60AXEX wire circuit bad damage found no damage Replace and adjust LSAX1ES See Repair Section Repair or replace the BL RD J2 wire or the RD P53LS wire if the boom raises OR repair or replace the OR BL J3 or RD WH P57PBD wires if the boom extends Consult the Genie Industries Service Department 5 122 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 21 Disconnect LSAX2ES no from the wiring harness Attempt to raise and Replace and adjust LSAX2ES See Repair Continued from page 5 108 Visually check bad LSAX2ES for damage good Section extend the boom Does the boom raise or extend Adjust LSAX2ES See Repair Section yes Check for continuity between the BL RD J2 and GR WH C60AXEX wires if the boom raises Visually inspect the continuity wiring looking for pinch found points and chafed or broken wires damage Repair or replace the BL
179. ck bad LSB3RS See Repair for debris under the limit Section OR remove the switch debris Continued from the previous page and attempt to retract the axles Do the axles retract good Adjust LSB3RS See Repair Section yes Disconnect the J20 12 Visually inspect the dane e Consult the Genie pin connector continuity ower limit switch E Industries Service Check for continuity in harness looking for Department the lower limit switch pinch points and chafed wire harness between or broken wires pin 3 and pin 4 of the connector to LSB3RS damage found Repair or replace the GR C61AXRT wire circuit or the OR no continuity S62BSTO wire circuit Disconnect the J2 black Visually inspect the e Consult the Genie lower limit switch Industries Service harness looking for pinch points and chafed or broken wires 35 pin connector from the ground control box TCON Disconnect LSB7DS Check for continuity in the lower limit switch wire harness damage between pin 6 and pin 7 found of the P20 connector Repair or replace the GR C61AXRT wire continuit Department circuit or the OR S62BSTO wire circuit no continuity Consult the Genie Industries Service Department 5 110 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from page 5 104 Using auxiliary power retract the boom until the boom is extended le
180. ckwise valve coil item BC or item FC good Check for an open or bad __ Repair or replace the short in the BR BR VLVRET6 wire VLVRETE wire from pin 30 of the J4 connector at the ground controls TCON to pin 2 of the Din connector at the turntable rotate clockwise valve coil item BC or item FC no good 5 4 to 7 4 ohms Consult the Genie Industries Service Check the resistance of the turntable rotate clockwise valve coil item BC or item FC Department 0 or infinite ohms Replace the valve coil If any other codes are on the display screen refer to the fault code chart for more information 5 132 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Turntable Rotate Counter Clockwise Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position press the foot switch and activate the function enable high RPM button and the turntable rotate counter clockwise button Are there any fault codes present on the display at the ground controls yes Continued on the next page no Chart 23 Press down the foot switch and activate th
181. come on while the boom is anywhere in the range shown 4 Move the drive steer control handle off center Result No drive function should operate 5 Push the drive enable button and slowly move the drive steer control handle off center Result The drive function should operate Collision hazard Always use the ACAUTION color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel af When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved Yellow If the drive steer control handle is not moved within two seconds of pushing the drive enable button the drive function will not operate Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 25 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational Collision hazard Be sure that the AWARNING machine is not in free wheel or partial free wheel configuration Refer to B 12 in this section Confirm the Proper Brake Configuration Select a te
182. connect the J20 12 BL WH C70PBE wire pin connector and inuity from pin 4 of the J20 check for continuity connector to pin 19 of between pin 4 and pin 9 the J2 connector at the of the J20 connector on ground controls the upper J2 harness no continuity Repair or replace the BL WH C70PBE wire from pin 3 of the duetsch connector at LSB3RO to pin 4 of the J20 connector OR check for an open in the OR BK C64LS wire circuit 5 206 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 42 Continued from page 5 204 Is MOTOR COIL FAULT es Check for an open or bad _ Repair or replace the present on the display y short in the RD WH RD WH V29MS wire screen V29MS wire from pin 4 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the 2 speed valve coil item DA good Check for an open or bad 1 Repair or replace the short in the BR VLVRET BR VLVRET wire wire from pin 1 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the 2 speed valve coil item DA good 7 4 to 9 4 ohms Consult the Genie Industries Service Disconnect the wires from the 2 speed valve coil item DA Test the Department resistance of the valve coil no 0 or infinite ohms Replace the coil Continued on the next page
183. connectors at the toggle switch and pins 4 6 and 8 of the P20 connector at the circuit board good Check for an open or short in the platform bad rotate clockwise membrane decal at the ground controls between pin 1 of the J11 membrane decal no connector at the circuit board and pin 3 of the J11 membrane decal connector at the circuit board good Check for an open or short in the platform bad rotate counter clockwise membrane decal at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 8 of the J11 membrane connector at the circuit board good Consult the Genie Industries Service Department Continued on the next page Replace the toggle switch Repair or replace the internal platiorm wire harness Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the ground control box membrane decal OR consult the Genie Industries Service Department 5 152 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is PLATFORM ROTATE Continued from the VALVE FAULT present on previous page the display screen no If any other codes are on the display screen refer to the fault code chart for more information Check for an open or short in the GR BK C18PRR wir
184. control box Bad K2 relay inside turntable control box or bad K2 relay inside platform control box Open in Boom envelope safety circuits or operational limit switches LSB3EO LSB13A0 LSB4E0 or LSB14AO have failed Open in Boom envelope safety circuits or operational limit switches LSB3EO LSB13A0 LSB4EO or LSB14AO have failed Boom extension cables out of adjustment or LSB6S limit switch is bad or there is an open in the safety circuit wiring Open in axle safety switch circuit or limit switch LSB7DS LSAX1ES or LSAX2ES have failed or operational limit switch LSB1DO has failed Replace K5 or K1 relays or consult Genie Industries Service Department Replace relays or consult Genie Industries Service Department Refer to chart 18 or 19 to troubleshoot Refer to chart 18 or 19 to troubleshoot Refer to chart 20 or 21 to troubleshoot Refer to chart 18 or 19 and chart 20 or 21 to troubleshoot Continued on next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 9 Section 5 Troubleshooting Flow Charts EE FAULT CODE CHART Diagnostic code displayed SAFETY SWITCH P12 FAULT Condition Axle retract inoperative Possible Causes Open in stowed safety circuit or limit switch LSB7DS or LSB3RS have failed or operational limit switches LSB1DO or LSB3RO have failed First Edition First Printing Solution Refer to chart 18 or 19 and chart 20 or 21 to tro
185. ctor at LSB7DS Repair or replace the GR WH C60AXEX wire OR repair or replace the no continuity WH BK P53LS wire Consult the Genie Industries Service Department 5 124 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 21 Continued from Fully retract the boom Visually check LSB3RS Replace and adjust age 5 108 Disconnect LSB3RS for damage and check LSB3RS See Repair pag and attempt to extend for debris under the limit Section OR remove the the boom switch debris Does the boom extend Adjust LSB3RS See Repair Section Disconnect the J20 12 Visually inspect the Consult the Genie pin upper limit switch Aug lower limit switch wiring Industries Service harness connector harness looking for Department Check for continuity pinch points and chafed between pin 5 and pin 8 or broken wires of the J20 connector Repair or replace the OR RD P63LS wire ae circuit OR repair or no continuity replace the RD WH P57PBD wire circuit Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 125 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 21 Fully extend the axles Visually check LSB3RS Replace and adjust Continued from page 5 109 Disconnect LSB3RS for damage and check bad LSB3RS See Repair an
186. ctor at the turntable rotate counter clockwise valve valve coil item BG or item FG Repair or replace the BR VLVRET6 wire good 5 4 to 7 4 ohms Consult the Genie Industries Service Check the resistance of the turntable rotate counter clockwise valve Department coil item BC or item FC 0 or infinite ohms Replace the proportional valve coil Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 137 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 24 Platform Level Function Inoperative Be sure all other functions operate normally Be sure the platform out of level LED and ICON are not flashing at the ground control box Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position press down the foot switch and activate the function enable high RPM button and the platform level up button Are there any diagnostic codes present on the display at the ground controls yes Continued on the next page Turn the key switch to yes platform controls and test the platform level toggle switch for proper operation See Repair Section Is the switch faulty Check for an open or bad short in the internal platform control box wire harness between the 2 1 2 2 and 2 3 connectors at the toggle s
187. ctor at the ground controls 5 56 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from the previous page Section 5 Troubleshooting Flow Charts PE Raise boom to greater than 68 degrees and extend the boom to 100 feet Is BOOM LENGTH Disconnect and test Yes_ SB3EO See Repair bad Section SWITCHES FAULT present on the display screen good With LSB3EO disconnected but installed on machine check for continuity between pin 3 and pin 4 of the deutsch connector that is connected to LSB3EO no continuity continuity Connect LSB3EO to upper J2 harness and disconnect the J20 connector Check for au continuity between the continuity BL BK C71PBE wire and the OR BK C64LS no wire from pin 10 of the J20 connector to pin 9 of the J20 connector no continuity Repair or replace the BL BK C71PBE wire from pin 3 of the deutsch connector at LSB3EO to pin 10 of the J20 connector OR check for an open in the OR BK C64LS wire circuit If BOOM LENGTH SWITCHES FAULT is present on the display screen when the boom is extended to greater than 100 feet check the extend cable adjustment OR LSB3RO LSB3EO or LSB4E0 are not installed properly OR glide blocks on side of the number 3 boom tube need to be shimmed OR consult the Genie Industries Service Department CHART 15 Replace and adjust LSB3EO See Repair
188. ctor at the ground controls to the engine oil pressure sensor on engine bad_ Repair or replace the WH BK C25PSR wire good Replace oil pressure sensor PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 25 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 4 Continued from the previous page Is ENGINE yes TEMPERATURE VALUE TOO HIGH present on the display screen no Is ENGINE yes TEMPERATURE SENSOR VALUE TOO HIGH or ENGINE TEMPERATURE SENSOR VALUE TOO LOW present on the display screen Is ENGINE TEMPERATURE Be SENSOR SHORT TO y 5V present on the display screen no Is ENGINE TEMPERATURE e SENSOR SHORT TO ZS OV present on the display screen no Continued on the next page Is the engine block yes Check radiator fins for excessively hot clogging OR refer to the engine manual for troubleshooting an overheating engine no Check for a short in the bad __ Repair or replace the WH RD C26TSR wire WH RD C26TSR wire from pin 13 of the J3 connector at the ground control box to the temperature sensor on engine good Replace the temperature sensor Replace the temperature sensor Check for an open in bad Repair or replace the WH RD C26TSR wire WH RD C26TSR wire from pin 13 of the J3 connector at the ground controls to the engine temperature sensor on engine good
189. ctrical swivel through pin 2 of the upper P8 connector to pin 2 of the lower P8 connector then from pin 1 of the lower J8 connector to pin 1 of the J1 connector at the drive chassis controller DCON Continued from page 5 35 Check for an open in YL D82CAN wire circuit from pin 18 of the J1 connector at the ground controls to pin A of the J6 connector at the electrical swivel through pin A of the upper P6 connector to pin A of the lower P6 connector then from pin A of the lower J6 connector to pin 18 of the J1 connector at the drive chassis controller DCON Repair open in YL D82CAN wire Check for an open in Repair open in the GR GR D81CAN wire D81CAN wire circuit from pin 17 of the J1 connector at the ground control box to pin B of the upper J6 connector at the electrical swivel through pin B of the upper P6 connector to the P6 lower connector then from pin B of the lower J6 connector to pin 17 of the J1 connector at the drive chassis controller DCON Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 37 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 10 Ground Controls Inoperative Platform Controls Operate Normally Be sure all other functions operate normally including the platform controls Be sure the batteries are fully charged and properly connected
190. cure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 2 Check the Oil Cooler and Cooling Fins Deutz Models Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system Bodily injury hazard D AWARNING 229 injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns Oil Cooler 1 Open the latches from the engine side cover Remove the cover 2 Inspect the oil cooler for leaks and physical damage 3 Clean the oil cooler of debris and foreign material Cooling and Fan Blower Fins 4 Inspect the fan blower fins for physical damage 5 Clean the fan blower fins of debris and foreign material Inspect the cylinder head cooling passages and fins for physical damage or foreign material using a flashlight Clean the cylinder head cooling passages of debris an
191. d Check for an open or bad __ Repair or replace the short in the BR VLVRET BR VLVRET wire wire from pin 1 of the J2 connector at the ground controls to pin 2 of the Din connector at the jib boom up valve coil item CL good 4 4 to 6 4 ohms Consult the Genie Industries Service Check the resistance of jib boom up valve coil item CL Department 0 or infinite ohms Replace the valve coil Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 159 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 31 Jib Down Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position activate the function enable high RPM button and the jib boom down button Are there any diagnostic codes present on the display at the ground controls yes Continued on the next page no Activate the function enable and the jib boom down membrane button Is there an audible beep yes Test the jib boom up down toggle switch at the platform controls for proper operation See Repair Section Is the switch faulty no Check for an open or short in the internal platform control box wire harness between the 3 1 3
192. d attempt to retract for debris under the limit Section OR remove the the axles switch debris Do the axles retract good Adjust LSB3RS See yes Repair Section Disconnect the J20 12 Visually inspect the ne Consult the Genie pin upper limit switch continuity lower limit switch wiring 96 Industries Service harness connector harness looking for Department Check for continuity pinch points and chafed between pin 3 and pin 4 or broken wires of the connector to LSB3RS damage found Repair or replace the OR S62BSTO wire circuit OR repair or no continuity replace the GR C61AXRT wire circuit Disconnect the J2 black Visually inspect the oe Consult the Genie 35 pin connector from Industries Service the ground controls TCON and disconnect LSB7DS Check for continuity between pin 6 and pin 7 damage of the P20 12 pin lower found limit switch harness connector lower limit switch wiring harness looking for pinch points and chafed or broken wires continuity Department Repair or replace the OR S62BSTO wire circuit OR repair or replace the GR C61AXRT wire circuit no continuity Consult the Genie Industries Service Department 5 126 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 21 Connect LSAX1ES Consult the Genie Fully retract the boom Industries Service and fully ex
193. d foreign material 4 24 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 3 Check the Engine Belt s Deutz and Perkins Models Maintaining the engine belt s is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING 2odily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Burn injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate TABLE B PROCEDURES 2 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Deutz models 4 Remove the front engine access cover mounting fasteners and remove the front engine access cover All models 5 Inspect the engine belt for Cracking Glazing Separation Brea
194. d no controls and both Emergency Stop buttons pulled out to theon position activate thefunction enable high RPM button and the boom down button Are there any diagnostic codes present on the display screen at the ground controls yes Is SAFETY SWITCH P22 e5 FAULT and SAFETY SWITCH P22R FAULT present on the display screen Is BOOM UP DWN JOYSTICK NOT yes CALIBRATED present on the display screen Is BOOM UP DWN JOYSTICK SHORTED TO 0 VOLTS OR BOOM UP DWN JOYSTICK SHORTED TO 5 VOLTS OR BOOM yes UP DWN JOYSTICK VALUE TOO HIGH OR BOOM UP DWN JOYSTICK VALUE TOO LOW present on the display screen no Continued on the next page Activate the boom down button Is there an audible beep when button is pressed no Consult the Genie Industries Service Department The ground control membrane decal may need to be replaced Refer to Chart 27 Re calibrate boom up down joystick See Repair Section OR replace the boom up down joystick Check for damaged wires inside the platform control box between the boom up down joystick connector P1 and the circuit board connector P20 OR replace the boom up down joystick OR consult the Genie Industries Service Department Chart 14 yes ej Continued on page 5 53 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 49 Section 5 Troubleshooting Flow Charts First Edition First Printing
195. d spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 But op protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 4 Scheduled Maintenance Procedures First Edition First Printing BEER TABLE A PROCEDURES 4 Be sure that the battery separator wire connections are tight 5 Remove the battery vent caps from both batteries and check the specific gravity of each battery with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced 6 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 7 Install the vent caps Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 4 22 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 1 Check the Radiator Liquid Cooled Models Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through
196. d using hydraulic cylinders at each wheel Correct steering geometry is maintained through the use of four steering sensors one at each wheel Steering angles are sent from the primary steering sensor to DCON and the appropriate adjustments are made to the other three wheels to correspond with the steer mode selected If the machine is equipped with four wheel steering there are four steering modes available 2 wheel front steer 2 wheel rear steer 4 wheel coordinated steer and crab steer Having independent control over each wheel allows the machine to determine the correct wheel geometry in each steering mode Washing electronic components is not suggested Instead use low pressure compressed air to remove debris from these components Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 3 3 Section 3 Theory of Operation First Edition First Printing EE This page intentionally left blank 3 4 Genie S 100 amp S 105 amp S 120 amp 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure
197. de cover and locate the tank return filters The system return filter is located near the top of the hydraulic tank and the drive motor case drain return filter is located below the system return filter TABLE B PROCEDURES 2 Place a suitable container under the hydraulic tank return filters Remove each filter with an oil filter wrench 4 Apply a thin layer of clean oil to the new oil filter gaskets 5 Install the new system return filter Genie part number 61326 and tighten it securely by hand 6 Install the drive motor case drain return filter Genie part number 44207 and tighten it securely by hand 7 Clean up any oil that may have spilled during the procedure 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the filters 9 Start the engine from the ground controls 10 Inspect the filters and related components to be sure that there are no leaks Hydraulic tank return filters Genie part numbers 61326 44207 System return filter Drive motor case drain return filter Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 9 Replace the Hydraulic Tank Breather Filter Replacement of the hydraulic tank breather filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorl
198. drive pump Disconnect the motor case drain from one drive motor Start the engine and activate the drive forward function for one minute measuring the volume of oil Is the oil volume greater than 1 gallon 3 8 liters Repeat for each motor Disconnect and plug the no Repair or replace the A amp B hoses at the drive hydraulic swivel manifold Start the engine and activate the drive forward function Is the pressure 4250 psi 293 bar or more yes Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 201 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 41 Drive Enable Fault Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency stop buttons pulled out to the on position fully retract the boom and lower the boom below 10 degrees Push the steer mode select button for square end blue end steer and rotate the boom until it is between the circle end yellow end tires At the platform controls does the drive enable LED turn on yes no Rotate the boom until it is Outside the circle end yes yellow end tires At the platform controls does the drive enable LED turn on no Check LST10 for proper Operation and bad installation See Repair
199. dures 38 Activate the function enable high RPM button and attempt to extend the boom Result The boom should not extend to more than 3 feet 0 9 m Result If the boom extends to more than 3 feet 0 9 m the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING extends to more than 3 feet 0 9 m stop immediately and retract the boom until the boom is extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury 39 Activate the function enable high RPM button and attempt to raise the boom Result The boom should not raise to more than 11 Result If the boom continues to raise the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING raises to more than 11 stop immediately and lower the boom until the boom is less than 11 See Repair Section Failure to retract the boom could result in death or serious injury TABLE B PROCEDURES 40 Remove the wire jumper installed in step 36 and connect the deutsch connector to LSAX1ES 41 Disconnect the circle end axle extend safety switch LSAX2ES and install a wire jumper between pin 3 and pin 4 of the deutsch connector 42 Activate the function
200. e previous page Replace the key switch Key switch contact legend Press each button on Replace the ground the ground control controls membrane panel Is an audible decal OR et Genie beep heard when each Industries Service L AA D button is pressed Department Consult the Genie i Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 39 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 11 Platform Controls Inoperative Ground Controls Operate Normally Be sure all cables from chassis through the cable track are in good condition with no kinks or abrasions Be sure the batteries are fully charged and properly connected Key switch contact legend Does engine start from yes platform controls no With the ground control Emergency Stop button pulled out to theon position check the voltage of the GRN wire at terminal 2 of key switch contact BA The GRN wire checked should originate from pin 3 of the J7 connector 12V With the key switch turned to platform controls and the Emergency Stop button pulled out to the oN position check the voltage at BL wire on terminal 1 of key switch contact BA 12V Continued on the next page ov oV Start the engine from the platform controls Press down the foot switch and press the foot switch activated high RPM button Does the en
201. e section Calibrate propel thresholds refer to repair section DRIVE VALVE FAULT BRAKE VALVE FAULT MOTOR COIL FAULT AUX PROPEL VALVE FAULT PLATFORM LEVEL TOGGLE Drive forward and drive reverse functions inoperative Drive forward or drive reverse functions inoperative High drive inoperative Auxiliary drive forward or reverse inoperative Only seen if Aux Drive option is enabled from display Refer to display module section Manual platform level inoperative Drive forward or drive reverse valve coils circuits open or shorted to ground or the coils are bad Brake valve circuit open or shorted to ground or coil is bad Motor coil circuit open or shorted to ground or the coil is bad Auxiliary propel valve coils circuits open or shorted to ground or the coils are bad Shorted platform level toggle switch Refer to charts 39 and 40 to troubleshoot Refer to charts 39 and 40 to troubleshoot Refer to chart 42 to troubleshoot Refer to chart 44 To troubleshoot Refer to charts 25 and 26 to SWITCHES FAULT from platform or turntable controls Ion the platform control box or shorted troubleshoot platform level up or down membrane switch on the turntable membrane panel PLATFORM LEVEL SENSOR Platform level and boom up down Open circuit between platform level Refer to chart 24 to troubleshoot DEGREES SHORTED TO 0V unctions inoperative sensor and platform control box PLATFORM LEVEL SENSOR
202. e turntable rotate counter no clockwise membrane button Is there an audible beep yes Are there mechanical yes restrictions keeping the turntable from rotating Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine At the ground controls press and hold the function enable high RPM button and activate the turntable rotate counter clockwise button and check the pressure less than 2600 psi 2600 psi or more 2600 PSI Disconnect the turntable Or more rotate motor brake hose and install a 0 to 5000 PSI 345 bar pressure gauge into the hose Activate the function enable high RPM button and the turntable rotate counter clockwise button and check the pressure less than 2600 PSI Repair or replace the brake See Repair Section Replace the ground control membrane decal OR consult the Genie Industries Service Department Remove or repair the mechanical restrictions Repair or replace the turntable rotate proportional valve item BG or item FG OR repair or replace the turntable rotate directional valve item BC or item FC OR repair or replace the turntable rotate motor counterbalance valves OR repair or replace the rotate motor OR the boom function manifold could have an internal fault Consult the Genie Industries Service Department Consult the Genie Industries Service Department Pa
203. e button and the platform rotate counter clockwise button Is there an audible beep yes At the platform controls test the platform rotate toggle switch for proper operation See Repair Section Is the switch faulty no Check for an open or short in the internal platform control box wire harness between the 1 1 1 2 and 1 3 connectors at the toggle switch and pins 4 6 and 8 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function manifold and start the engine At the ground controls activate the function enable high RPM button and the platform rotate counter clockwise button and check the pressure 3000 PSI or more Are there mechanical restrictions keeping the platform rotate counter clockwise function from operating yes Remove or repair the mechanical restrictions no yes bad less than 3000 psi no Replace the ground control membrane decal OR consult the Genie Industries Service Department Repair or replace the internal platform wire Replace the toggle switch harness Repair or replace the platform rotate valve item CD or item GD OR repair or replace the rotator counterbalance valves OR repair or replace the rotator OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department
204. e control valve coil item BO Repair or replace the RD WH V75PRLO wire Check for an open or short in the BR bad VLVRET1 wire from pin 35 of the J2 connector at the ground controls to pin 2 of the DIN connector on the boom extend sequence control valve coil tem BO Repair or replace the BR VLVRET1 wire good 3 4 to 5 4 ohms Consult the Genie Industries Service Test resistance of the boom extend sequence control valve coil item BO Department 0 or infinite ohms Replace the boom extend sequence control valve coil item BO Refer to Chart 18 Boom Envelope Operational Switch Failure 100 S 105 models OR refer to Chart 19 Boom Envelope Operational Switch Failure 120 S 125 models 5 62 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 16 Reset the boom extend limit option to NO LIMIT See Repair Section Activate the high Using the display scroll RPM function enable to the options screen Is button and the boom the boom extend limit extend button Will the option set to 80 feet boom extend to more 24 4 m than 80 feet 24 4 m Continued from page 5 58 yes Consult the Genie Industries Service Department Using the display scroll the boom angle status screen Raise the boom above 53 degrees Is gt 50 DEGREES present on the display screen
205. e engine tray See capacity specifications TABLE B PROCEDURES 3 Remove the drain plug from the oil pan and allow all of the oil from the engine to drain into a suitable container Cummins Model a filter head b oil filter c oil filler cap Install the drain plug into the engine and tighten Use an oil filter wrench and remove the oil filter Clean inside the filter head Fill the filter with clean engine oil o N DOO fF Apply a thin layer of clean oil to the new filter gasket Genie part number 62436 Install the filter and tighten it securely by hand 9 Clean up any oil that may have spilled during the procedure 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 11 Fill the engine with new oil per specifications and install the oil filler cap 12 Start the engine from the ground controls and allow the engine to run for 30 seconds Stop the engine 13 Check the oil filter and oil drain plug for leaks 14 Wait 15 minutes after stopping the engine and check the engine oil level on the dipstick Add oil if needed 15 Dispose of the used oil and filter properly Cummins B3 9L Engine 11 5 quarts Oi
206. e from pin 4 of the J2 connector at the platform controls box to pin 1 of the Din connector at the platform rotate valve coil item CD or item GD good Check for an open or short in the BR VLVRET wire from pin 1 of the J2 connector at the ground controls TCON to pin 2 of the Din connector at the platform rotate valve at item CD or item D good Check the resistance of the platform rotate valve coil item CD or item GD 0 or infinite ohms Replace the valve coil 4 4 to 6 4 ohms CHART 28 bad _ Repair or replace the GR BK C18PRR wire bad __ Repair or replace the BR VLVRET wire Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 153 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 29 Platform Rotate Counter Clockwise Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position activate the function enable high RPM button and the platform rotate counter clockwise button Are there any diagnostic codes present on the display at the ground controls yes Continued on the next page no Activate the function enabl
207. e no chassis controller DCON yes Continued on page 5 37 CHART 9 Check for an open in RD S56PRV wire circuit from pin 5 of the J2 connector at the ground control box to pin 1 of the upper J8 connector at the electrical swivel then from pin 1 of the upper P8 connector at the electrical swivel to the lower P8 connector at the electrical swivel to pin 1 of the lower J8 connector to pin 5 of the J1 connector at the drive chassis controller DCON If any other codes are on the display screen displayed refer to the fault code chart for more information OR consult the Genie Industries Service Department Check for an open in WHT P21DCON wire circuit from pin 2 of the J2 connector at the ground control box to pin 1 of the upper J7 connector at the electrical swivel then from pin 1 of the upper P7 connector at the electrical swivel to the lower P7 connector to pin 1 of the lower J7 connector to pin 2 of the J1 connector at the drive chassis controller DCON Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts CHART 9 Continued from the previous page Install a 0 to 5000 psi 345 bar pressure gauge to the test port on the steer axle manifold and disconnect LSAX1RO or LSAX2RO With the key switch turned to platform controls start the engine and press down the foot switch and activate the axle retract button and c
208. e rotate functions inoperative Shorted circuit between platform Refer to charts 22 and 23 to SHORTED TO 5V rom platform control card and turntable rotate roubleshoot joystick TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Damaged circuit between platform Refer to charts 22 and 23 to VALUE TOO HIGH rom platform control card and turntable rotate troubleshoot joystick or Joystick may need to be replaced TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Damaged circuit between platform Refer to charts 22 and 23 to VALUE TOO LOW rom platform control card and turntable rotate troubleshoot joystick or Joystick may need to be replaced TURNTABLE ROTATE BUTTONS Turntable rotate functions inoperative Shorted turntable rotate membrane Consult Genie Industries Service FAULT rom turntable on turntable membrane panel Department The turntable membrane panel may need to be teplaced Continued on next page Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Diagnostic code displayed TURNTABLE ROTATE SPEED NOT CALIBRATED TURNTABLE ROTATE FLOW VALVE NOT CALIBRATED TURNTABLE ROTATE FLOW VALVE FAULT TURNTABLE ROTATE CW VALVE FAULT TURNTABLE ROTATE CCW VALVE FAULT Condition Turntable rotate function speeds to fast or to slow No movement on Turntable rotate functions until joystick is moved past
209. e stop OR does the boom stop at 75 80 feet and is the raise boom arrow flashing boom Continued on the next page Chart 19 Is the boom length equal no Is the boom length equal to 75 5 80 5 feet to 101 106 or 111 feet yes yes Continued on page 5 79 Attach a digital protractor to the top of the boom Read the boom angle 65 degrees Continued on page 5 82 Safety switch LSB4ES has tripped software version 1 01 Engine stops and fault message scrolls across the screen version 1 04 and greater Engine stops and the retract boom LED amp LCD flash along with the auxiliary power button at the platform controls and the battery icon at the ground controls Continued on page 5 81 53 degrees Continued on page 5 84 Continued on page 5 79 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 19 Continued from the previous page Attach a digital protractor to the top of the boom outermost boom tube section Raise the boom to greater than 53 degrees but less than 68 degrees Scroll down the status screen until the boom length screen appears Extend the boom while observing the display screen Does the engine stop at 101 106 feet yes no Scroll down the status screen until BOOM ANGLE appears on the display screen Raise the boom to greater than 6
210. e turntable rotate drive brake Cap the fittings Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION Ve drive motor drive brake brake drain plug drive hub pivot bolt mounting bolt adjustment bolt with lock nut drive hub drain plug sa ro Q0 0 o Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 4 Remove the turntable rotate drive hub mounting bolts and pivot bolt Remove the turntable rotate drive hub with a suitable lifting device of ample capacity AWARNING Crushing hazard The turntable rotate drive hub may become unbalanced and fall when it is removed from the machine if it is not properly supported 5 Remove the drive brake drain plug from the side of the drive brake and drain the oil from the drive brake into a suitable container See capacity specifications 6 Remove the drive hub drain plug from the side of the drive hub and drain the oil from the drive hub into a suitable container See capacity specifications 7 Fill the drive hub with oil until the oil is level with the bottom of the threads Install t
211. e wire Start troubleshooting between pin 5 of the J20 harness from the P26 from the beginning of connector and pin 5 of connector near the the chart OR consult the the J21 connector breakout at the side of Genie Industries Service the boom to the J20 Department connector and the J21 connector checking for pinch points and chafed or shorted wiring Continued from the previous page Repair the OR RD P63LS wire OR repair the GR WH S59CNBK wire Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department 5 116 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from page 5 106 Using auxiliary power raise the boom to greater than 53 degrees and extend the boom to yes approximately 95 feet Start the engine and disconnect LSB8AS Does the engine stop no Disconnect LSB4ES Does the engine stop yes no Disconnect the J20 Ke 12 pin and J21 8 pin LP Deutsch connectors inside the counterweight area of the machine Does the engine stop and does P9A P9B P10 P11 P12 P14 P18 and boom length fault appear on the display screen at the ground controls no Continued on the next page Section 5 Troubleshooting Flow Charts PE Visually check LSB8AS for damage and check bad for debris under the limit switch good Adjust LSB8AS See Repair Section Vi
212. eck the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the engine oil dipstick Add oil as needed Cummins models Result The oil level should be within the L and H marks on the dipstick Deutz models Result The oil level should be within the two marks on the dipstick Perkins models Result The oil level should be within the two notches on the dipstick Cummins B3 9L Engine 11 5 quarts Oil capacity including filter 10 9 liters Cummins B3 9L Engine Engine oil viscosity requirements below 68 F 20 C 5W 30 13 to 68 F 25 to 20 C 10W 30 above 15 F 9 C 15W 40 Use oils meeting API classification CE labeled CE SG 4 6 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures Deutz F4L 913 Engine 14 3 quarts Oil capacity including filter 13 5 liters Deutz F4L 913 Engine Engine oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades OR ACEA classification E1 96 Perkins 1004 42 Engine 8 9 quarts
213. ected but installed on machine check for continuity between pin 3 and pin 4 of the deutsch connector that connects to LSB2RO continuit no continuity Check for proper installation of LSB2RO or consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts PE Disconnect the 12 pin deutsch connectors that join the upper J2 harness to the lower J2 harness Check for voltage on BL C76PBE wire connected to pin 3 on 12 pin deutsch connector at the lower J2 harness Is there voltage present yes Repair or replace the BL C76PBE wire from pin 3 of the deutsch connector at LSB4EO to pin 3 of the 12 pin deutsch connector at the turntable Replace and adjust LSB2RO See Repair Section Connect LSB2RO to the upper J2 harness no Disconnect the J20 12 continuity pin and J21 8 pin deutsch connectors that join the upper harness to the lower harness Check for continuity in the BK C69PBE wire from pin 9 of the J20 connector and pin 4 of the J21 connector continuity Repair or replace the BK C69PBE wire from pin 4 of the J21 connector on turntable to pin 18 of the J2 connector at the ground controls CHART 15 Repair or replace the BL C76PBE wire from pin 3 of the 12 pin deutsch connector at the turntable that joins the lower J2 harness to the upper J2 harness to pin 28 of the J2 connector at the ground controls Repair or replace the BK C6
214. ector continuity Disconnect and test LSB13A0 See Repair Section Connect LSB13A0 and disconnect the J2 connector from the ground control box Check for continuity between the WH C77AS wire and the OR BK C64LS wire at pin 29 and pin 13 of the J2 connector continuity Check for proper installation and adjustment of boom angle limit switches See Repair Section OR consult the Genie Industries Service Department bad continuit bad continuit Replace LSB1DO Check for proper adjustment of LSBiDO See Repair Section OR repair or replace the RD C68PBD wire from pin 3 of the deutsch connector to pin 17 of the J2 connector at the ground control box OR repair or replace open in the OR BK C64LS wire to pin 4 of the deutsch connector at LSB1DO Replace LSB13A0 Check for proper adjustment of LSB13AO see Repair Section OR repair or replace the WH C77AS wire from pin 3 of the deutsch connector to pin 29 of the J2 connector at the ground control box OR repair or replace open in the OR BK C64LS wire to pin 4 of the deutsch connector at LSB13A0 5 44 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Boom Up Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the platform is level to gravity within 7 d
215. ed to page 5 93 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Install the arm onto e LSB6S and install the H page boom end cover onto the boom Raise the boom to approximately 60 degrees and extend the boom to approximately 95 feet Place a metal washer on limit switch LSB13A0 to close the contacts Lower the boom Will the boom lower to below 50 degrees DANGER IF THE BOOM LOWERS BELOW 50 DEGREES STOP IMMEDIATELY Fully retract the boom and lower the boom until the boom is on the rest pad and continue to activate the boom down function for five seconds Extend the boom until the display screen reads BOOM LENGTH gt 0 Is the alarm sounding DANGER IF THE ALARM IS NOT SOUNDING STOP IMMEDIATELY Continued on the next page Continued to page 5 95 Continued to page 5 97 CHART 20 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 87 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 20 Continued from the previous page With the boom in the stowed postion retract the axles until the LSAX1ES and LSAX2ES axle safety switches are activated Disconnect LSAX1EO and install a wire jumper between terminals 3 and 4 on the connector Disconnect LSAX2EO and install a wire jumper between terminals 3 and 4 on the connector
216. eeeeeeeeeeeeenaaeeeeeeeeaaees 5 138 25 Platform Level Up Function Inoperative 0 0 0 0 eeceeseeeeeeenneeeeeeeenneeeeeeeenaaees 5 140 26 Platform Level Down Function Inoperative ecceceeeeeeeeeeeeeeeeeneeeeeeeeeeeaees 5 144 27 Platform Level Safety Eau 5 148 28 Platform Rotate Clockwise Function Inoperative eesseeeeeeeeeeeeeeeneen nns 5 151 29 Platform Rotate Counter Clockwise Function Inoperative eeeseeseeeesees 5 154 30 Jib Up Function Inoperative sessssscre E 5 157 31 Jib Down Function Inoperative A 5 160 32 Auxiliariy Functions Inoperative 0 0 cece eeeeenneeeeeeeeeaeeeeeeeeaaeeeeeeseaaees 5 163 33 Axle Extend Function Inoperative eccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeaeees 5 168 34 Axle Retract Function Inoperative cccececccseceeeeeencneeeeeeeeeaeeeeeeeenaaeeeeenees 5 174 35 Blue End Blue Side Steering Function Inoperative seeeseeeeeeeeeeneeenn 5 178 36 Blue End Yellow Side Steering Function Inoperative ccceeeeeeeeeeeeeees 5 181 37 Yellow End Blue Side Steering Function Inoperative cceeeeeeeeeeeeeees 5 184 38 Yellow End Yellow Side Steering Function Inoperative seneese 5 187 39 Drive Forward Function Inoperative cece eeeceeeeeeeceeeeeeeeeeaeeeeeeeenaaeeeeeeeeaaees 5 190 40 Drive Reverse Function INOperative cecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeneaeees 5 196 41 Drive Enable Fault rencoriiirenirniiv
217. een pin 6 and pin 7 damage of the P20 12 pin lower found limit switch harness connector lower limit switch wiring harness looking for pinch points and chafed or broken wires continuity Department Repair or replace the OR S62BSTO wire circuit OR repair or replace the GR C61AXRT wire circuit no continuity Consult the Genie Industries Service Department 5 102 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts S CHART 20 Continued from page 5 90 Connect LSAX1ES Fully retract the boom and fully extend the axles Raise the boom to approximately 30 degrees Disconnect LSAX1ES Disconnect LSB3RS and install a wire jumper between terminal 3 and terminal 4 of the connector to LSB3RS Attempt to retract the axles Do the axles retract yes Extend the axles no Disconnect LSB7DS from the wiring harness Attempt to retract the axles Do the axles retract yes Disconnect the J2 black 35 pin connector from the ground control box Check for continuity between pin 3 and pin 4 of the connector to LSB7DS continuity no continuity Consult the Genie Industries Service Department Consult the Genie Industries Service Department Visually inspect bad Replace and adjust LSB7DS for damage LSB7DS See Repair Section good Adjust LSB7DS See Repair Sect
218. egrees Be sure the batteries are fully charged and properly connected With the key switch turned to ground no controls and both Emergency Stop buttons pulled out to theon position activate the function enable high RPM button and the boom up button Are there any diagnostic codes present on the display screen at the ground controls yes Is SAFETY SWITCH P22 FAULT and SAFETY SWITCH P22R FAULT present on the display screen Is BOOM UP DWN JOYSTICK NOT yes CALIBRATED present on the display screen Is BOOM UP DWN JOYSTICK SHORTED TO 0 VOLTS OR BOOM UP DWN JOYSTICK SHORTED TO 5 VOLTS OR BOOM yes UP DWN JOYSTICK VALUE TOO HIGH OR BOOM UP DWN JOYSTICK VALUE TOO LOW present on the display screen no Continued on the next page Activate the boom up button Is there an audible beep when button is pressed no Consult the Genie Industries Service Department The ground control membrane decal may need to be replaced Refer to Chart 27 Re calibrate the boom up down joystick See Repair Section OR replace the boom up down joystick Check for damaged wires inside the platform control box between the boom up down joystick connector P1 and the circuit board connector P20 OR replace the boom up down joystick OR consult the Genie Industries Service Department Chart 13 yes aj Continued on page 5 48 PartNo 62401 Genie S 10
219. egrees and extend the boom to yes approximately 95 feet Start the engine and disconnect LSB8AS Does the engine stop no Disconnect LSB4ES yes Does the engine stop no Disconnect the J20 12 pin and J21 8 pin Deutsch connectors yes inside the counterweight area of the machine Does the engine stop no Continued on the next page Visually check LSB8AS bad for damage See Repair Section good Adjust LSB8AS See Repair Section Visually check LSB4ES bad for damage See Repair Section good Adjust LSB4ES See Repair Section Check for a short between the WH RD SJ1 wire and the bad RD WH P57PBD wire from pin 1 to pin 8 of the J20 connector good Check for a short between the BK RD SJ2 wire and the RD BK bad P58LS wire from pin 2 of the J20 connector and pin 3 of the J21 connector good Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department CHART 20 Replace and adjust LSB8AS See Repair Section Replace and adjust LSB4ES See Repair Section Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the RD WH P57PBD wire Visually trace the limit switch upper wire harness f
220. eling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained level by the communication between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the ground controls will open the appropriate solenoid valve s at the platform manifold to maintain a level platform A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the platform controls and extend the axles 2 Turn the key switch to ground controls 3 Push and hold a function enable speed select button and fully retract the boom 4 Push and hold a function enable speed select button and adjust the platform to a level position using the platform level up down buttons TABLE B PROCEDURES Push and hold a function enable speed select button and fully raise the boom Result The platform should remain level at all times to within 2 degrees If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off Push and hold a function enable speed select button and fully lower the boom Result The platform should remain level at all times to within 2 deg
221. elope Operational Switch Failure S 120 and S 125 Models A boom envelope safety fault is the result of the boom exceeding the operational limits and activating the safety switches OR when the safety switches are tripped within the operational range Press the and keys together to access the status screen The status screen can display the following information Hydraulic pressure Boom Length Boom Angle Axle status Boom lengths are given in feet The first number is the length for a S 120 the second number is for a S 125 For example 75 5 80 5 feet Greater than or equal to is indicated by gt on the display A digital protractor will be needed to properly troubleshoot the machine Be sure the batteries are fully charged and properly connected The ground control box yes display reads SAFETY SWITCH P9A FAULT and SAFETY SWITCH P9B FAULT or SAFETY SWITCH P9B FAULT Did the engine shut off while the boom was extending no Did the engine shut off while the boom was being lowered yes Unable to determine from the operator when the safety switch was tripped Using auxiliary power retract the boom to less than 75 80 feet and lower the boom to a horizontal position Start the engine Access the status screen and engine scroll down until the boom length screen appears Extend the boom while observing the display screen Does the engin
222. emove the red secondary lock and re insert the terminal until it locks into place Push in the secondary lock to lock the terminal into place Repair or replace the RD C27AUX wire in the manifold harness Replace the negative ground wire cable from auxiliary pump motor mounting bolt to ground Consult the Genie Industries Service Department 5 164 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 32 Press and hold the At the auxiliary pump 3000 psi The battery cable Continued from auxiliary power button at disconnect the hose terminal connections page 5 163 the ground controls and from port P3A IN at the oe may be dirty OR repair hold a boom function distribution manifold and button Does the install a 0 to 5000 psi function operate 345 bar pressure gauge into the pressure or replace the battery cables port of the pump Press and hold the auxiliary power button and press the platform level up down button and note the pressure less than 3000 psi Adjust the auxiliary Press and hold the pump 3000 psi relief auxiliary power button a e the ay iD SE SE Kee the cl G Ge ng ie platform level up down and hold the auxiliary power button and press the platform level up down button and note the pressure button and adjust the relief valve pressure to 3
223. emperature Sending Units Deutz Model 7 51 Ground Controls PA CWOOM e EE 7 52 T2 Membrane DeCall 2 22eeteEe iiien EUREN bein EECH 7 53 FO eelere EE 7 54 Limit Switches Ge WEE IIe 7 57 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 xiii First Edition First Printing a _______________________________ TABLE OF CONTENTS Section Seven Repair Procedures continued Hydraulic Pumps SH upon PUMPS acers enn a el vuuaieeed deeg S 7 60 92 Drive PUMI E 7 61 EE RE EU e PUMP WEE 7 64 94 ee EE 7 65 Manifolds 10 1 Function Manifold Components S 100 and S 105 Models sasnenasaeeeaaanne 7 66 10 2 Valve Adjustments Function Manifold S 100 and S 105 Models 7 70 10 3 Proportional Valves Function Manifold ccecccccceeeeeeeeeeeeeeeeeeseeeeeeneeeens 7 71 10 4 Function Manifold Components S 120 and S 125 Models ssssssnnneeeeeeaeeen 7 72 10 5 Valve Adjustments Function Manifold S 120 and S 125 Models 7 76 10 6 Proportional Valves Function Manifold 0 2 eee ceeeeeeeeeeeeneeeeeeeenaaeeeeeeeeaaas 7 77 10 7 Distribution Manifold Components sssseeesseeesseesrsssiressrnsstnnenrnrnnnsernesrenssres 7 78 10 8 Valve Adjustments Distribution Manifold AA 7 80 10 9 Platform Manifold Components S 100 and S 120 Models aaasnnnnaneaeaaann 7 82 10 10 Platform Manifold Components S 105 and S 125 Models scceeeeseeees 7 84 10 11
224. en or shorted to ground or the coil itself is bad Boom up valve coil circuit open or shorted to ground or the coil itself is bad Boom down valve coil circuit open or shorted to ground or the coil itself is bad Boom angle operational switches out of sequence Calibrate Boom up down Thresholds refer to repair section Refer to charts 13 and 14 to troubleshoot Refer to chart 13 to troubleshoot Refer to chart 14 to troubleshoot Refer to chart 12 to troubleshoot EXTEND RETRACT JOYSTICK NOT CALIBRATED EXTEND RETRACT JOYSTICK SHORTED TO 0V EXTEND RETRACT JOYSTICK SHORTED TO 5V EXTEND RETRACT JOYSTICK VALUE TOO HIGH Extend retract functions inoperative rom platform Extend retract rom platform unctions inoperative Extend retract ive rom platform unctions inopera Extend retract ive rom platform unctions inopera Extend retract joystick not calibrated Open circuit between platform control card and extend retract joystick Shorted circuit between platform control card and extend retract joystick Damaged circuit between platform control card and extend retract joystick or Joystick may need to be replaced Calibrate extend retract joystick refer o repair section Refer to charts 16 and 17 to troubleshoot Refer to charts 16 and 17 to roubleshoot Refer to charts 16 and 17 to troubleshoot Continued on next page PartNo 62401 Ge
225. enable high RPM button and attempt to extend the boom Result The boom should not extend to more than 3 feet 0 9 m Result If the boom extends to more than 3 feet 0 9 m the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING extends to more than 3 feet 0 9 m stop immediately and retract the boom until the boom is extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 51 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 43 Activate the function enable high RPM button and attempt to raise the boom Result The boom should not raise to more than 11 Result If the boom continues to raise the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING raises to more than 11 stop immediately and lower the boom until the boom is less than 11 Failure to lower the boom could result in death or serious injury 44 Remove the wire jumper installed in step 41 and connect the deutsch connector to LSAX2ES Reverse Load Moment Switch LSB20LO 45 Activate the function enable
226. end of the machine Result Each wheel at the circle end of the machine should rotate with minimum effort 12 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands Lower the machine llisi Fai AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE D PROCEDURES D 4 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the boom to a horizontal position 2 Install a safety chock Genie part number 75097 onto the hydraulic lift cylinder extension rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the boom The lift cylinder safety chock is available through Genie Genie part number 75097 Be sure that each turntable rotation bearing mounting bolt above the turntable is torqued in sequence to 190 ft lbs 258 Nm Bolt torque sequence Raise the boom to a horizontal position Remove the safety
227. engine Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the steer axle manifold no Start the engine and activate the steer functions in both directions Is the pressure less than 3000 psi 207 bar yes Exchange the circle end yes yellow side steer valve item EC with the circle end blue side steer valve item ED Start the engine and activate the steer function Does the circle end yellow side steering function in both directions Repair or replace the steer cylinder OR repair or replace the pilot operated check valves items EG and EHH OR there may be a fault in the manifold OR consult the Genie Industries Service Department Recalibrate the steer joystick see Repair Section OR replace the steer joystick Check for mechanical restrictions keeping the steer function from moving OR repair or replace the steer cylinder OR repair or replace the pilot operated check valves item EG and EHH OR consult the Genie Industries Service Department Replace the faulty steer valve 5 184 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from the previous page Is STEERING JOYSTICK SHORTED TO 0 VOLTS or STEERING JOYSTICK SHORTED TO 5 VOLTS or STEERING JOYSTICK VALUE TOO HIGH or STEERING JOYSTICK VALUE TOO Low present on the display screen yes Is YELLOW E
228. ensor circuit Refer to chart 4 to troubleshoot VALUE TOO HIGH damaged or sensor may need to be replaced ENGINE OIL PRESSURE SENSOR Engine runs then dies Engine oil pressure sensor circuit Refer to chart 4 to troubleshoot VALUE TOO LOW damaged or sensor may need to be replaced ENGINE TEMPERATURE VALUE Engine runs then dies Engine temperature above maximum Refer to chart 4 to troubleshoot TOO HIGH allowable temp for engine ENGINE TEMPERATURE SENSOR Engine runs then dies Engine temperature sensor circuit Refer to chart 4 to troubleshoot SHORTED TO 0V shorted to ground ENGINE TEMPERATURE SENSOR Engine runs then dies Engine temperature sensor circuit Refer to chart 4 to troubleshoot SHORTED TO 5V open ENGINE TEMPERATURE SENSOR Engine runs then dies Engine temperature sensor circuit Refer to chart 4 to troubleshoot VALUE TOO HIGH damaged or sensor may need to be replaced ENGINE TEMPERATURE SENSOR Engine runs then dies Engine temperature sensor circuit Refer to chart 4 to troubleshoot VALUE TOO LOW TURNTABLE LEVEL SENSOR X DIRECTION SHORTED TO 0V TURNTABLE LEVEL SENSOR X DIRECTION SHORTED TO 5V TURNTABLE LEVEL SENSOR X DIRECTION VALUE TOO HIGH TURNTABLE LEVEL SENSOR X DIRECTION VALUE TOO LOW TURNTABLE LEVEL SENSOR Y DIRECTION SHORTED TO 0V Unit out of level LED icon and alarm active Unit out of level LED icon and alarm active Unit out of level LED icon and alarm active Unit out of level LED
229. epartment Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 141 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 25 Is BOOM UP OVERLOAD Are there mechanical FAULT present on the restrictions keeping the Continued from the previous page display screen boom down function from operating no Check LSB20LO for proper operation See Repair Section good Check for proper adjustment of LSB20LO good Check for an open or short in the RD BK C115LS wire from pin 17 of the J4 connector at the ground controls to LSB20LO good no Check for an open or short in the BR VLVRET5 wire from pin 14 of the J4 connector at the ground controls to LSB20LO good Consult the Genie Industries Service Department Continued on the next page es bad bad bad bad Remove or repair the mechanical restrictions Replace and adjust LSB20LO See Repair Section Adjust LSB20LO See Repair Section Repair or replace the RD BK C115LS wire Repair or replace the BR VLVRET5 wire 5 142 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is PLATFORM LEVEL UP Continued from the VALVE FAULT present on previous page the display screen no If any other codes are on the display screen refer to the fault
230. er to Repair Section 5 1 How to Remove a Fixed Turntable Cover 7 Loosen the turntable drive hub mounting bolts Do not remove them It may be necessary to raise the boom slightly to access all the turntable drive hub mounting bolts d fi s motor brake drive hub pivot bolt mounting bolt adjustment bolt with lock nut O Oo 0 o 8 Loosen the turntable drive hub pivot bolt Do not remove it 9 Loosen the lock nut on the turntable drive hub adjustment bolt 10 Tighten the turntable drive hub adjustment bolt until the turntable drive hub gear is fully engaged and tight into the turntable rotate gear 11 Turn the adjustment bolt 1 4 turn counterclockwise Tighten the lock nut on the adjustment bolt 12 Rotate the drive hub away from the turntable until it contacts the adjustment bolt Torque the drive hub mounting bolts to 210 ft lbs 283 Nm 13 Torque the turntable rotate pivot bolt to 210 ft lbs 283 Nm 14 Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary 15 Install the ground control side fixed turntable cover onto the machine and tighten the retaining fasteners Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures D 6 Grease the Turntable Rotation Bearing and Rotate Ge
231. erative Be sure the boom is in the stowed position Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position press the the start assist button Is there an audible beep when button is activated Turn the key switch to platform controls Press the engine start assist button Is there an audible beep when membrane is activated Turn the key switch to ground controls Press the engine start assist button and check the voltage at the BK WH R34SA wire at the engine start assist component Locate the engine start assist relay in the engine bay near the batteries Pull the relay from the socket just enough to expose the spade terminals for testing Activate the start assist and check the voltage at relay terminal 87 Continued on the next page Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the platform control box membrane decal OR consult the Genie Industries Service Department Replace the engine start assist component OR consult the Genie Industries Service Department Repair or replace the BK WH R34SA wire from terminal 87 to the engine start assist component 5 210 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition
232. ertion on the connectors or for broken or shorted wires good Begin troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department With the key switch 12V turned to ground controls press and hold the engine start button and check the voltage at pin C of the connector Check the fan belt break no switch Disconnect the continuity two white wires and use an ohmmeter to check for continuity continuity Visually trace ckt C21IGN from the fan belt break switch to the J3 connector on the ground control box damage found no damage found Replace relay K6 inside the ground control box OR consult the Genie Industries Service Department Visually trace the RD BAT CBL A wire from pin 1 to the splice in the engine harness checking for pinch points and chafed shorted wiring and repair the RD BAT CBL A wire Repair damage to wiring If engine still won t start consult the Genie Industries Service Department Replace the fuel solenoid Make sure the fan belt is in good condition OR check the adjustment of the switch Repair any damage to ckt C21IGN wire circuit from the fan belt break switch to the J3 connector at the ground control box 5 24 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Engine Starts and Runs
233. evious page Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the steer axle extend manifold Press down the foot switch and activate the auxiliary power and activate the forward and reverse function and check the pressure Exchange the forward valve item JA with the reverse valve item JB Press down the foot switch and activate the auxiliary power Activate the forward and reverse function and check the pressure Does the function operate Replace the faulty valve At the ground controls confirm that the auxiliary drive option has been activated in the display options module OR consult the Genie Industries Service Department Check that the machine is on level ground OR repair or replace valves JE JD JA JB JF or JC OR the auxiliary manifold may have an internal fault Consult the Genie Industries Service Department Repair or replace valves JE JD JA JB JF or JC OR the auxiliary manifold may have an internal fault Consult the Genie Industries Service Department 5 214 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 6 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Hl Repair any machine damage o
234. fasteners Deutz models Perform every 125 hours A 20 Batteries B 9 Hydraulic tank breather filter B 10 Medium and high pressure filters B 11 Electrical wiring B 12 Brake configuration B 13 Tires and wheels B 14 Drive hub oil level B 15 Engine RPM B 16 Key switches B 17 Emergency Stop B 18 Ground control override B 19 Safety envelope B 20 Platform self leveling B 21 Horn B 22 Foot switch B 23 Engine idle select B 24 Drive enable system B 25 Drive brakes B 26 Drive speed stowed B 27 Drive speed raised or extended B 28 Alarm package B 29 Engine oil and filter Cummins models B 30 Fuel tank cap vent B 31 Hydraulic oil analysis Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures ee STS MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Semi annual or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each
235. fuel tank cap Dry the cap using low pressure Kai D compressed air Ww d Ki 4 Repeat step 2 See E 1 Test or Replace the Hydraulic Oil Install the fuel tank cap onto the fuel tank Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 63 Section Ae Scheduled Maintenance Procedures First Edition First Printing Table C Procedures C 1 Check the Engine Valve Clearances Deutz Models Complete information to perform this procedure is available in the Deutz 913 Operation Manual Deutz part number 0297 9690 Genie part number 62446 C 2 Clean the Fuel Pump Strainer Perkins Models Cleaning the fuel pump strainer is essential to good engine performance and service life A dirty or clogged strainer may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the strainer be cleaned more often Explosion and fire hazard Engine A DANGER fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Tag disconnect and plug the fuel line from the fuel tank at the inline fuel filter water separator head Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section A Scheduled Maintenance Procedure
236. functions inoperative Drive functions inoperative valve coils circuits open or shorted to ground or the coils are bad Drive joystick not calibrated Calibrate drive joystick refer to repair section DRIVE JOYSTICK SHORTED TO 0V Drive functions inoperative Open circuit between platform control card and drive joystick Refer to charts 39 and 40 to troubleshoot DRIVE JOYSTICK SHORTED TO 5V Drive functions inoperative Shorted circuit between platform control card and drive joystick Refer to charts 39 and 40 to troubleshoot Continued on next page Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Diagnostic code displayed Condition Section 5 Troubleshooting Flow Charts PE Possible Causes FAULT CODE CHART Solution DRIVE JOYSTICK VALUE TOO Drive functions inoperative Damaged circuit between platform Refer to charts 39 and 40 to HIGH control card and drive joystick or troubleshoot Joystick may need to be replaced DRIVE JOYSTICK VALUE TOO Drive functions inoperative Damaged circuit between platform Refer to charts 39 and 40 to LOW control card and drive joystick or troubleshoot DRIVE VALVE NOT CALIBRATED No movement on Drive forward or reverse functions until joystick is moved past half stroke Joystick may need to be replaced Reset propel valve defaults set from display Refer to Display modul
237. ge yes yes Section 5 Troubleshooting Flow Charts PE Check for damaged wires in internal platform controls wire harness between steer joystick connector P4 and and circuit board connector P20 OR consult the Genie Industries Service Department Check square end blue end blue side steer sensor for proper installation and Operation see Repair Section good Check for an open or short in the OR C111LFS wire from pin B of the square end blue side steer sensor connector to pin 13 of the J2 connector on the drive chassis controller DCON good Check for an open or short in the GR WH P109ANG wire from pin A of the square end blue side steer sensor connector to pin 20 of the J2 connector on the drive chassis controller DCON good Check for an open or short in the BK P110RT wire from pin C of the square end blue side steer sensor connector to pin 19 of the J2 connector on the drive chassis controller DCON good Consult the Genie Industries Service Department bad bad bad bad CHART 35 Replace the steer sensor See Repair Section Repair or replace the OR C111LFS wire Repair or replace the GR WH P109ANG wire Repair or replace the BK P110RT wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 179 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 35 Is BLUE END BLUE
238. ggle switch Repair or replace the internal platiorm wire harness Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the ground control box membrane decal OR consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 145 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 26 Is BOOM DOWN Are there mechanical yes Remove or repair the Continued from the OVERLOAD FAULT yes restrictions keeping the mechanical restrictions revious page prg H page boom down function present on the display screen from operating no Check LSB20LO for pone operation See epair Section Replace and adjust bad LSB20LO See Repair Section good Check for proper bad Adjust LSB20LO See adjustment of LSB20LO Repair Section good Check for an open or bad _ Repair or replace the short in the RD BK RD BK C115LS wire C115LS wire from pin 17 of the J4 connector at the ground controls to LSB2OLO good d Check for an open or bad __ Repair or replace the short in the BR BR VLVRET5 wire VLVRET5 wire from pin 14 of the J4 connector at the ground controls to LSB2OLO good Consult the Genie Industries Service Department Continued on the next page 5 146 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 624
239. gine change to high RPM yes Troubleshoot each function individually Repair open in the GRN wire Check to see if the key switch internal cam is releasing key switch contact BA no Replace the key switch Test or replace the foot switch see Repair Section OR repair open in the RD C56FTS wire and the RD R56FTS wire from the foot switch to pin 16 and pin 17 of the J2 connector at the platform control box yes Replace key switch contact BA 5 40 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page With the key switch oV turned to platform controls and both Emergency Stop buttons pulled out to the ON position check the voltage at the ESTOP 1 wire on the input side terminal 2 of the platform Emergency Stop contact The ESTOP 1 wire checked should originate from pin 29 of the J20 connector 12V Check the voltage of the ESTOP 2 wire at the 12V output side terminal 1 of the platform Emergency Stop contact The ESTOP 2 wire checked should originate from pin 30 of the J20 connector oV Check to see if Emergency Stop button es is releasing the contact no Replace the Emergency Stop button Repair open in the ESTOP 1 wire Press down the foot switch and activate each membrane decal button Is there an audi
240. gle status Is Department scroll to the Boom gt 10 degrees showing on length status screen the screen Is gt 0 showing on the 9 screen yes Disconnect LSBiDO bad pepe and adjust and check for proper LSB1DO See Repair operation Section good Reconnect LSB1DO Adjust LSB1DO See Disconnect the J2 Repair Section OR connector at the ground continuity repair or replace the RD controls and check for C68PBD wire from pin 3 continuity between pin of the deutsch connector 17 and pin 13 of the J2 to pin 17 of the J2 connector connector at the ground controls OR repair or yes replace the OR BK C64LS wire at pin 4 of no continuity ao connector at Check for proper installation and adjustment of boom angle limit switches OR consult the Genie Industries Service Department Disconnect LSB3RO bad _ Replace and adjust and check for proper LSB3RO See Repair Section operation See the Repair Section good Continued on the next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 205 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 42 With LSB3RO Check for proper EE disconnected but still installation of LSB3RO H page installed on the gt OR consult the Genie machine check for Industries Service continuity between pin 3 Department amp pin 4 of the duetsch connector to LSB3RO no continuity Connect LSB3RO Repair or replace the Dis
241. hange the square end yellow side steer valve item EA with the square end blue side steer valve item EB Start the engine and activate the steer function Does the square end blue side steering function in both directions es Repair or replace the steer cylinder OR repair or replace the pilot operated check valves items EK and EDD OR there may be a fault in the manifold OR consult the Genie Industries Service Department Recalibrate the steer joystick see Repair Section OR replace the steer joystick Check for mechanical restrictions keeping the steer function from operating OR repair or replace the steer cylinder OR repair or replace the pilot operated check valves items EK and EDD OR consult the Genie Industries Service Department Replace the faulty steer valve 5 178 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from the previous page Is STEERING JOYSTICK SHORTED TO 0 VOLTS or STEERING JOYSTICK SHORTED TO 5 VOLTS or STEERING JOYSTICK VALUE TOO HIGH or STEERING JOYSTICK VALUE TOO Low present on the display screen Is BLUE END BLUE SIDE STEER SENSOR SHORTED TO 0 VOLTS or BLUE END BLUE SIDE STEER SENSOR SHORTED TO 5 VOLTS or BLUE END BLUE SIDE STEER SENSOR VALUE TOO HIGH or BLUE END BLUE SIDE STEER SENSOR VALUE TOO LOW present on the display screen no Continued on the next pa
242. he C76PBE and or C64LS wire circuits Loosen the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Loosen the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 81 Section 5 Troubleshooting Flow Charts CHART 19 Press amp keys together to access the status screen Scroll down until BOOM ANGLE Continued from pages 5 77 5 78 and 5 81 ep degrees is present on the display screen What boom angle is shown on the display 65 degrees Continued on the next page First Edition First Printing SSS ooo eee Go to lift function ramp time Turn the key switch to the OFF position Press and hold the 1 button and turn the key switch to ground controls Press UL then scroll until UP DOWN RAMP DECEL is present on the display software version 1 01 Reset the ramp time to 250 ms software version 1 06 or greater Reset the ramp time to 500 ms yes Turn the key switch to the OFF position Press and hold the 1 button and turn the key switch to ground controls Press and scroll down until BOOM UP DOWN SPEED ABOVE 100 FEET is present on the display Does the display show 20 yes Attach a digital protractor to the top of mo t
243. he J26 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring bad Repair the OR RD P63LS wire OR repair the GR WH S59CNBK wire bad good CHART 20 Replace and adjust LSB6S See Repair Section Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 20 Check for a short Visually trace the wire Start troubleshooting a de the between the OR RD harness from the P26 from the beginning of H page P63LS wire and the connector near the the chart OR consult the GR WH S59CNBK wire breakout at the side of Genie Industries Service from pin 5 of the J20 the boom to the J20 Department connector to pin 5 of the connector and the J21 J21 connector connector checking for pinch points and chafed or shorted wiring Repair the OR RD P63LS wire OR repair the GR WH S59CNBK wire Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department 5 94 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from page 5 87 Using auxiliary power raise the boom to greater than 53 d
244. he boom tube Raise _ continuity the boom until the boom angle is at 68 degrees Disconnect LSB14A0 deutsch connector and check for continuity between terminals 3 and 4 continuity Connect LSB14A0 Lower the boom until the boom angle is 65 degrees Disconnect LSB9AS deutsch connector and check for no continuity between pins 1 and 2 and between pins 3 and 4 continui no continuity Begin troubleshooting from the beginning OR consult Genie Industries Service Department software version 1 01 Reset the ramp time to 250 ms software version 1 06 or greater Reset the ramp time to 500 ms no Reset the boom speed to 20 Loosen the LSB14A0 mounting fasteners and adjust the switch so it closes when the boom angle reaches 68 degrees Loosen the LSB9AS mounting fasteners and adjust the switch so the contacts of the switch open when the boom angle reaches 65 degrees NOTE Loosening the LSB9AS fasteners will also loosen the LSB8AS fasteners Be sure to adjust LSB8AS before returning the machine to service 5 82 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 19 Disconnect LSB14A0 Remove the orange Continued from the previous page Are the terminals are no secondary lock and reinsert the terminals Install the orange secondary lock inserted properly
245. he drain plug and tighten When removing the drive brake plug on machines before serial number 158 replace the drive hub plug with the new O ring style drive hub plug Genie part number 75107 8 Fill the drive brake with oil until the oil is level with the bottom of the threads Install the drain plug and tighten When removing the drive hub plug on machines before serial number 158 replace the drive hub plug with the new O ring style drive hub plug Genie part number 75107 TABLE D PROCEDURES 9 Install the drive hub onto the machine Install the pivot bolt and the mounting bolts and tighten the bolts until they are finger tight 10 Install the turntable rotate drive motor hoses into the turntable rotate drive motor and install the turntable rotate drive brake hose into the turntable rotate drive brake CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Adjust the turntable rotation gear backlash See D 5 Check the Turntable Rotation Gear Backlash 12 Install the ground control side fixed turntable cover onto the machine and tighten the retaining fasteners Turntable rotate drive hub oil Capacity 92 fl oz 2 7 liters Type SAE 80W 90 EP multipurpose gear oil Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE D PROCEDURES D 8 Inspect the Engine Belt
246. heck the hydraulic pressure Adjust the steer axle manifold system relief valve item EZ or item HZ all the way in clockwise counting the number of turns Press down the foot switch and activate the axle retract button and check the hydraulic pressure Re connect the AXLE FULLY RETRACTED proximity switch and repair or replace the relief valve item EZ or item HZ OR repair or replace priority flow regulator valve item AD OR repair or replace the multi function solenoid valve item AA OR repair or replace differential sensing valve item EP ot item HP OR repair or replace load sense flow regulator valve item EO or item HO OR the distribution or steer axle manifolds have an internal fault Consult the Genie Industries Service Department First Edition First Printing Troubleshoot steering axle functions individually or consult the Genie Industries Service Department Press down the foot switch and activate the axle retract button and adjust the relief pressure to 3000 psi 207 bar Re connect LSAX1RO and LSAX2RO Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts EE CHART 9 Is the sensor power LED Check for an open in BR activated on the drive GNDDCON wire circuit chassis controller from pin 1 of the J2 DCON connector at the ground controls to pin 2 of the upper J8 connector at the ele
247. high RPM button and fully retract the boom 46 Activate the function enable high RPM button and lower the boom onto the boom rest pad and continue to hold the boom lower function button for 5 seconds 47 Activate the function enable high RPM button and extend the boom until gt 0 is present on the display screen at the ground controls Result The alarm should sound and REVERSE LOAD MOMENT FAULT Should be present on the display screen at the ground controls Result If the alarm does not sound or if REVERSE LOAD MOMENT FAULT iS not present on the display screen at the ground controls the LSB20LO switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the alarm AWARNING does not sound or if REVERSE LOAD MOMENT FAULT is not present on the display screen at the ground controls stop immediately and fully retract the boom Failure to retract the boom could result in death or serious injury 48 Activate the function enable high RPM button and raise the boom to clear the alarm 49 Activate the function enable high RPM button and lower the boom to the stowed position 50 Turn the key switch to the orF position Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 20 Test the Platform Self leveling Automatic platform self lev
248. hould be parallel with hose Install a 0 to 5000 PSI 345 bar pressure gauge to the test port on the function manifold Start the engine from the ground controls Activate the function enable high RPM button and the boom retract button and check the hydraulic pressure less than 2600 psi Disconnect the fuel solenoid wiring connector Remove the function pumps from the main pump but leave all hoses connected Press the engine start button and crank the engine over while observing spline drive that the gear pumps plug into spline does not turn The engine to pump flex plate coupling is faulty OR the main pump is faulty Consult the Genie Industries Service Department Do the pumps feel excessively hot Open valves and start the engine Check all machine functions for correct operation Troubleshoot each function individually OR consult the Genie Industries Service Department Troubleshoot inoperative boom functions and inoperative drive functions separately Chart 7 If engine has been run with valves closed it may have damaged one or all of the pumps Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 31 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 8 Boom Up Down Extend Retract Turntable Rotate and Platform Functions inoperative Drive Steer and Ax
249. ib boom up membrane button at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 7 of the J11 membrane decal connector at the circuit board good Check for an open or short in the jib boom down membrane button at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 4 of the J11 membrane decal connector at the circuit board good Consult the Genie Industries Service Department es bad bad bad Replace the toggle switch Repair or replace the internal platform wire harness Replace the ground control box membrane decal OR consult the Genie Industries Service Department Replace the ground control box membrane decal OR consult the Genie Industries Service Department 5 158 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is JIB VALVE FAULT present on the display Continued from the previous page screen no If any other codes are on the display screen refer to the fault code chart for more information CHART 30 Check for an open or bad Repair or replace the short in the GR C43JU GR C43JU wire wire from pin 5 of the J2 connector at the platform controls box to pin 1 of the Din connector at the jib boom up valve coil item CL goo
250. ic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position and the axles extended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the ground controls side turntable side cover Refer to Repair Section 5 1 How to Remove a Hinged Turntable Cover 2 Close the three hydraulic shutoff valves located at the hydraulic tank open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosep 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 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container See capacity specifications Remove the ground controls support bracket retaining fasteners and remove the ground control box assembly from the machine Component damage hazard CAUTION Be sure to pro
251. ic tank return filter from the hydraulic tank return filter head TABLE E PROCEDURES 15 Remove the case drain filter from the case drain filter head 16 Remove the suction strainers from the tank and clean them using a mild solvent 17 Rinse out the inside of the tank using a mild solvent 18 Install the suction strainers using Loctite 567 on the pipe threads Always use Loctite 567 on all pipe threads 19 Install the drain plug using Loctite 567 on the pipe threads Always use Loctite 567 on all pipe threads 20 Install the hydraulic tank onto the machine 21 Install the hydraulic tank retaining straps and install the hydraulic tank retaining fasteners 22 Install the horn and horn retaining fasteners onto the machine Connect the wiring 23 Install the ground control box assembly and assembly retaining fasteners onto the machine 24 Install the two suction hoses and the supply hose for the auxiliary power unit onto the machine 25 Install the case drain hose onto the return filter head 26 Install the T fitting and 2 hoses connected to it to the hydraulic tank return filter head Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE E PROCEDURES 27 Fill the tank with hydraulic oil until the level is 3 4 inch 19 mm from the top of the sight gauge Do not overfill 28 Apply teflon tape to the
252. ice Department yes Continued to page 5 103 Visually check LSB3RS for damage and check bad for debris under the limit switch Replace and adjust LSB3RS See Repair Section OR remove the debris good Adjust LSB3RS See Repair Section no damage Consult the Genie Visually inspect the Industries Service lower limit switch harness looking for pinch points and chafed or broken wires Department damage found Repair or replace the GR C61AXRT wire circuit or the OR S62BSTO wire circuit no damage Consult the Genie Visually inspect the Industries Service lower limit switch harness looking for pinch points and chafed or broken wires Department damage found Repair or replace the GR C61AXRT wire circuit or the OR S62BSTO wire circuit Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from page 5 86 Using auxiliary power retract the boom until the boom is extended less than 75 feet Start yes the engine Disconnect LSB4ES Does the engine stop no Disconnect LSB8AS yes Does the engine stop no Disconnect the J20 12 pin and J21 8 pin deutsch connectors es inside the counterweight area of the machine Does the engine stop no Continued on the next page Visually check LSB4ES bad for damage
253. ich if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 1 Section Ae Scheduled Maintenance Procedures First Edition First Printing SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Bis ts oi ES Maintenance Schedule There are five types of maintenance inspections that mu
254. ilter Switch Float Switch Foot switch Signal Forward Fuel Select gas LP suffix GEN ANG ABV AFV APV AREV AREV ASV AXEX AXOS AXRT BAT BEX BST BRK CAN CAN SHLD CNBK DTA DTA DCON DRE EDC ESPD ESL FLR FLTR FTS FWD FUEL 6 4 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 First Edition First Printing Section pe Schematics WIRE CIRCUIT LEGEND Fuel Solenoid FSOL Primary Boom Up Down Flow Control PBF Ground Control TCON Primary Lockout 1 PIL Horn HRN Primary Lockout 2 P2L Ignition IGN Proportional Valve PRV Jib Down JD Proximity Sensor PXS Jib Flow Control JFC Receptacle REC Jib Select Valve JSV Reverse REV Jib Up JU Right Front RF Lamps LPS Right Front Steer Sensor RFS Left Front LF Right Rear RR Left Front Steer Sensor LFS Right Rear Steer Sensor RRS Left Rear LR RPM RPM Left Rear Steer Sensor LRS Sec Boom Down SBD Limit Switch LS Sec Boom Extend SBE Load Sensor LDS Sec Boom Extend Retract Flow Control SERF Low fuel LOF Sec Boom Retract SBR Motor Shift Speed MS Sec Boom Up SBU Multi Function Valve MFV Sec Boom Up Down Flow Control SBFC Platform Control PCON Secondary Boom SB Platform Level Down PLD Secondary Boom Lockout Valve SBLO Platform Level Flow Control PLF Spare SP Platform Level Up PLU Start Aid Glow Plug or choke SA Platform Rotate Flow Control PRF Starter STR Platform Rotate Left CCW PRL Steering Valve CW STG Platform Rotate Right CW PRR Stee
255. immediately Auxiliary power is designed for short term use only and excessive use will result in battery drain and component damage Perform this procedure with the axles extended and the engine off 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Simultaneously push and hold the auxiliary power button and push each boom function button To conserve battery power test each function through a partial cycle Result All boom functions should operate Turn the key switch to platform controls Press down the foot switch o E o o Simultaneously press and hold the auxiliary power button and activate each function control handle toggle switch or button To conserve battery power test each function through a partial cycle Result All boom functions should operate 4 16 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures A 16 Test the Tilt Sensor and Alarm The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate Select a level test area The tilt alarm should not be sounding prior to the test Be sure the engine is off 1 Turn the key switch to ground controls and pull out the Emergency Stop buttons out to the on position at both the ground and pl
256. ing CHART 2 Disconnect the J16 3 Check the drive chassis pin connector from the harness for physical electrical swivel harness damage to the harness and check the voltage at Repair any damage LSB7DS Is there found voltage present Continued from the previous page Disconnect the P6 3 Check the wires going pin connector from the into the electrical swivel electrical swivel and Check to see if any of check the voltage at the wires are shorted LSB7DS Is there together Use an voltage present ohmmeter to check for any shorts between circuits on the electrical rotator Visually trace the S56PRV wire circuit and the limit switch harness checking for pinch points and chafed or shorted wiring Is there damage found Repair or replace S56PRV wire circuit Consult the Genie Industries Service Department 5 20 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 2 With the key switch Press each button on Open the ground control turned to ground the ground control box box and check to make controls press the and listen for a beep sure that the ribbon engine start button Is when each button is cables to the large there an audible beep pressed Is an audible printed circuit board are beep heard when each connected properly OR switch is pressed consult the Genie Industries Service Replace ground con
257. ing fastener Be sure that the lift pump body and cover are installed correctly An incorrect fit will let air into the fuel system 12 Clean up any fuel that might have spilled during the procedure 13 Bleed the fuel system See Maintenance Procedure B 4 Replace the Inline Fuel Filter Water Separator Element Before bleeding the system fill the fuel tank C 3 Replace the Fuel Filter Element Perkins and Cummins Models Replacing the diesel fuel filter element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Tag disconnect and plug the fuel line from the fuel tank at the inline fuel filter water separator head Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 2 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the
258. inued on the next page First Edition First Printing SSS ooo eee Go to lift function ramp time Turn the key switch to the OFF position Press and hold the 1 button and turn the key switch to ground controls Press LN 4 then scroll until UP DOWN RAMP DECEL is present on the display software version 1 01 Reset the ramp time to 250 ms software version 1 06 or greater Reset the ramp time to 500 ms yes Turn the key switch to the off position Press and hold the 1 button and turn the key switch to ground controls Press and scroll down until BOOM UP DOWN SPEED BELOW 80 FEET is present on the display Does the display show 60 yes Attach a digital protractor to the top of mo the boom tube Raise _ continuity the boom until the boom angle is at 53 degrees Disconnect LSB13AO deutsch connector and check for continuity between terminals 3 and 4 continuity Connect LSB14A0 Lower the boom until the boom angle is 50 degrees Disconnect LSB8AS deutsch connector and check for no continuity between pins 1 and 2 and between pins 3 and 4 continuity no continuity Begin troubleshooting from the beginning OR consult Genie Industries Service Department software version 1 01 Reset the ramp time to 250 ms software version 1 06 or greater Reset the ramp time to 500 ms no Reset the boom speed to 60 Loosen the LSB
259. ion no damage Consult the Genie Industries Service Visually inspect the lower limit switch harness looking for Department pinch points and chafed or broken wires damage found Repair or replace the RD S56PRV wire circuit or the OR S62BSTO wire circuit PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 103 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 21 Boom Envelope Safety Switch Failure S 120 and S 125 Models Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch yes Continued to turned to ground page 5 111 controls and both Emergency Stop buttons pulled out to the ON position start the engine Disconnect LSB3EO Raise the boom to a horizontal position and extend the boom Will the boom extend to more than 76 feet 23 2 m without stopping the engine DANGER IF THE BOOM EXTENDS TO MORE THAN 76 FEET 23 2 M WITHOUT STOPPING THE ENGINE STOP IMMEDIATELY Raise the boom to es Continued to approximately 60 page 5 113 degrees and extend the boom to more than 80 feet 24 4 m Disconnect LSB14AO and install a wire jumper between pin 3 and pin 4 of the connector to close the contacts Verify that the display screen at the ground controls reads gt 65 Extend the boom Will the boom extend to more than 101 feet 30 8
260. ion First Printing Section 5 Troubleshooting Flow Charts Continued from page 5 88 Disconnect LSAX2ES from the wiring harness Attempt to raise and extend the boom Does the boom raise or extend yes Check for continuity between the BL RD J2 and GR WH C60AXEX wires if the boom raises and check for continuity between the OR BL J3 and OR RD P63LS wires if the boom extends no continuity Check for continuity between terminals 1 and 2 of the connector to LSB7DS no continuity Consult the Genie Industries Service Department no continuity continuity Visually check LSAX2ES for damage good Adjust LSAX2ES See Repair Section Visually inspect the wiring looking for pinch points and chafed or broken wires no damage Consult the Genie Industries Service Department Visually inspect the wiring looking for pinch points and chafed or broken wires damage found Repair or replace the WH BL P53LS wire circuit OR repair or replace the GR WH C60AXEX wire circuit bad damage found no damage CHART 20 Replace and adjust LSAX2ES See Repair Section Repair or replace the BL RD J2 wire or the GR WH C60AXEX wire if the boom raises OR repair or replace the OR BL J3 or OR RD P63LS wires if the boom extends Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 am
261. ion First Printing TABLE A PROCEDURES 10 Stop the machine when the axles are fully extended Test the Ground Controls 11 Turn the key switch to ground controls 12 Do not press and hold a function enable speed select button Attempt to activate each boom and platform function button Result No boom and platform functions should operate 13 Press and hold a function enable speed select button and activate each boom and platform function button Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while boom is lowering Test the Platform Controls 14 Turn the key switch to platform controls 15 Do not press down the foot switch 16 Attempt to activate each machine function control handle toggle switch or button Result No boom and platform functions should operate 17 Press down the foot switch 18 Activate each machine function control handle toggle switch or button Result All functions should operate through a full cycle Descent alarm if equipped should sound while boom is lowering A 15 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operating the machine on engine power selecting auxiliary power will stop the engine
262. ircuit SCHEMAULC 7uuesegegbkktesgeeideeke tee kisaan annida EE EES ode 6 19 Electrical Schematic Generators 0 ccccccceeeeeceeeeeeeeeeeeeecaeeeeeeeeeesaaeeeeeeeeeeeaeetee 6 20 Electrical Schematic Deutz Models 0 ccscceeceeeeceeeeeeeeeeeeeeeeeeeeeeaeeesetaeeeteeeees 6 21 Electrical Schematic Cummins and Perkins Models ccceeeeeeeeeeeeeeeeeeeees 6 22 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 xi First Edition First Printing TABLE OF CONTENTS Section Six Section Seven Schematics continued Hydraulic Symbols Legend 6 24 Hydraulic Schematic S 100 Models with 2 Wheel Steer cccecceecessteeeeeeeees 6 25 Hydraulic Schematic S 100 Models with A Wheel Steer cccscceeeeesseeeeeeeees 6 27 Hydraulic Schematic S 105 Models with 2 Wheel Steer ccseccecceesseeeeeeeeees 6 29 Hydraulic Schematic S 105 Models with 4 Wheel Steer cccscceccseesteeeeeeeeees 6 31 Hydraulic Schematic S 120 Models 6 33 Hydraulic Schematic S 125 Models ccccccecceeesseceeeeeeesneeeeeeeeesneeeeeeeeesneeeeeeseeses 6 35 Repair Procedures Juttel ee EE 7 1 DEPAY e Le iiisutets seuccunceds n E E pivaduabers ieaeeunuete ben 7 2 Platform Controls d i CICUI BONS EE 7 5 t2 Membrane Docal resessie t e E th peeetenbete Lens 7 6 1 3 Joystick Controllers ccccceceeeeeeeeeececeeeeeeeeeeeeeaaeeeeaeeeeeeeeeesaaeeseeeeeeeseaeeseeas 7 7
263. ire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 17 Section 5 Troubleshooting Flow Charts EE CHART 2 Continued from page 5 16 Are all LED s at the platform control box Be dark or is the RED LED for system failure flashing no Press the engine start button at the platform no beep controls Is there an audible beep button beeps Test the foot switch See bad Repair Section good Without activating the yes membrane button does the auxiliary pump turn on Continued on the next page First Edition First Printing Check terminals for proper insertion at the black J1 connectors at ground and platform control boxes Are the terminals fully inserted yes Loosen the red secondary lock on the sides of the connector Do not remove the lock Insert the terminal fully until you hear it click into place and engage the secondary lock Press each button on the platform control box and listen for a beep when each button is pressed Is an audible beep heard when each switch is pressed no yes Replace the platform controls membrane switch decal Replace the foot switch Replace the membrane at the platform controls Check for damaged cables in the boom cable track Open the platform control box and check to make sure that the ribbon cables to the large printed circuit board are connected properly
264. irst Edition First Printing Section Ae Scheduled Maintenance Procedures A 1 Inspect the Manuals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure that the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed Table A Procedures A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the Genie S 100
265. is not less than specification shim as necessary to obtain zero clearance If the wear pads are still within specification refer to Repair Section 4 2 How to Shim the Boom 6 Remove the boom end cover retaining fasteners at the pivot end of the boom Remove the boom end cover from the machine Table D Procedures 7 Remove the boom side inspection cover retaining fasteners from the boom at the pivot end of the boom Remove the boom inspection cover from the machine 8 Repeat step 7 until all boom inspection covers at the pivot end of the boom are removed 9 Measure each wear pad at the pivot end of the boom 1 2 inch 12 7 mm Boom wear pad specifications Minimum thickness 10 Replace any wear pad if it is less than specification If a wear pad is not less than specification shim as necessary to obtain zero clearance 11 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding of the boom tubes Always maintain squareness between the outer and inner boom tubes Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE D PROCEDURES D 2 Check the Extendable Axle Wear Pads Maintaining the axle wear pads in good condition is essential to safe machine operation Wear pads are placed on axle tube surfaces to provide a low friction replaceable wear pad between
266. isplay threshold See Repair Section Continued on the next page Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 59 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 16 Is BOOM EXT RET FLOW Check for an open or bad Repair or replace the VALVE FAULT present on short in the BK RD BK RD CO9PEFF wire CO9PERF wire from pin 3 of the J4 connector at the ground controls to pin 1 of the DIN connector at the boom extend retract flow control valve coil item BB or FB Check for an open or bad _ Repair or replace the short in the BR BR VLVRET4 wire VLVRET4 wire from pin 1 of the J4 connector at the ground controls to pin 2 of the DIN connector on the boom extend retract flow control valve coil item BB or FB Continued from the previous page yes the display good 3 3 to 5 3 ohms Consult the Genie Industries Service Test resistance of the boom extend retract flow no control valve coil item BB or FB Department 0 or infinite ohms Replace the boom extend retract flow control valve coil item BB or FB Continued on the next page 5 60 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Is BOOM EXTEND VALVE FAULT present on the display yes Check f
267. ite ohms Replace the valve coil 5 186 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Yellow End Yellow Side Steering Function Inoperative Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency stop buttons pulled out to the on position start the engine from the platform controls and push the steer mode select button for circle end yellow end steer Press down the foot switch and activate the steer function in both directions Are there any diagnostic codes present on the display at the ground controls Is STEERING JOYSTICK NOT CALIBRATED present on the display screen Continued on the next page Stop the engine Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupler on the steer axle manifold Start the engine and activate the steer function in both directions Is the pressure less than 3000 psi 207 bar Stop the engine Exchange the circle end yellow side steer valve item EC with the circle end blue side steer valve item ED Start the engine and activate the steer function Does the circle end yellow side steering function in both directions Repair or replace the cylinder or pilot operated check valves items EH or EFF OR co
268. ition First Printing EEN TABLE G PROCEDURES 8 Extend the boom approximately 2 feet 0 6 m 9 Retract the boom While retracting the boom visually inspect the number 2 and number 3 boom tubes Result The number 2 should not move more than 1 2 inch 13 mm before the number 3 boom tube begins to retract If the number 2 boom tube moves more than 1 2 inch 13 mm before the number 3 boom tube begins to retract the boom extend retract cables need to be adjusted See Repair Procedure 4 5 How to Adjust the Boom Extend Retract Cables 4 72 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures D 1 Check the Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Start the engine from the ground controls 2 Raise the end of the boom to a comfortable working height chest high Stop the engine 3 Remove the protective covers from the platform end of each boom tube 4 Measure each wear pad 1 2 inch 12 7 mm Boom wear pad specifications Minimum thickness 5 Replace any wear pad if it is less than specification If a wear pad
269. joystick controllers for operational control Drive and steer functions are controlled through one dual axis joystick boom up down and turntable rotate functions are controlled through another dual axis joystick and the boom extend retract functions are controlled through a single axis joystick Standard toggle switches are used to control the platform level up down platform rotate and jib boom up down functions S 105 and S 125 models Membrane type switches are used to select the various steering and operating modes 3 2 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 3 Theory of Operation N THEORY OF OPERATION The drive chassis controller DCON has no operator accessible controls The various steering controls axle status brake and motor speed is managed by this controller There are status LED s on this module to indicate power data link communications system fault and sensor power Platform leveling is accomplished with electrohydraulic controls An angle sensor is mounted on the platform rotator which senses the level of the platform This signal is processed by PCON and sent to TCON using the data bus The signal from the tilt sensor on the turntable is compared to the PCON signal and adjustments are made to level the platform For safety machine drive speed is reduced relative to the steer angle of the wheels and boom length Steering is accomplishe
270. key switch T Ka Se tr po Sr lin TACTE oo aTe Battery separator Proximity switch i Power relay 1 fas Starter motor LU D1 1 ALTERNATOR a HF SENT TT Bar D Jo H1 afr tt i r D e s Main key switch PA ec Horn Proximity i aa A kill switch hades ooed an a a ALTERNATOR Engine cold start ignitor 6 16 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 Section Ge Schematics First Edition First Printing t Switch Harness Schemati imi L S 100 amp S 105 Models 12 Way Deutsch Connector Limit Switch Harness to Upper Limit Switch Harness 8 Way Deutsch Connector Limit Switch Harness to Upper Limit Switch Harness J20 J21 J27 2 Way Deutsch Connector Boom Harness Limit Switch Harness J30 4 Way Connector Limit Switch to Optional Hydraulic Pressure Sensor P20 P21 P27 P30 a y tr LO OO foe Ye LISYATA HMWVGH O1UdSZA e CS Hd z QY OTHdtZA bi SES ZS O O l
271. ks 6 Replace the belt if any damage is found 7 Inspect the generator belt if equipped for Cracking Glazing Separation Breaks Perkins engine Deutz engine a generator belt Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 8 Check the engine belt s for proper tension Perkins engine Deutz engine Deutz models 9 Install the front engine access cover mounting fasteners and install the front engine access cover All models 10 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 11 Swing the engine pivot plate in towards the machine 12 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Belts Genie part numbers Deutz Engine Belt 62431 Deutz Generator Belt 75053 Perkins Engine Belt 62428 Perkins Generator Belt 75053 3 8 inch to 1 2 inch 9mmto 12mm Belt deflection B 4 Replace the Inline Fuel Filter Water Separator Element Replacing the inline fuel filter water separator element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to
272. l capacity including filter 10 9 liters Oil filter Genie part number 62436 Cummins B3 9L Engine Engine oil viscosity requirements below 68 F 20 C 5W 30 13 to 68 F 25 to 20 C 10W 30 above 15 F 9 C 15W 40 Use oils meeting API classification CE labeled CE SG B 30 Inspect the Fuel Tank Cap Venting System A free breathing fuel tank cap is essential for good engine performance and service life A dirty or clogged fuel tank cap may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap be inspected more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the cap from the fuel tank 2 Check for proper venting Result Air should pass through the fuel tank cap When checking for positive fuel tank cap venting air should pass freely through the cap Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section A Scheduled Maintenance Procedures TABLE B PROCEDURES If the fuel tank cap vent is working properly B 31 roceed to step 5 P e S Perform Hydraulic Oil Analysis 3 Using a mild solvent carefully wash the
273. l on off solenoid and alternator field CR15 relay K1 powers P22R or CO3PBF circuit Boom up down valve coil CR13 relay K5 powers P_7 and throttle relay CR11 relay K3 powers P 6R2 or P54ENG circuits Sr 29 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 First Edition First Printing Section pe Schematics DCON DRIVE CHASSIS CONTROLLER J2 1 VLVRET BR 2 V61AXRT GR 3 V60AXEX GR WH 4 V29MS RD WH 5 UNUSED 6 V52AFV BL RD 7 V52REV BL RD 8 V36RRS BL 9 V37RRS BL BK 10 C111RRS OR 11 C111LRS OR 12 C111RFS OR 13 C111LFS OR 14 VLVRET2 BR 15 V32BRK WH RD 16 V36LRS BL 17 V37LRS BL BK 18 V36RFS BL 19 P110RT BK 20 P109ANG GR WH 21 V37RFS BL BK DCON DRIVE CHASSIS CONTROLLER J1 1 GND DCON BR 2 P21DCON WH 3 P53LS RD 4 UNUSED 5 S56PRV RD 6 C61AXRT GR 7 UNUSED 8 AXLE RET GND 9 C61LS GR 10 D80SHLD 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 C61LS A GR 16 UNUSED 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 UNUSED 21 UNUSED Drive Chassis Controller Pin Legend CONNECTOR dea OC Ve WHITE CLC CONNECTOR OOCOCL23 PIN NUMBERING FOR 22
274. l valve item BC or item FC OR repair or replace the turntable rotate motor counterbalance valves OR repair or replace the turntable rotate motor OR the boom function manifold could have an internal fault Consult Genie Industries Service Department Remove or repair the mechanical restrictions Repair or replace the brake See Repair Section 5 128 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Is TURNTABLE ROTATE JOYSTICK NOT CALIBRATED present on the display screen Continued from the previous page Is TURNTABLE ROTATE JOYSTICK SHORTED TO 0 VOLTS OR TURNTABLE ROTATE JOYSTICK SHORTED TO 5 VOLTS OR TURNTABLE ROTATE JOYSTICK VALUE TOO HIGH OR TURNTABLE ROTATE JOYSTICK VALUE TOO LOW present on the display screen Is TURNTABLE ROTATE FLOW VALVE NOT CALIBRATED present on the display screen Continued on the next page Section 5 Troubleshooting Flow Charts PE CHART 22 Recalibrate the turntable rotate joystick OR replace the turntable rotate joystick See Repair Section Check for an open or short in the internal platform control box wire harness between the P1 connector at the turntable rotate joystick and the P20 connector at the circuit board Repair or replace the internal platiorm control box wire harness Replace the turntable rotate joystick OR consult the Genie Industries Service Department
275. lace the Inline Fuel Filter Water Separator Element 4 26 B 5 Replace the Air Filter AANEREN 4 32 B 6 Inspect the Air Intake System 0 ccceeeeeeeeeeeeeeee eects eeeeeeeeeaaeeseeeeeseaeees 4 33 B 7 Check the Exhaust System ccccceeceeeeeeeeeeeeeceeeseeeeeeeeaaeeeteaeeeseeeeeenaeetees 4 33 vi Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing KE Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 8 Replace the Hydraulic Tank Return Eiter 4 35 B 9 Replace the Hydraulic Tank Breather Eiter 4 36 B10 Replace the Medium and High Pressure Hydraulic Filters A 4 37 B 11 Inspect the Electrical Wiring 0 cee eee eee tree eee eee e eee a neste eeeneaeeea 4 38 B 12 Confirm the Proper Brake Configuration ccccceeeeceeeeeeeeeeeeeeeeeeeeeeeneaeeeee 4 39 B 13 Inspect the Tires and Wheels including lug nut torque seeeseseeeeesnn 4 39 B 14 Check the Oil Level in the Drive Hubs sssssseesseeeseeessiressrnsssrrrerrrsrreessresens 4 40 B 15 Check and Adjust the Engine RPM cceccceeseeeeeceeeeeeeeeeseaeeeteeeeeettaaeeeee 4 41 B 16 Test the Key Switches ccccceccecseeeeeeeeeeeaeeeeeaeeeeeneeeeeeaaeeseaeeeteeeeeeseiaaeeea 4 44 B 17 Test the Emergency Stop Buttons ssessessseeeseeesirsesrressrnnsnrnennntsrrnsssrnsnn 4 46 B 18 Testthe Ground Control Override ccceeecceceeeeeeeeeeeeeeaeeeeeaeeeeeeeeeeenaeesee
276. ld relief valve is set at 3000 psi 206 8 bar the Function manifold relief valve is set at 2600 psi 179 3 bar the Platform manifold relief valve is located in the Distribution manifold and is set at 3000 psi 206 8 bar Drive functions are powered by a bi directional variable displacement piston pump rated at 28 gom 106 L min 2350 rpm Two internal 4250 psi 293 bar relief valves are used to prevent over pressurization of the closed loop drive system Theory of Operation The boom lift cylinder boom extend cylinders platform leveling slave cylinder platform rotator and jib boom cylinder S 105 and S 125 models incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure A regeneration circuit is used to increase the performance of the primary boom extension function This circuit transfers hydraulic fluid from one end of the primary cylinder into the other end when the cylinder is extending or retracting The auxiliary pump is a two section gear pump One section is rated at 1 85 gpm 7 L min and the other is rated at 0 59 gpm 2 2 L min The 1 7 gpm 7 L min section is supplied with a 2500 psi 172 4 bar relief valve and the 0 59 gom 2 2 L min section is supplied with a 3000 psi 206 8 bar relief valve Electrical System Two separate 12V batteries are used for this system The larger Group 4D battery is used to start the engine and power the auxiliary pump The smaller
277. le Extend Retract Functions Operational Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the oPEN position Be sure the hydraulic tank is filled to the correct level Be sure the batteries are fully charged and properly connected Install a 0 to 5000 PSI 345 bar pressure gauge to the test port on the function manifold Start the engine from the ground controls Activate the function enable high RPM button and the boom retract button and check the hydraulic pressure Adjust the function manifold system relief valve item BI or FI all the way in clockwise counting the number of turns Activate the function enable high RPM button and the boom retract button and check the hydraulic pressure Check the function pump See Repair Section Replace the relief valve item BI or Fl OR repair or replace the differential sensing valve item BP or FP OR repair or replace the load sense priority flow regulator valve item BE or FE OR the manifold has an internal fault Consult the Genie Industries Service Department Troubleshoot each function individually OR consult the Genie Industries Service Department Hold the function enable high RPM button and press the boom retract button and adjust the relief valve pressure to 2600 psi 179 bar Replace the 17 gpm 64 4 L min function pump Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 Firs
278. le container See capacity specifications 6 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap 7 Open the drain valve on the radiator and allow the coolant to drain into a suitable container 8 After all the coolant has drained close the drain valve 9 Open the drain valve on the engine block and allow the coolant to drain into a suitable container 10 After all the coolant has drained close the drain valve 11 Replace all coolant hoses and clamps 12 Fill the radiator with the proper coolant mixture coolant and water for your climate until it is full Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE E PROCEDURES 13 Fill the coolant recovery tank to the coLD FULL line on the tank 14 Clean up any coolant that may have spilled during this procedure 15 Start the engine from the ground controls and let it run until the engine is up to operating temperature Continue to run the engine until the coolant has circulated the cooling system 16 Stop the engine 17 Allow the engine to cool 18 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 19 Swing the engine pivot plate in towards the machine 20 Install the bolt
279. leshoot JIB UP DOWN TOGGLE SWITCHES FAULT Jib functions inoperative Shorted jib toggle switch on the platform control box or shorted jib up or down membrane switch on the turntable membrane panel Refer to charts 30 and 31 to troubleshoot Continued on next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 7 Section 5 Troubleshooting Flow Charts EE FAULT CODE CHART Diagnostic code displayed Condition Possible Causes First Edition First Printing Solution JIB VALVE FAULT Jib up or jib down inoperative Jib up or jib down coils circuits open Refer to charts 30 and 31 to or shorted to ground or coils are bad troubleshoot ENGINE SPEED NO RESPONSE Engine runs then dies Engine RPM signal from alternator Refer to chart 4 to troubleshoot below 100RPM ENGINE SPEED VALUE TOO HIGH Engine runs then dies Engine RPM signal from alternator Refer to chart 4 to troubleshoot above 3500RPM ENGINE OIL PRESSURE VALUE Engine runs then dies Engine oil pressure below 12psi Refer to chart 4 to troubleshoot TOO LOW ENGINE OIL PRESSURE SENSOR Engine runs then dies Engine oil pressure sensor circuit Refer to chart 4 to troubleshoot SHORTED TO 0V shorted to ground ENGINE OIL PRESSURE SENSOR Engine runs then dies Engine oil pressure sensor circuit Refer to chart 4 to troubleshoot SHORTED TO 5V open ENGINE OIL PRESSURE SENSOR Engine runs then dies Engine oil pressure s
280. ll the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Tag disconnect and plug the fuel line from the fuel tank at the inline fuel filter water separator head Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE E PROCEDURES 6 Remove and replace the following fuel line hoses and clamps Perkins models Hose from the fuel tank to the inline fuel filter water separator Hose from the inline fuel filter water separator to the fuel lift pump Hose from the fuel lift pump to the fuel filter Cummins models Hose from the fuel tank to the inline fuel filter water separator Hose from the inline fuel filter water separator to the fuel lift pump Hose from the fuel injectors to the fuel tank 7 Clean up any fuel that may have spilled during this procedure 8 Install the fuel tank line onto the inline fuel filter water separator head Tighten the hose clamp 9 Install the ground control side fixed turntable cover onto the machine and tighten the retaining fasteners 10 Bleed the fuel system See Maintenance Procedure B 4 Replace the Inline Fuel Filter Water Separator Element Before bleeding the system fill the fuel tank E 4 Check the Engine Valve Clearances Cummins Models Complete information to perform this procedure is available in the Cummins Oper
281. low Charts CHART 20 Continued from page 5 88 Disconnect LSAX1ES from the wiring harness Attempt to raise and extend the boom Does the boom raise or extend yes Check for continuity between the BL RD J2 and RD P53LS wires if the boom raises and check for continuity between the OR BL J3 and RD WH P57PBD wires if the boom extends no continuity Check for continuity 2 of the connector to LSB7DS no continuity Consult the Genie Industries Service Department no continuity between terminals 1 and continuity Visually check LSAX1ES for damage good Adjust LSAXiES See Repair Section Visually inspect the wiring looking for pinch points and chafed or broken wires no damage Consult the Genie Industries Service Department Visually inspect the wiring looking for pinch points and chafed or broken wires damage found Repair or replace the WH BL P53LS wire circuit OR repair or replace the GR WH C60AXEX wire circuit bad damage found no damage First Edition First Printing Replace and adjust LSAX1ES See Repair Section Repair or replace the BL RD J2 wire or the RD P53LS wire if the boom raises OR repair or replace the OR BL J3 or RD WH P57PBD wires if the boom extends Consult the Genie Industries Service Department Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edit
282. ls TCON CR CONTROL RELAY WITH NUMBER AND FUNCTION PLUG JACK CONNECTOR DESCRIPTION AND OR LOCATION CR8 WORK LIGHT RELAY P1 J1 Black 23 Pin AMP Connector Ground Controls to Boom Harness CR9 FLASHING BEACON RELAY P2 J2 Black 35 Pin AMP Connector CR10 IGNITION FUEL ALTERNATOR FIELD Ground Controls to Limit Switch Harness CR11 P6R2 CIRCUIT P3 J3__ White 23 Pin AMP connector Ground Controls to Engine Harness P4 J4_ White 35 Pin AMP connector Ground Controls to Function Manifold P5 J5__ Black 4 Way Molex connector Ground Controls to Engine Harness P10 J10 Ground Controls PC Board to Membrane Decal P11 J11 Ground Controls PC Board to Membrane Decal P24 J24 9 Way Deutsch Tether Connector P25 J25 8 Way Deutsch Connector Limit Switch Harness to Upper Limit Switch Harness CR12 P6R1 CIRCUIT CR13 P7 CIRCUIT CR14 P7R CIRCUIT CR15 BOOM UP DOWN CR16 CHOKE GLOW PLUG RELAY CR17 RPM RELAY CR18 DRIVE LIGHT RELAY P27 J27 2 Way Deutsch Connector Boom Harness Limit Switch Harness H HORN OR ALARM H1 ALARM AT GROUND CONTROLS GND CHASSIS GROUND KS KEY SWITCH KS1 MAIN KEY SWITCH KS2 SERVICE BYPASS RECOVERY KEY SWITCH P POWER SWITCH P1 GROUND CONTROLS EMERGENCY STOP BUTTON Y VALVE COIL Y21 BOOM UP DOWN F C Y22 BOOM EXTEND RETRACT F C Y23 TURNTABLE ROTATE F C Y24 BOOM UP Y25
283. lt deflection 3 8 to 1 2 inch Oil viscosity requirements 9 to 12 mm below 32 F 0 C ow 13 F to 68 F 25 C to 20 C 5W 20 10 F to 104 F 12 C to 40 C 10W 30 14 F to 122 F 10 C to 50 C 15W 40 above 23 F 5 C 20W 50 Engine oil should have properties of API classification CF4 grade OR ACEA classification E3 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 2 7 Section 2 e Specifications SPECIFICATIONS Cummins Engine B3 9L Displacement 238 cu in 3 9 liters Number of cylinders 4 Bore and stroke 4 02 x 4 72 inches 102 x 120 mm Horsepower 75 2200 rpm Firing order 1 3 4 2 Compression ratio 16 5 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle no load 1300 rpm High idle no load 2350 rpm Valve clearance cold Intake 0 010 in 0 254 mm Exhaust 0 020 in 0 508 mm Lubrication system Oil pressure 50 psi 3 45 bar Oil capacity 9 5 quarts including filter 9 liters Oil viscosity requirements below 68 F 20 C 5W 30 10 to 68 F 23 to 20 C 10W 30 above 15 F 9 C 15W 40 Use oils meeting API classification CE labeled CE SG First Edition First Printing nn __________ ______________ __ Injection system Injection pump make Bosch Injection pump pressure 5500 psi 379 2 bar Injector opening pressure 3480 psi 240 bar Fuel requirement Alternator output
284. lt in death or serious injury 4 Be sure that all fasteners are tight 5 Inspect all welds for cracks 6 Inspect for exhaust leaks i e carbon buildup around seams and joints 7 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 8 Swing the engine pivot plate in towards the machine 9 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 8 Replace the Hydraulic Tank Return Filters Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns Perform this procedure with the engine off There are two return filters on the machine One is the system return filter and the other one is the return filter for the drive motor case drains 1 Open the ground controls side turntable si
285. m drive pressure 4250 psi 293 bar Charge pump Type gear Displacement 2350 rpm 5 2 gpm 19 7 L min Charge pump pressure 290 psi 20 bar Function manifold Function relief 2600 psi valve pressure 179 3 bar Boom extend relief 1800 psi valve pressure 124 1 bar Four wheel steer and axle extend retract manifold Steer axle extend 3 gpm flow regulator 11 4 L min Drive manifold Brake relief pressure 250 psi 17 2 bar Drive motors Displacement per revolution variable 0 73 to 2 75 cu in 12 cc to 45 cc First Edition First Printing KH Function pump Type two section gear pump Displacement Pump 1 1 75 cu in 28 7 cc Displacement 2350 rpm Pump 1 17 8 gom 67 4 L min Displacement Pump 2 1 cu in 16 4 cc Displacement 2350 rpm Pump 2 10 2 gpm 38 5 L min Auxiliary pump Type two section gear pump Displacement Section 1 0 159 cu in 2 61 cc Displacement 2687 rpm Section 1 1 85 gpm 7 L min Displacement Section 2 0 051 cu in 0 84 cc Displacement 2687 rpm Section 2 0 59 gpm 2 2 L min Auxiliary pump relief pressure Section 1 2500 psi 172 4 bar Section 2 3000 psi 206 8 bar Hydraulic filters High pressure filter B3 200 High pressure filter 100 psi bypass pressure 6 9 bar Medium pressure filter B3 200 Medium pressure filter 87 psi bypass pressure 6 bar Hydraulic tank circuit 10 micron with 25 psi return line filter 1 7 bar bypass D
286. m pin 1 of the J2 connector at the drive chassis controller to pin 2 of the DIN connector at the axle extend retract valve coils item ES or item HS good Check the resistance of the axle extend retract valve coils item ES or item HS CHART 33 bad Repair or replace the GR WH C60AXEX wire bad Repair or replace the BR VLVRET1 wire 5 4 to 7 4 ohms Consult the Genie Industries Service Department 0 or infinite ohms Replace the valve coil PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 169 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 33 Continued from page 5 168 Remove both the axle access plates and visually check each axle extend proximity switch Is the switch target in line with the switch yes Measure the distance from the target to the axle extend proximity switch Is the distance between 1 8 and 3 16 inch 3 1 and 4 8 mm yes Disconnect LSAX1EO from the wire harness and check the resistance across pin 3 and 4 of LSAX1 EO Is the resistance less than 1 ohm yes Disconnect LSAX2EO from the wire harness and check the resistance across pin 3 and 4 of LSAX2EO Is the resistance less than 1 ohm yes Disconnect the J1 black 23 pin connector from the drive chassis controller and check to make sure that pin 15 and pin 23 are properly inserted properly inserted
287. mage There are five hydraulic filters located on the machine There is two tank return filters one medium pressure filter and two high pressure filters All the filters have condition indicators on them except the drive motor case drain return filter 1 Start the engine from the platform controls Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE A PROCEDURES 2 Change the engine idle to high rpm rabbit symbol kb d S a foot switch activated high idle indicator light b low idle indicator light c high idle indicator light d engine idle speed select button Press the engine idle speed select button until the indicator light next to foot switch activated high idle rabbit symbol is on Tank Return Filter 3 Inspect the filter condition indicator gauge a filter condition indicator gauge Result The needle on the gauge should be operating in the green area If the needle is in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See B 8 Replace the Hydraulic Tank Return Filters Medium and High Pressure Filters The medium and high pressure filters are mounted to the engine side bulkhead A filter condition indicator is located on the top of each filter 4 Inspect the filter condition indicators a high pressu
288. mes out from the vent been removed from the fuel screw system This will ensure that the pump is free of air and prevent any damage to the pumps by metal to metal contact 6 While continuing to operate the priming lever tighten the vent screw Torque the vent screw to 80 in lbs 9 Nm If the engine does not start or runs erratically refer to the Cummins Operation and Maintenance Manual Cummins part number 3810205 Genie part number 62448 for additional information on the fuel system 10 Clean up any diesel fuel that may have spilled during the procedure Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 29 Section 4 Scheduled Maintenance Procedures First Edition First Printing SSS es TABLE B PROCEDURES 12 Remove the engine pivot plate retaining 3 Install the bolt that was just removed into the fastener from the engine pivot plate anchor hole anchor hole to secure the engine pivot plate at the pivot end of the engine pivot plate from moving 13 Swing the engine pivot plate in towards the AWARNING Crushing hazard Failure to install machine the bolt into the engine pivot plate to secure it from moving could 14 Install the bolt that was just removed into the result in death or serious injury original hole to secure the engine pivot plate 4 Loosen the fuel filter water separator filter vent screw located on top of the fuel filter water separator head AWARNING Crushing hazard Failure
289. models Check for bad proper installation of LSB3EO OR consult the Genie Industries Service Department S 120 and S 125 models Connect LSB3EO Disconnect and test LSB4EO See Repair Section good Continued on the next page Continued on page 5 56 Replace and adjust LSB3EO See Repair Section Disconnect the upper J2 harness from the lower J2 harness Check for voltage on the BL BK C71PBE wire on pin 10 of the 12 pin deutsch connector at the lower J2 harness Is there voltage present voltage present no voltage present Repair or replace the BL BK C71PBE wire from pin 3 of the deutsch connector at LSB3EO to pin 10 of the 12 pin deutsch connector at the turntable 120 and S 125 models Replace and adjust LSB4EO See Repair Section Repair or replace the BL BK C71PBE wire from pin 10 of the 12 pin deutsch connector at the turntable that joins the lower J2 harness to the upper J2 harness to pin 20 of the J2 connector at the ground controls 5 54 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from the previous page With LSB4EO disconnected check for voltage on BL C76PBE wire at pin 3 of the yes deutsch connector that was connected to LSB4EO Is there voltage present no Connect LSB4E0 bad Disconnect and test LSB2RO See Repair Section good With LSB2RO disconn
290. move both plugs and drain the oil into a suitable container 3 Drive the machine until one plug hole is at the top and the other is at 90 a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE D PROCEDURES 5 Install the plug into the drive hub When removing the drive hub plug on machines before serial number 158 replace the drive hub plug with the new O ring style drive hub plug Genie part number 75107 6 Repeat steps 1 through 5 for all the other drive hubs Drive hub oil Capacity 83 fl oz 2 5 liters Type SAE 80W 90 EP multipurpose gear oil Turntable Rotate Drive Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin 2 e 9 N y unlocked 2 Remove the ground control side fixed turntable cover Refer to Repair Section 5 1 How to Remove a Fixed Turntable Cover 3 Tag disconnect and plug the turntable rotate drive motor hoses at the turntable rotate drive motor and the turntable rotate drive brake hoses at th
291. mp S 120 amp S 125 iii Section 1 Safety Rules First Edition First Printing SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following o Indicates the presence of a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury Indicates the presence of ACAUTION p a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information other protective clothing if the situation amp Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components and lifting or placing loads Always wear approved steel toed shoes e Be aware of potential crushing hazards el Workplace Safety Be sure to keep sparks flames and Ae lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage V Be sure that all
292. n First Printing Section 5 Troubleshooting Flow Charts PE Disconnect the hydraulic 2500 PSI Repair or replace the hose from the P portat or more _ hydraulic swivel OR the turntable section of consult the Genie the hydraulic swivel Industries Service Plug the port and Department connect the hydraulic hose into a 0 to 5000 PSI 345 bar gauge Do NOT start the engine damage could result Activate the auxiliary hydraulic pump and the axle extend function and check the pressure Continued from the previous page Consult the Genie Industries Service Department CHART 33 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 173 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 34 Axle Retract Function Inoperative Be sure the boom is in the stowed position Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform no controls and both Emergency stop buttons pulled out to theon position start the engine Press down the foot switch and activate the axle retract function Are there any diagnostic codes present on the display at the ground controls yes Is AXLE EXT RET BUTTONS FAULT present yes on the display screen no Is AXLE VALVE FAULT es present on the display screen no Continued on the ne
293. n filter 44207 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures E 2 Change or Recondition the Engine Coolant Liquid Cooled Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine ca E e engine pivot plate anchor hole engine pivot plate retaining fastener a b TABLE E PROCEDURES 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Puton protective clothing and eye wear Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitab
294. n open or short in the BR VLVRET wire circuit from pin 1 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the brake valve coil Repair or replace the BR VLVRET wire Check the resistance of Consult the Genie the brake valve coil Industries Service item DO Department 0 or infinite ohms Replace the coil 5 198 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 40 At the ground controls Readjust engine high SEN display scroll until idle See Maintenance pag engine speed is present Section Is the engine high idle set to 2350 rpm Stop the engine Install Continued on two 0 to 5000 PSI 345 page 5 201 bar pressure gauges on the quick disconnects to the A amp B ports of drive pump Start the engine Is the pressure 250 psi 17 2 bar or more Stop the engine Repair or replace the Disconnect the hoses drive pump from A amp B ports on drive pump and plug the ports Start the engine Is the pressure 250 psi 17 2 bar or more Press down the foot Repair or replace the switch and activate the drive pump drive reverse function Is the pressure 4250 psi 293 bar or more Continued on the next page Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 199 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 40
295. n the distribution manifold oV Continued on page 5 35 Chart 9 Check for a short to battery positive on the OR RD C113MFV wire from pin 23 of the J4 connector at the multi function solenoid valve item AA OR consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 9 Test the 10 gpm Replace the relief valve Ge SCH the 38 L min pump See item AC OR repair or P page Repair Section replace priority flow regulator valve item AD OR repair or replace differential sensing valve item CO Replace the 10 gpm or item GO in OR repair 38 L min pump or replace load sense flow regulator valve item CP S 105 or S 125 models OR the distribution or platform manifolds have an internal fault Consult the Genie Industries Service Department 5 34 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Are there any diagnostic Continued trom codes present on the page 5 33 yes display screen at the ground controls no Continued on the next page Section 5 Troubleshooting Flow Charts S Is SAFETY SWITCH P7R FAULT present on YS the display screen no Is DCON CAN NO RESPONSE present on the display screen yes Is the power LED activated on the driv
296. nal in place Loosen but do not remove the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 85 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 20 Boom Envelope Safety Switch Failure S 100 and S 105 Models Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position start the engine Disconnect LSB3EO Raise the boom to a horizontal position and extend the boom Will the boom extend beyond 76 feet without stopping the engine DANGER IF THE BOOM EXTENDS BEYOND 76 FEET WITHOUT STOPPING THE ENGINE STOP IMMEDIATELY Remove the jumper from LSB14A0 Retract the boom to within 2 inches of full retraction and fully lower the boom Remove the boom end cover from the pivot end of the boom and remove the arm from the cable break limit switch LSB6S Using the arm just removed from LSB6S rotate the head of the switch 45 degrees clockwise and attempt to extend the boom Does the boom extend and does P10 not appear on the display screen at ground controls DANGER IF THE BOOM EXTENDS STOP IMMEDIATELY Continued on the next page yes Continued to page 5 91 Continu
297. nce of the boom extend retract flow control valve coil item BB or item FB 3 3 to 5 3 ohms Consult the Genie Industries Service Department bad Repair or replace the BK RD CO9PEFF wire bad Repair or replace the BR VLVRET4 wire Oor Or Replace the boom extend retract flow control valve coil Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is BOOM RETRACT VALVE Continued from the FAULT present on the previous page display no S 100 and S 105 models Consult the Genie Industries Service Department S 120 and S 125 models Is LOCKOUT VALVE P1 FAULT present on the display screen yes Continued on the next page CHART 17 Check for an open or bad Repair or replace the short in the BK WH CO8PBR wire from pin 10 of the J4 connector at the ground controls to BK WH CO8PBR wire pin 1 of the DIN connector on the boom retract valve coil item BQ or item FQ good Check for an open or bad_ Repair or replace the short in the BR BR VLVRET7 wire VLVRET7 wire from pin 27 of the J4 connector at the ground controls to pin 2 of the DIN connector on boom retract valve coil item BQ or item FQ Consult the Genie Industries Service good 3 4 to 5 4 Check the resistance of ohms the boom retract valve coil item BQ or item Department
298. nchor hole at the pivot end of the engine pivot plate 10 Swing the engine pivot plate in towards the machine 11 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Cummins and Perkins models B 16 Test the Key Switches Proper key switch action and response is essential to safe machine operation Failure of either key switch to function properly could cause a hazardous operating situation There are two key switches on the machine the Main key switch and the Service Bypass Recovery key switch The Main key switch controls machine operation from the ground or platform controls When the Service Bypass Recovery key switch is turned to the service bypass position the boom can be raised while the axles are retracted This feature of the machine is especially helpful for storage purposes or when loading the machine for transport When the boom is raised with the axles retracted the boom cannot be rotated past either circle end wheel When the Service Bypass Recovery key switch is turned and held to the recovery position the auxiliary power unit will turn on and fully retract the boom and then lower the boom to a stowed position This feature of the machine is especially helpful if the operator in the platform cannot lower
299. nction inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold Start the engine and activate the function enable high RPM button and the boom up button and check the pressure Exchange boom up down flow control valve item BF or item FF with the boom extend retract flow control valve item BB or item FB and check the boom up function Does the function operate Replace the faulty flow control valve Remove or repair the mechanical restrictions Replace the boom up down directional valve item BD or item FD Check for mechanical restrictions keeping the boom from moving OR repair or replace the boom lift cylinder or cylinder counterbalance valve OR consult the Genie Industries Service Department Repair or replace the boom lift cylinder or cylinder counterbalance valves OR the boom function manifold could have an internal fault Consult the Genie Industries Service Department 5 48 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Boom Down Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the platform is level to gravity within 7 degrees Be sure the batteries are fully charged and properly connected With the key switch turned to groun
300. nd the J21 connector to the ground controls checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the RD BK P58LS wire First Edition First Printing 5 92 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from page 5 86 Disconnect LSB6S Start the engine and attempt to extend the boom Does the boom not extend and is fault code P10 on the display screen at the ground controls yes Disconnect the J26 cable break harness from the upper limit switch harness on the yes side of the boom tube at the pivot end Attempt to extend the boom Does the boom not extend and is fault code P10 on the display screen at the ground controls Disconnect the J20 12 pin and J21 8 pin deutsch connectors inside the counterweight yes area of the machine Using auxiliary power attempt to extend the boom Does the boom not extend and is fault code P10 on the display screen at the ground controls no Continued on the next page Visually check LSB6S for damage See Repair Section good Adjust LSB6S See Repair Section Physically pull the harness from the cable track checking for pinch points and chafed and shorted wiring and repair or replace the upper cable break harness Visually trace the upper cable break harness from t
301. ndustries Service Department Repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR consult the Genie Industries Service Department 5 144 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Is PLATFORM LEVEL Continued from the TOGGLE SWITCHES yes previous page FAULT present on the display screen no Continued on the next page Section 5 Troubleshooting Flow Charts Test the platform level toggle switch at the platform controls for proper operation See Repair Section Is the switch faulty no Check for an open or short in the internal platform control box wire harness between the 2 1 2 2 and 2 3 connectors at the toggle switch and pins 3 5 and 7 of the P20 connector at the circuit board good Check for an open or short in the platform level membrane decal at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 5 of the J11 membrane decal connector at the circuit board good Check for an open or short in the platform level membrane decal at the ground controls between pin 1 of the J11 membrane decal connector at the circuit board and pin 6 of the J11 membrane decal connector at the circuit board good Consult the Genie Industries Service Department yes bad bad bad CHART 26 Replace the to
302. ne and item BN OR repair activate the function cylinder or cylinder enable high RPM button counterbalance valve and the boom retract OR consult the Genie button and check the Industries Service pressure Department Continued from page 5 67 Exchange boom extend retract flow control valve item BB or item FB with the boom up down flow control valve item BF or item FF and check the boom retract function Does the function operate Replace the faulty flow control valve Adjust the boom relief valve item BI or item Fl See Repair Section OR repair cylinder or cylinder counterbalance valve OR function manifold could have an internal fault Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 71 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 18 Boom Envelope Operational Switch Failure S 100 and S 105 Models A boom envelope safety fault is the result of the boom exceeding the operational limits and activating the safety switches OR when the safety switches are tripped within the operational range Press the and keys together to access the status screen The status screen can display the following information Hydraulic pressure Boom Length Boom Angle Axle status Boom lengths are given in feet The first number is the length for a S 100 the second number is for a S 105 For
303. nel As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button 1 Start the engine from the ground controls 2 Push in the Emergency Stop button to the orr position Result The engine should shut off and no machine functions should operate 3 Start the engine from the platform controls Push down the Emergency Stop button to the OFF position Result The engine should shut off and no machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control B 18 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or OFF position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform Emergency Stop button to the orF position 2 Start the engine from the ground controls 3 Operate each boom function through a partial cycle Result All boom functions should operate Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Sched
304. nie S 100 amp S 105 amp S 120 amp S 125 5 3 Section 5 Troubleshooting Flow Charts EE FAULT CODE CHART Diagnostic code displayed EXTEND RETRACT JOYSTICK VALUE TOO LOW Condition Extend retract functions inoperative from platform Possible Causes Damaged circuit between platform control card and extend retract joystick or Joystick may need to be replaced First Edition First Printing Solution Refer to charts 16 and 17 to troubleshoot EXTEND RETRACT BUTTONS FAULT BOOM EXT RET SPEED NOT CALIBRATED BOOM EXT RET FLOW VALVE NOT CALIBRATED BOOM EXT RET FLOW VALVE FAULT Extend retract from turntable unctions inoperative Extend retract or to slow unction speeds to fast No movement on extend retract functions until joystick is moved past half stroke Extend retract functions inoperative Shorted boom extend retrac membrane on turntable membrane panel Extend retract speed calibration set from display or Reset Boom ext ret flow valve defaults set from display Refer to Display module section Reset Boom extend retract flow valve defaults set from display Refer to Display module section Boom extend retract flow valve coil circuit open or shorted to ground or the coil itself is bad Consult Genie Industries Service Department The turntable membrane panel may need to be replaced Calibrate Boom extend retract speed refer to repair section Calibrate Boom extend re
305. nnect LSB3EO Check that the terminals popar are properly inserted properly inserted Test LSB3EO for proper operation See Repair bad Section good Check for an open or short in the C71PBE and C64LS wire circuits Trace the circuits back to the ground control box Check the wiring at the connector between the upper and lower limt switch harness Make sure that terminal 10 on J20 is properly inserted bad good Check to make sure that pin 20 on the J2 connector at the ground control box is properly inserted ushed ack terminals are good Check to make sure that pin 13 on the J2 le connector at the ground control box is properly inserted terminals are good Replace the ground control box OR consult the Genie Industries Service Department First Edition First Printing Loosen but do not remove the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Replace and adjust LSB3EO See Repair Section Repair or replace the C71PBE and or C64LS wire circuits OR loosen but do not remove the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Loosen but do not remove the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Loosen but do not remove the red secondary lock and re inser
306. nspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Checklist A YN R Checklist B YN R A 1 Manuals A 2 Decals and placards A 3 Damage and loose or missing parts A 4 Engine oil level A 5 Engine coolant level Liquid cooled models A 6 Engine belt s Cummins models A 7 Engine cooling fan Liquid cooled models B 1 Check radiator Liquid cooled models B 2 Oil cooler and fins Deutz models B 3 Engine belt s Deutz and Perkins models B 4 Replace inline fuel filter water separator B 5 Replace air filter B 6 Air intake system B 7 Exhaust system A 8 Drain inline fuel filter water separator B 8 Hydraulic tank return filters A 9 Inspect air filter A 10 Fuel leaks A 11 Hydraulic oil level A 12 Hydraulic leaks A 13 Hydraulic filter condition indicators A 14 Platform and ground controls A 15 Auxiliary power A 16 Tilt sensor and alarm A 17 Operating envelope Perform after 40 hours A 18 Perform 30 day service A 19 Engine
307. nsult the Genie Industries Service Department Recalibrate the steer joystick see Repair Section OR replace the steer joystick Chart 38 Check for mechanical restrictions keeping the steer function from moving OR repair or replace the steer cylinder OR repair or replace the pilot operated check valves item EH or EFF OR consult the Genie Industries Service Department Replace the faulty steer valve PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 187 Section 5 Troubleshooting Flow Charts EE CHART 38 Continued from the previous page Is STEERING JOYSTICK SHORTED TO 0 VOLTS or STEERING JOYSTICK SHORTED TO 5 VOLTS or STEERING JOYSTICK VALUE TOO HIGH or STEERING JOYSTICK VALUE TOO Low present on the display screen yes Is YELLOW END YELLOW DE STEER SENSOR SHORTED TO 0 VOLTS or yes YELLOW END YELLOW DE STEER SENSOR SHORTED TO 5 VOLTS or YELLOW END YELLOW DE STEER SENSOR ALUE TOO HIGH or YELLOW END YELLOW DE STEER SENSOR VALUE TOO LOW present on the display screen no Continued on the next page Check for damaged wires in internal platform controls PCON wire harness between steer joystick connector P4 and and circuit board connector P20 OR consult the Genie Industries Service Department Check circle end yellow end yellow side steer sensor for proper installation and Operation see Repair Section good
308. nsult the Genie Industries Service Department Repair or replace the RD C107AF wire OR consult the Genie Industries Service Department Repair or replace the alternator OR check the fan belt OR consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 27 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 5 Engine High Idle Inoperative Be sure mechanical linkage is not binding Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position start the engine and select the high RPM mode Does the 2 speed solenoid pull in no Check the voltage of the BK RD C35RPM wire at the 2 speed solenoid 12V Continued on the next page yes Check high idle adjustment see Maintenance Section OR refer to the engine manual for troubleshooting the fuel injection system Check the voltage at 12V pin 2 of the J3 connector at the ground controls Loosen the K7 relay inside the ground control oV box just enough to expose the spade terminals of the relay and check the voltage at terminal 85 of the relay 12V Check continuity from pin 2 or pin 3 of the J5 no connector to terminal 85 of the K7 relay Is there continuity yes Check the voltage at 12V terminal 30 of
309. o EE LSB6S and install the H page boom end cover onto the boom Raise the boom to approximately 60 degrees and extend the boom to approximately 95 feet 29 m Disconnect LSB13A0 and install a wire jumper between terminals 3 and 4 of the connector to LSB13A0 Lower the boom Will the boom lower to less than 50 degrees DANGER IF THE BOOM LOWERS TO LESS THAN 50 DEGREES STOP IMMEDIATELY Continued to page 5 119 Remove the wire jumper from the connector to LSB13A0 and connect LSB13A0 to the wire harness Raise the boom to the maximum angle and extend the boom to approximately 120 feet Disconnect LSB14A0 and install a wire jumper between terminals 3 and 4 of the connector to LSB14A0 Lower the boom Will the boom lower to below 65 degrees DANGER IF THE BOOM LOWERS BELOW 65 DEGREES STOP IMMEDIATELY Continued on the next page 5 106 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 21 Fully retract the boom no Continued to and lower the boom until page 5 121 the boom is on the rest pad and continue to activate the boom down function for five seconds Extend the boom until the display screen reads BOOM LENGTH gt 0 Is the alarm sounding DANGER IF THE ALARM IS NOT SOUNDING STOP IMMEDIATELY Continued from the previous page With the boom in the es Continued to stowed posti
310. oes the boom stop extending at 3 5 feet 1 1 m NOTE IF THE BOOM EXTENDS TO MORE THAN 4 FEET 1 3 M IMMEDIATELY STOP Continued to page 5 101 Connect LSB3EO LSAX1EO LSAX2E0 LSAX1ES LSAX2ES LSB3RS LSB7DS to the wiring harness Extend the boom to approximately 5 feet 5 m Disconnect LSAX1ES Attempt to retract the axles Do the axles retract Continued to page 5 102 Continued on the next page CHART 20 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 20 Continued from the previous page Connect LSAX1ES LSAX2ES LSB3RS LSB7DS to the wiring harness Extend the boom to approximately 5 feet 1 5 m Disconnect LSAX1ES Attempt to retract the axles Do the axles retract no Fully extend the axles no Disconnect LSB3RS from the wiring harness and attempt to retract the axles Do the axles retract yes Disconnect the J20 12 pin connector Check for continuity in the lower limit switch wire harness between pin 3 and pin 4 of the connector to LSB3RS continuit no continuity Disconnect the J2 black 35 pin connector from the ground control box TCON Disconnect LSB7DS Check for continuity in the lower limit switch wire harness between pin 6 and pin 7 of the P20 connector continuit no continuity Consult the Genie Industries Serv
311. on good Check for an open or bad short in the RD BK C115LS wire from pin 17 of the J4 connector at the ground controls to LSB20LO good Check for an open or bad short in the BR VLVRET5 wire from pin 14 of the J4 connector at the ground controls to LSB20LO good Consult the Genie Industries Service Department Remove or repair the mechanical restriction Remove or repair the mechanical restriction Replace and adjust LSB20LO See Repair Section Adjust LSB20LO See Repair Section Repair or replace the RD BK C115LS wire Repair or replace the BR VLVRET5 wire 5 136 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Is TURNTABLE ROTATE Continued from the CCW VALVE FAULT previous page present on the display screen no If any other codes are on the display screen refer to the fault code chart for more information yes CHART 23 Check for an open or bad short in the WH BK CO5TRR wire from pin 25 of the J4 connector at the ground controls to Repair or replace the WH BK CO5TRR wire pin 1 of the Din connector at the turntable rotate counter clockwise valve coil item BG or item FG good Check for an open or bad short in the BR VLVRETE wire from pin 30 of the J4 connector at the ground controls to pin 2 of the Din conne
312. on With LSB14AO0 disconnected check for voltage on the WH BK C78AS wire at pin 3 of the deutsch connector that was connected to LSB14A0 no voltage present Check for proper adjustment of the boom angle limit switches See Repair Section OR consult the Genie Industries Service Department bad voltage present bad voltage present Replace LSB13A0 Repair or replace the WH C77AS wire from pin 3 of the deutsch connector to pin 29 of the J2 connector at ground control box Replace LSB14A0 Repair or replace the WH BK C78AS wire from pin 3 of the deutsch connector to pin 30 of the J2 connector at the ground control box 5 42 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page With the machine on level ground attach a digital level to the boom While monitoring the level raise the boom from the ground controls to an angle of yes approximately 60 degrees Is BOOM ANGLE SWITCHES FAULT present on the display screen at the ground controls S 100 and S 105 models Confirm that the boom angle switches are properly adjusted See Repair Section OR consult the Genie Industries Service Department S 120 and S 125 models Raise the boom from the ground controls to an angle greater than 68 degrees Is BOOM ANGLE SWITCHES FAULT
313. on retract page 5 122 the axles until the LSAX1ES and LSAX2ES axle safety switches are activated Disconnect LSAX1EO and install a wire jumper between terminals 3 and 4 on the connector Disconnect LSAX2EO and install a wire jumper between terminals 3 and 4 on the connector Disconnect LSAX2ES and install a wire jumper between terminals 1 and 2 and install a wire jumper between terminals 3 and 4 on the connector Disconnect LSB3RS and LSB7DS from the wire harness Attempt to raise the boom and attempt to extend the boom Does the boom raise or extend NOTE IF THE BOOM RAISES OR EXTENDS IMMEDIATELY STOP Continued on the next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 107 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21 Remove the wire jumper Continued to Continued from the previous page from the LSAX2ES page 5 123 connector and connect LSAX2ES to the wire harness Disconnect LSAX1ES and install a wire jumper between terminals 1 and 2 and between terminals 3 and 4 on the connector Attempt to raise the boom and attempt to extend the boom Does the boom raise or extend NOTE IF THE BOOM RAISES OR EXTENDS IMMEDIATELY STOP Continued to page 5 124 Fully retract the boom Remove the wire jumper from the LSAX1ES connector Connect LSB7DS to the wire harness Install a digital protractor onto the top of the
314. on the next page Are there mechanical yes restrictions keeping the boom down function from operating no Are there mechanical es restrictions keeping the load moment function from operating Test LSB20LO for proper operation See Repair Section bad good Check for proper bad adjustment of LSB20LO good Check for an open or bad short in the RD BK C115LS wire from pin 17 of the J4 connector at the ground controls to LSB20LO good Check for an open or bad short in the BR VLVRET5 wire from pin 14 of the J4 connector at the ground controls to LSB20LO good Consult the Genie Industries Service Department CHART 22 Remove or repair the mechanical restriction Remove or repair the mechanical restriction Replace and adjust LSB20LO See Repair Section Adjust LSB20LO See Repair Section Repair or replace the RD BK C115LS wire Repair or replace the BR VLVRET5 wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 131 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 22 Continued from the previous page Is TURNTABLE ROTATE Check for an open or bad Repair or replace the CW VALVE FAULT yes short in the WH CO4TRL WH CO4TRL wire present on the display wire from pin 25 of the J4 connector at the ground controls to pin 1 screen of the Din connector at the turntable rotate clo
315. oolant has circulated the cooling system 3 Stop the engine 4 Allow the engine to cool until the temperature of the coolant is below 140 F 60 C Burn hazard Beware of hot ACAUTION coolant Contact with hot coolant may cause severe burns 5 Remove the radiator filler cap Inspect the cap for wear Replace as necessary Burn hazard Allow any pressure ACAUTION to dissipate gradually before removing the radiator cap 6 Drain some coolant from the cooling system into a suitable container 7 Use a special coolant hydrometer to check the temperature and the specific gravity of the coolant 8 Adjust the mixture of the coolant as necessary to protect the engine to 34 F 37 C 9 Install the radiator filler cap Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures C 6 Inspect the Boom Extend Retract Cables The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Inspecting for foreign objects damage and or improper adjustment of the boom extend retract cables on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise Perform this procedure with the boom in the stowed position and the engine off 1 Remove
316. op buttons pulled out to the oN position does the engine crank over from the ground control box no Turn the key switch to es platform controls Does the engine crank over from the platform controls no Is wire jumper installed between pins H and J of the tether interface plug just behind the ground control box yes Check the voltage of the system battery and the engine start battery Are both batteries 12V or more yes Check the display at the ground controls to verify that the display screen is active Are there numbers on the screen yes Continued on the next page Go to page 5 18 Go to page 5 21 Install wire jumper between pins H and J of the tether interface plug just behind the ground control box Check battery condition OR check alternator OR check battery cables OR replace the battery OR check the battery separator Reset the 40A circuit breaker OR See Chart 1 5 16 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Key switch contact legend Replace the starter relay yes with a like relay horn and press the engine start button Does the engine crank over no Remove the relay Press iy the engine start button at the ground controls and check for voltage between pin 86 and pin 85 of the
317. op of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron equivalent Tank capacity 55 gallons 208 liters Hydraulic system 80 gallons including tank 303 liters Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures A 12 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic tank filter fittings hoses auxiliary power unit and turntable surface Engine compartment fittings hoses pumps filters and turntable surface All hydraulic cylinders All hydraulic manifolds Boom The underside of the turntable The underside of the drive chassis Axles Ground area under the machine TABLE A PROCEDURES A 13 Check the Hydraulic Filter Condition Indicators Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation The filter condition indicators will show when the hydraulic flow is bypassing a clogged filter If the filters are not frequently checked and replaced impurities will remain in the hydraulic system and cause component da
318. open or short in the OR S62BSTO wire from pin 6 of the 12 pin deutsch connector on the turntable that connects to the lower J2 harness to the upper J2 harness to pin 11 jof the J2 connector at the ground controls Repair or replace the OR S62BSTO wire Consult the Genie Industries Service Department CHART 34 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 177 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 35 Blue End Blue Side Steering Function Inoperative Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency stop buttons pulled out to theon position start the engine and push the steer mode select button for square end blue end steer Press down the foot switch and activate the steer function in both directions Are there any diagnostic codes present on the display at the ground controls no yes Is STEERING JOYSTICK NOT CALIBRATED yes present on the display screen no Continued on the next page Stop the engine Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupler on the steer axle manifold Start the no engine and activate the steer function in both directions Is the pressure less than 3000 psi 207 bar yes Stop the engine Exc
319. operating yes Remove or repair the mechanical restrictions no yes bad less than 3000 psi no Chart 30 Replace the ground control membrane decal OR consult the Genie Industries Service Department Repair or replace the internal platform wire Replace the toggle switch harness Repair or replace the jib up valve item CL OR repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department Repair or replace the cylinder counterbalance valves OR repair or replace the cylinder OR consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 157 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 30 Continued from the previous page Is JIB UP DWN TOGGLE SWITCHES FAULT present on the display screen no Continued on the next page yes Test the jib boom up down toggle switch at the platform controls for proper operation See Repair Section Is the switch faulty Check for an open or short in the internal platform control box wire harness between the 3 1 3 2 and 3 3 connectors at the toggle switch and pins 10 9 and 12 of the P20 connector at the circuit board good Check for an open or short in the j
320. or an open or bad short in the BK CO7PBE wire from pin 9 of the J4 connector at the ground controls to pin 1 of the DIN connector at the boom extend valve coil item BR or item FR good Check for an open or bad short in the BR VLVRET7 wire from pin 27 of the J4 connector at the ground controls to pin 2 of the DIN connector at the boom extend valve coil item BR or item FR good Test resistance of the boom extend valve coil item BR or FR no 0 or infinite ohms Replace the boom extend valve coil item BR or FR Continued on the next page 3 4 to 5 4 ohms CHART 16 Repair or replace the BK C07PBE wire circuit Repair or replace BR VLVRET wire circuit Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 61 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 16 Is LOCKOUT VALVE P2 Continued from the FAULT present on the previous page display no Is BOOM DOWN OVERLOAD FAULT present on the display no If any other fault codes are present refer to the fault code chart at the beginning of this section for more information yes yes Check for an open or bad short in the RD WH V75PRLO wire from pin 24 of the J2 connector at the ground controls to pin 1 of the DIN connector on the boom extend sequenc
321. oting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Hl Repair any machine damage or malfunction before operating the machine H Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the circle end wheels Turntable secured with the turntable rotation lock pin Key switch in the orF position with the key removed Welder disconnected from the machine if equipped with the weld cable to platform option Wheels chocked Before Troubleshooting E KR E KR Read understand and obey the safety rules and operating instructions printed in the Genie S 100 and Genie S 105 Operator s Manual or the Genie S 120 and Genie S 125 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it f
322. our meter on the filter Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 8 Install the fuel tank hose onto the inline fuel filter water separator head Tighten the hose clamp 9 Bleed the fuel system See Maintenance Procedure B 4 Replace the Inline Fuel Filter Water Separator Element Before bleeding the system fill the fuel tank TABLE D PROCEDURES D 10 Check the Engine Valve Clearances Perkins and Cummins Models Perkins models Complete information to perform this procedure is available in the Perkins User s Handbook Perkins part number TPD 1349 Genie part number 62447 Cummins models Complete information to perform this procedure is available in the Cummins Operation and Maintenance Manual Cummins part number 3810205 Genie part number 62448 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing Table E Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently The machine uses Dexron equivalent hydraul
323. p S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 20 Lower the boom to Replace and adjust approximately 10 LSB7DS See Repair degrees Disconnect Section LSB7DS and attempt to raise the boom Does the boom raise Continued from page 5 89 Disconnect the J2 black Visually inspect the Consult the Genie 35 pin connector from siy lower limit switch wiring Industries Service the ground control box harness looking for Department TCON Check for a pinch points and chafed short between the GR or broken wires WH C60AXEX wire and the WH BK P53LS wire at pin 1 and pin 2 of the connector at LSB7DS Repair or replace the GR WH C60AXEX wire OR repair or replace the no continuity WH BK P53LS wire Consult the Genie Industries Service Department 5 100 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 20 Continued from Fully retract the boom Visually check LSB3RS Replace and adjust age 5 89 Disconnect LSB3RS for damage and check LSB3RS See Repair pag and attempt to extend for debris under the limit Section OR remove the the boom switch debris Does the boom extend Adjust LSB3RS See Repair Section Disconnect the J20 12 Visually inspect the Consult the Genie pin upper limit switch Aug lower limit switch wiring Industries Service harness connector harne
324. p any additional personnel from entering the area and do not operate the machine Repair the leak immediately Component damage hazard Damage to the fuel injection pump battery and starter motor can occur if the stater motor is used excessively to eliminate air from the fuel system Do not engage the starter motor for more than 30 seconds at a time Wait 120 seconds between starter motor engagements Component damage hazard Operate the engine at low idle speed for a minimum of two minutes immediately after air has been removed from the fuel system This will ensure that the pump is free of air and prevent any damage to the pumps by metal to metal contact If the engine does not start or runs erratically refer to the Deutz Operation Manual Deutz part number 0297 7341 Genie part number 62446 for additional information on the fuel system First Edition First Printing Cummins models 1 Controlled venting is provided at the injection pump Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically If the fuel filter is changed in accordance with instructions no manual bleeding of the fuel system is needed Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the 3 pi
325. perly support the ground control box Do not allow the ground control box to hang by the wiring or cables Tag and disconnect the wires from the horn Remove the horn retaining fasteners and remove the horn from the machine 4 86 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 6 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves Cap the fittings 7 Tag disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank 8 Tag disconnect and plug the case drain hose at the return filter Cap the fitting on the return filter head 9 Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter head 10 Remove the hydraulic tank breather filter from the tank 11 Remove the hydraulic tank strap retaining fasteners and remove the hydraulic tank straps from the machine 12 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 13 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank could become unbalanced and fall if it is not properly supported and secured to the overhead crane when it is removed from the machine 14 Remove the hydraul
326. place the GR WH P109ANG wire bad __ Repair or replace the BK P110RT wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 185 Section 5 Troubleshooting Flow Charts First Edition First Printing EH CHART 37 Is YELLOW END BLUE If any other codes are Continued from the previous page SIDE STEER VALVE FAULT no present on the display screen refer to the fault present on the display screen code chart for more information yes Check for an open or bad Repair or replace the short in the BL V36LRS BL V36LRS wire wire from pin 16 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the circle end blue side steer valve coil item ED good Check for an open or bad Repair or replace the short in the BL BK BL BK V37LRS wire V37LRS wire from pin 17 of the J2 connector at the drive chassis controller DCON to pin 1 of the Din connector at the circle end blue side steer valve coil item ED good Check for an open or bad __ Repair or replace the short in the BRN BR VLVRET2 wire VLVRET2 wire from pin 14 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the circle end blue side steer valve coil item ED good Check the resistance of 4 8 to 6 8 Consult the Genie the circle end blue side ohms Industries Service steer valve coil item ED Department 0 or infin
327. proximately 95 feet 29 m 6 Remove the wire jumper installed in step 3 and connect the deutsch connector to LSB14A0O 65 Angle Safety Switch LSB9AS 7 Raise the boom to the maximum angle 8 Fully extend the boom 9 Disconnect the 68 proximity switch LSB14A0 and install a wire jumper between pin 3 and pin 4 of the deutsch connector Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 10 Start the engine and activate the function enable high RPM button and lower the boom to 65 Result The engine should stop and the boom down function should be disabled Result If the engine does not stop and the boom continues to lower to less than 65 the LSB9AS switch is out of adjustment or the wiring is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING lowers to less than 65 without stopping the engine stop immediately and raise the boom until the boom is elevated to greater than 68 Failure to raise the boom could result in death or serious injury 11 Measure the angle of the boom Result The angle of the boom should be greater than 65 12 Using auxiliary power raise the boom until the boom angle is greater than 68 13 Remove the wire jumper installed in step 9 and connect the deutsch connector to LSB14A0O 50
328. pump good Replace the auxiliary pump relief valve OR consult the Genie Industries Service Department 5 166 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Turn the key switch to platform controls Press down the foot switch and press and hold the auxiliary power button and move the steer joystick to the right or left Check voltage of the OR RD C113MFV wire circuit of the multifunction valve item AA at the distribution manifold Replace the multifunction valve less than 5V Disconnect the J4 white not Loosen but do not 35 pin connector from properly remove the red the ground controls and inserted secondary lock and re check to make sure that insert the terminal until it pin 23 is properly locks into place Push in inserted the secondary lock to lock the terminal into place properly inserted Visually trace the manifold harness from the ground controls to the multifunction valve item AA and check for damage to the harness Is there damage to the harness Repair or replace the the manifold harness Consult the Genie Industries Service Department CHART 32 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 167 Section D Troubleshooting Flow Charts First Edition First Printing Chart 33
329. r No adjustment is required 8 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 9 Swing the engine pivot plate in towards the machine 10 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Belts Genie part numbers 62437 60725 Cummins engine belt Cummins generator belt TABLE A PROCEDURES A 7 Check the Engine Cooling Fan Liquid Cooled Models Maintaining the engine cooling fan is essential to good engine performance and service life The machine will not operate properly with a loose or defective cooling fan and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Bodily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Open the engine side turntable cover and locate the engine cooling fan 2 Inspect the engine cooling fan for Cracking Loose rivets if equipped Bent or loose blades 3 Check the fan to make sure it is securely mounted Tighten the cooling fan mounting fasteners if necessary 4 Replace the cooling fan if any damage is found
330. r FB with the boom up down flow valve item BF or FF Check the boom extend function Does the function operate Adjust the boom extend relief valve item BA or item FA See Repair Section OR repair the cylinder OR repair the cylinder counterbalance valve OR consult the Genie Industries Service Department The boom function manifold could have an internal fault PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 65 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 16 Fully raise the boom and extend the boom to 100 feet 30 5 m Using the display scroll Continued from page 5 64 to the boom length status screen Is 100 present on the display screen yes display shows gt 80 Fully retract the boom Lower the boom until the boom is horizontal Check the cable adjustment See Repair Section Do the cables need to be adjusted Fully lower the boom Disconnect and test LSB4EO See Repair Section good Check for an open in the OR BK C64LS wire from pin 4 of the deutsch connector at LSB4EO to pin 9 of the J20 connector at the ground controls good Check for an open in the BL C76PBE wire from pin 3 of the deutsch connector at LSB4EO to pin 3 of the J20 at the ground controls good Check for an open in the BL C76PBE wire from pin 3 of the P20 connector to pin 28 of the J2 connector at ground controls bad
331. r malfunction before operating the machine Before Troubleshooting H Read understand and obey the safety rules and operating instructions printed in the Genie S 100 and Genie S 105 Operator s Manual or Genie S 120 and Genie S 125 Operator s Manual M Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 1 Section pe Schematics Te Electrical Components First Edition First Printing Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number E Battery 12V DC 105AH 57159 oe LI EE Group 277M nananana 1 Bea Ee onei Battery 12V DC 19
332. r was changed with the display while the engine was running Turn key switch to platform control position and depress platform Emergency stop Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Chart 1 Display Not Active Check that the ribbon cable that is connected If the ribbon cable is Open the ground control damaged replace the box and check that the LED green LED on bottom of _active between display and bad _ display If connector is not fully inserted and locked push plug into circuit board is not circuit board is active Be sure the key switch is in the appropriate damaged and connector is fully inserted and locked into circuit board connector until it is fully inserted and locked If position the display is still not LED not ood active replace display Be sure that both active i i Emergency Stop Replace the display buttons are pulled out to the on position Check voltage on pin 1 Check voltage on pin 1 Consult the Genie and pin 2 of the J5 12V ___ of the P7 connector Industries Service connector inside the inside of the ground Department OR the control box replace the ground control box TCON Be sure the circuit breakers are not d ground control box tripped TCON Be sure the batteries are fully charged and properly connected Main key switch contacts
333. radeability boom stowed 40 Boom function speeds maximum from platform controls Jib boom up S 125 models 28 to 32 seconds Jib boom down S 125 models 28 to 32 seconds Boom up 80 to 88 seconds 100 to 110 seconds Boom fully retracted Boom extended to gt 4 ft gt 1 2 m time between fully lowered and a fully raised position Boom extended to gt 80 ft gt 24 4 m time between 53 envelope limit and a fully raised position Boom extended to gt 100 ft gt 30 5 m 24 to 28 seconds time between 68 envelope limit and a fully raised position 50 to 55 seconds Boom down 80 to 88 seconds 100 to 110 seconds Boom fully retracted Boom extended to gt 4 ft gt 1 2 m time between fully raised and a fully lowered position Boom extended to gt 80 ft gt 24 4 m time between fully raised and the 50 envelope limit Boom extended to gt 100 ft gt 30 5 m 24 to 28 seconds time between fully raised and the 65 envelope limit 50 to 55 seconds Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 2 Specifications EH SPECIFICATIONS Boom extend Machine Specifications horizontal O to 80 ft 0 to 24 4 m 75 to 83 seconds vertical O to 120 ft 0 to 36 6 m 170 to 190 seconds S 100 and S 105 Models Boom retract Stowed dimensions S 100 S 105 horizontal 80 ft to 0 24 4 m to 0 75 to 83 seconds
334. ranking ampere 1020A R it 25A rate 325 minutes Exhaust noi oe eye 0 15mm Fan belt deflection 3 8 to 1 2 inch SE 9 to 12 mm 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 below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades OR ACEA classification E1 96 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 2 9 Section 2 e Specifications First Edition First Printing m SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok O ring face seal fittings and hose ends Machines that utilize Parker Seal Lok O ring face seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE Dash Installing Size into 4 Aluminum Torque Procedure 1 Replace the O ring The O ring must be 3 Be sure that the face seal O ring is seated and replaced anytime the seal has been broken retained properly The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight The O rings used in the
335. rative yellow side steering sensor and DCON box or steering sensor may need to be replaced YELLOW END BLUE SIDE STEER Yellow end blue side steering Open circuit between yellow end blue Refer to chart 37 to troubleshoot SENSOR SHORTED TO 0V unctions inoperative side steering sensor and DCON box YELLOW END BLUE SIDE STEER Yellow end blue side steering Shorted circuit between yellow end Refer to chart 37 to troubleshoot SENSOR SHORTED TO 5V unctions inoperative blue side steering sensor and DCON box YELLOW END BLUE SIDE STEER Yellow end blue side steering Damaged circuit between yellow end Refer to chart 37 to troubleshoot SENSOR VALUE TOO HIGH unctions inoperative blue side steering sensor and DCON box or steering sensor may need to be replaced YELLOW END BLUE SIDE STEER Yellow end blue side steering Damaged circuit between yellow end Refer to chart 37 to troubleshoot SENSOR VALUE TOO LOW unctions inoperative blue side steering sensor and DCON box or steering sensor may need to be replaced YELLOW END YELLOW SIDE Yellow end yellow side steering Open circuit between yellow end Refer to chart 38 to troubleshoot STEER SENSOR SHORTED TO OV functions inoperative yellow side steering sensor and DCON box YELLOW END YELLOW SIDE Yellow end yellow side steering Shorted circuit between yellow end Refer to chart 38 to troubleshoot STEER SENSOR SHORTED TO 5V functions inoperative yellow side steering sensor and DCON box YELLO
336. rcuit i e LS or limit sw 2 The circuit number may be used more than once in a circuit For Example C 74 PRLO This is the circuit for the lockout valve 1 C stands for control 74 is the number of the circuit for the primary 1 lock out valve PRLO stands for Primary Lockout S 62 BSTO This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed S stands for safety 62 is the number of the circuit for boom stowed and BSTO stands for Boom Stowed P 48 LP P stands for power 48 is the circuit number for work lamps and LP stands for Lamp R 48 LP R stands for relay In this case it is the wire that feeds the relay coil for the work lamp All other numbers remain the same V 61 AXRT V stands for valve power 61 stands for axle retracted circuit and AXRT is the mnemonic for Axle Retracted First Edition First Printing Eee _____ ____ Circuit suffix Definition AC Generator Angle Auxiliary Boom Valve Auxiliary Forward Valve Auxiliary Platform Valve Auxiliary Reverse Valve Auxiliary Reverse Valve Auxiliary Steer Drive Valve Axle Extend Valve Axle Oscillate Axle Retract Valve Battery Boom Extended Boom Stowed Brake Bypass Valves CAN High Signal CAN Low Signal CAN Shield Chain Break Data High Data Low Drive Chassis Controller Drive Enable Electrical Displacement Control Engine Speed Select Engine Status Lamp Filter Restricted F
337. re filters b filter condition indicators medium pressure filter Result The filter condition indicators should be operating with the plungers in the green area H any of the indicators display the plunger in the red area this indicates that a hydraulic filter is being bypassed and the filter should be replaced See B 10 Replace the Medium and High Pressure Hydraulic Filters 4 14 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures A 14 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise ADANGER Tip over hazard Do not raise or extend the boom unless both axles are extended If the axle extension system is not operating correctly the stability of the machine is compromised and it may tip over Be sure the axles are retracted before performing this procedure 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the on position at both the ground and platform controls Result The LCD screen will come on and display no
338. re the wires good good Check to make sure that pin 20 of the J2 bad connector at the ground controls is properly inserted good Check to make sure that pin 13 on the J2 bad connector at the ground control box is properly inserted good Replace the ground control box OR consult the Genie Industries Service Department First Edition First Printing Remove the orange secondary lock and re insert the terminal epee and adjust LSB3EO See Repair Section Repair or replace the C71PBE and or C64LS wire circuits OR remove the orange secondary lock and re insert the terminal Loosen the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place Loosen the red secondary lock and re insert the terminal Install the secondary lock in to secure the terminal in place 5 74 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Press amp keys together to access the status screen Scroll down until BOOM ANGLE Continued from page 5 72 is present on the display screen What boom angle is shown on the display gt 50 degrees Continued on the next page Section 5 Troubleshooting Flow Charts PE Go to lift function ramp time Turn the key switch to the OFF position Press and hold the 1 button and turn the key switch to g
339. reen no CHART 23 Check for an open or bad_ Repair or replace short in the WH RD CO6TRF wire from pin 4 of the J4 connector at the ground controls to WH RD CO6TRF wire pin 1 of the Din connector at the turntable rotate proportional valve coil item BG or item FG good Check for an open or bad_ Repair or replace the short in the BR BR VLVRET4 wire VLVRET4 wire from pin 1 of the J4 connector at the ground controls to pin 2 of the Din connector at the turntable rotate proportional valve coil item BG or item FG good 4 3 to 6 3 ohms Consult the Genie Industries Service Check the resistance of the turntable rotate proportional control Department valve coil item BG or item FG 0 or infinite ohms Replace the proportional valve coil Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 135 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 23 Continued from the previous page Continued on the next page Is BOOM DOWN OVERLOAD FAULT present on the display screen no Are there mechanical yes restrictions keeping the boom down function from operating no Are there mechanical es restrictions keeping the load moment function from operating Test LSB20LO for proper operation See Repair Section bad good Check for proper bad adjustment of LSB20LO See Repair Secti
340. rees If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 53 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 21 Test the Horn A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn B 22 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released Pressing down the foot switch will also shift
341. relay socket Check pin 9 of the J3 connector at the ground control box to verify that no the pin is fully inserted into the connector Is the pin fully inserted yes Inspect for open circuit or damage in C33STR bad wire circuit Visually trace the engine harness from the starter relay to the ground control box good Check the main key Se switch Contact AA in any should be OPEN in the off position and position CLOSED when the key is turned to platform controls or ground controls switch good Consult Genie Industries Service Department Replace the faulty relay ov Check for 12V at pin 30 12V Install the engine start relay and disconnect the starter relay wire P33STR Press engine start button and check for voltage on P33STR 12V Repair or replace the starter solenoid OR replace the starter Loosen the red secondary lock on the sides of the connector and insert the terminal until you hear it click into place Engage the secondary lock Repair any damaged wiring or open circuits Protect wiring from future damage Make sure cam on key switch is not damaged or stripped and repair or replace OR replace contact AA CHART 2 Inspect the red wire ckt BAT CBL making sure it is not chafed or disconnected from the battery separator Visually trace the P33STR wire circuit checking for pinch points and chafed or shorted wiring and repair the P33STR w
342. ress down the foot switch Move the boom control handle to the pown position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction 4 60 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 29 Replace the Engine Oil and Filter Cummins Models Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A daily check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 250 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap from the valve cover 2 Place a suitable container under th
343. rew until the low idle is 1300 rpm Tighten the locknut 10 Install the secondary idle adjustment screw cap and tighten Do not over tighten 11 Push and hold the function enable high speed button Note the engine rpm on the display Result High idle should be 2350 rpm If the high idle is correct disregard adjustment step 12 12 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rom or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz models Low idle 1300 rpm High idle 2350 rpm Cummins and Perkins models 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine Se OS ip D ARTI ae Ji s E Ge a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 2 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Star
344. ries Service Department Consult the Genie Industries Service Department Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 211 Section 5 Troubleshooting Flow Charts First Edition First Printing _ _ CHART 43 Continued from the previous page Check for continuity Repair or replace the between terminal 85 of BR VLVRET wire from the engine start assist terminal 85 of the relay and pin 16 of the engine start assist relay J3 white 23 pin to pin 16 of the J3 connector at the ground connector controls Is there continuity Replace the engine start assist relay OR consult the Genie Industries Service Department 5 212 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Auxiliary Drive Function Inoperative Be sure the auxiliary drive option has been activated Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the on position press down the foot switch and activate the auxiliary power membrane and move the drive joystick in the forward direction Are there any dignostic codes present on the display screen at the ground controls no
345. ring Valve CCW STCC Platform Tilt Alarm PTA Temp Sender TSR Platform Tilt Sensor PTS Temp Switches TS Pressure Sender PSR Tether TET Pressure Switches PS _ Tilt Alarm X axis TAX Pri Boom down PBD Tilt Alarm Y axis TAY Primary Boom Down PBD Ground Control Panel TCON Primary Boom Extend Retract Lockout Valve PBL Turntable Rotate Flow Control TRF Primary Boom Extend PBE Turntable Rotate Right CW TRR Primary Boom Extend Retract Flow Control PERF Turntable Tilt Alarm TTA Primary Boom Retract PBR Turntable Tilt Sensor TTSR Primary Boom Up PBU _ Test Switch TSW Part No 62445 Genie S 100 amp S 105 amp S 120 amp S 125 6 5 Section pe Schematics First Edition First Printing WIRE CIRCUIT LEGEND Wire Coloring 1 All cylinder extension colors are solid and all retract functions are striped black When using black wire the stripe shall be white 2 All rotations that are LEFT or CW are solid RIGHT or CCW are striped and black When the wire is black the stripe is white 3 All proportional valve wiring is striped Wire Color Legend BL Blue BL BK Blue Black BL RD Blue Red BL WH Blue White BK Black BK RD Black Red BK WH Black White BR Brown GRN Green GR BK Green Black GR 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 WHT White WH BK White Black WH RD White Red YL Yellow Color Circuit and Primary function RD 1 Primary boom up drive
346. rinting Section pe Schematics Turntable Controller Pin Legend CK basic sib UCI CONNECTOR soar ean e Va aN aN aN A k MACHINE O00 SE a EXTEND AXLE o E a PIN NUMBERING FOR W 23 PIN CONNECTORS CONNECTOR De CEC Se Il MOOCOCOCOCOC 1 porta i SS O a NN 8 I CONNECTOR PIN NUMBERING FOR 35 PIN BLACK ammm CONNECTORS CONNECTOR TCON TCON TCON TCON TCON TURNTABLE TURNTABLE TURNTABLE TURNTABLE TURNTABLE CONTROLLER CONTROLLER CONTROLLER CONTROLLER CONTROLLER J1 J2 J2 J3 J4 1 GNDPCON BR 2 P52PCON BL RD 3 C46HN WH 4 C470UT WH BK 5 P23PCON BK 6 S56PRV RD 7 P56PRV RD 8 R48LP WH RD 9 R49LP WH BK 10 D80SHLD 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 P97TET BK 16 UNUSED 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 TETFUNC WH 21 TETGND BR 22 P96TET RD 23 P9STET OR 8 120 amp S 125 MODELS 1 GNDDCON BR 2 P21DCON RD 3 P53LS WH BK 4 P54ENG BK WH 5 P56PRV RD 6 P57PBD RD WH 7 P58LS RD BK 8 S59CNBK GR WH 9 C60AXEX GR WH 10
347. rive motor case drain filter 10 micron Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 2 e Specifications Perkins Engine 1004 42 Displacement 258 cu in 4 23 liters Number of cylinders 4 4 06 x 5 inches 103 1 x 127 mm Bore amp stroke Horsepower 81 2200 rpm Firing order 1 3 4 2 Compression ratio 18 5 1 Compression pressure SPECIFICATIONS Injection system Injection pump make Zexel Injector opening pressure 2204 psi 152 bar Fuel requirement diesel number 2 D At operating temperatures below 32 F 0 C use a special winter fuel Summer grade Winter grade Alternator output 55A 12V Battery System pressure psi or bar of the lowest cylinder must be at Type 12V Group 27TM least 75 of the highest cylinder Quantity 1 AH rating 109AH Low idle no load 1300 rpm Cold cranking ampere 630A Reserve capacity 25A rate 160 minutes High idle no load 2350 rpm Battery Engine starting Valve clearance cold Type 12V Group 4D Intake 0 008 in Quantity 1 0 20mm AH rating 190AH Cold cranking ampere 1020A Exhaust 0 018 in Reserve capacity 25A rate 325 minutes 0 45 mm Cooling system Lubrication system g sy Engine capacity 9 5 quarts Oil pressure 51 psi 9 liters 3 45 bar System capacit 20 quarts Oil capacity 8 9 quarts y ES 18 GE including filter 8 4 liters i Fan be
348. rom movement Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 1 Section 5 Troubleshooting Flow Charts First Edition First Printing TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter onmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process
349. rom the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the RD BK P58LS wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 20 Check for a short between the WH RD SJ1 wire and the WH BK P53LS wire from pin 1 of the P20 connector to pin 2 of the P21 connector Continued from the previous page Check for a short between the BK RD SJ2 wire and the BK WH P54ENG wire from pin 2 of the P20 connector to pin 3 of the P21 connector Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the WH BK P53LS wire Visually trace the limit switch lower wire harness from the P20 connector and the P21 connector to the ground controls TCON checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the WH P54ENG wire 5 96 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow
350. rotate the head of the switch 45 degrees clockwise and activate the function enable high RPM button and attempt to extend the boom Result The boom extend function should be disabled Result If the boom extends the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING extends at all stop immediately and retract the boom until the boom is extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 29 Activate the function enable high RPM button and attempt to retract the boom Result The boom retract function should be enabled Result If the boom does not retract the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired See Repair Section 30 Using the arm just removed from LSB6S rotate the head of the switch 90 degrees counter clockwise and activate the function enable high RPM button and attempt to extend the boom Result The boom extend function should be disabled Result If the boom extends the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING extends at all
351. round controls and both Emergency Stop buttons pulled out to theon yes position push one of the LCD screen buttons until PLATFORM LEVEL SENSOR DEGREES is present on the display Is the angle displayed 10 degrees or more no Continued on the next page Turn the Service Bypass key switch to the service bypass mode Activate the function enable high RPM button and the platform level button in the corrective direction Can the platform be leveled back to within 10 degrees of level yes Return the Service Bypass key switch to the run mode Is SAFETY SWITCH P22 FAULT present on the display screen Is SAFETY SWITCH P22R FAULT present on the display screen no Refer to the appropriate platform level inoperative chart and continue troubleshooting no yes yes Return the Service Bypass key switch to the run mode See Chart 24 Start troubleshooting from the beginning of this chart Start troubleshooting from the beginning of this chart 5 148 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 27 Is SAFETY SWITCH P22 e FAULT present on the y short in the RD P87PTS wire from pin 23 of the J2 connector at the platform controls to pin 5 of the deutsch connector at the platform level sensor Check for an open or bad Repair or replace the Continued
352. round controls Press UD 4 then scroll until BOOM EXTEND RETRACT RAMP DECEL is present on the display software version 1 01 Is the ramp time shown 250 ms software version 1 06 Is the ramp time shown 500 ms yes Turn the key switch to the off position Press and hold the button and turn the key switch to ground controls Press and scroll down until BOOM UP DOWN SPEED BELOW 80 FEET is present on the display Does the display show 60 yes Attach a digital protractor to the top of mo the boom tube Raise continuity the boom until the boom angle is at 53 degrees Disconnect LSB13AO deutsch connector and check for continuity between terminals 3 and 4 continuity Connect LSB14A0 Lower the boom until the boom angle is 50 degrees Disconnect LSB8AS deutsch connector and check for no continuity between pins 1 and 2 and between pins 3 and 4 continuity no continuity Consult the Genie Industries Service Department CHART 18 software version 1 01 Reset the ramp time to 250 ms software version 1 06 Reset the ramp time to 500 ms no Reset the boom speed to 60 Loosen the LSB13AO mounting fasteners and adjust the switch so that it closes when the boom angle reaches 53 degrees Loosen the LSB8AS mounting fasteners and adjust the switch so that the contacts of the switch open when the boom angle reaches 50 degrees Part No
353. rt No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 133 Section 5 Troubleshooting Flow Charts CHART 23 Is TURNTABLE ROTATE JOYSTICK NOT CALIBRATED present on the display screen Continued from the previous page Is TURNTABLE ROTATE JOYSTICK SHORTED TO 0 VOLTS OR TURNTABLE ROTATE JOYSTICK SHORTED TO 5 VOLTS OR TURNTABLE ROTATE JOYSTICK VALUE TOO HIGH OR TURNTABLE ROTATE JOYSTICK VALUE TOO LOW present on the display screen Is TURNTABLE ROTATE FLOW VALVE NOT CALIBRATED present on the display screen Continued on the next page First Edition First Printing SSS eos Recalibrate the turntable rotate joystick OR replace the turntable rotate joystick See Repair Section Check for an open or short in the internal platform control box wire harness between the P1 connector at the turntable rotate joystick and the P20 connector at the circuit board Repair or replace the internal platiorm control box wire harness Replace the turntable rotate joystick OR consult the Genie Industries Service Department Calibrate the turntable rotate joystick See Repair Section 5 134 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Continued on the next page Is TURNTABLE ROTATE FLOW VALVE FAULT present on the display sc
354. s TABLE CG PROCEDURES 2 Remove the engine pivot plate retaining 5 Locate the fuel lift pump fastener Swing the engine pivot plate out away from the machine Spl 4a ES a engine pivot plate anchor hole b engine pivot plate retaining fastener a fuel lift pump 3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 6 Remove the fuel lift pump cover retaining fastener Remove the cover and seal from the 4 Install the bolt that was just removed into the top of the fuel lift pump anchor hole to secure the engine pivot plate from moving D a AA Di AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate anchor hole to secure it from moving could result in death or serious injury a cover with retainer b strainer c seal d pump body e priming lever Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 65 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE G PROCEDURES 7 Remove the strainer from the fuel lift pump 8 Using a mild solvent carefully wash the inside of the fuel lift pump body 9 Using a mild solvent clean the strainer the seal and the lift pump cover 10 Install the strainer and seal onto the fuel lift pump body 11 Install the cover onto the fuel lift pump Tighten the fuel lift pump cover retain
355. s Check and Adjust the Engine RPM Replace the Engine Oil and Filter Deutz and Perkins Models TABLE A PROCEDURES Cummins models A 3 A 5 B 5 B 8 B 13 C 3 D 8 D 10 B 15 B 28 Inspect for Damage and Loose or Missing Parts Check the Engine Coolant Level Liquid Cooled Models Replace the Air Filter Replace the Hydraulic Tank Return Filters Inspect the Tires and Wheels including lug nut torque Replace the Fuel Filter Element Perkins and Cummins Models Inspect the Boom Extend Retract Cables Check the Turnable Rotation Bearing Bolts Check the Engine Belt s Cummins Models Check the Engine Valve Clearances Cummins and Perkins Models Check and Adjust the Engine RPM Replace the Engine Oil and Filter Cummins Models Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section 4 Scheduled Maintenance Procedures First Edition First Printing TABLE A PROCEDURES Perkins models A 3 A 5 B 3 B 5 B 8 B 13 C 6 D 4 D 10 B 15 CA Inspect for Damage and Loose or Missing Parts Check the Engine Coolant Level Liquid Cooled Models Check the Engine Belt s Perkins Models Replace the Air Filter Replace the Hydraulic Tank Return Filters Inspect the Tires and Wheels including lug nut torque Replace the Fuel Filter Element Perkins and Cummins Models Inspect the Boom Extend Retract Cables Check the Turnable Rotation Bearing
356. s 4 46 B 19 Test the Safety Envelope and Circuits c cccecceeeeeeeeeeeeeeeeeeeeeseeeeeeeeaeeees 4 47 B 20 Test the Platform Self leveling c cccceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeaaeeseeeeeeeeaeees 4 53 GESCHEET 4 54 B 22 Test the Foot Switch 0 cceccccceeeeeeceeeeeeeeeeeeeceaaeeseceeeesaaeeeseaaeeeeeeeeeesaaeeee 4 54 B 23 Test the Engine Idle Select 200 ceeccececseeeeeeeeeeeeeeseeeeeeeseeeeeseaeeeeeneeeeeaaeeee 4 55 B 24 Test the Drive Enable System cccceccceeeeeeeeeeneeeeeceeeeeeeeeeesaaeeseeeeeeeeaeees 4 56 B 25 Test the Drive Brakes saucs i dente celts eeeceetetith nearness 4 57 B 26 Test the Drive Speed Stowed Position c cececceeeeceeeeeeeeeeeeaeeeeeeeeeeeaeees 4 58 B 27 Test the Drive Speed Raised or Extended Position csecceeeeeeseeeeees 4 58 B 28 Test the Alarm Package if equipped 0 0 0 eeeeeeentteeeeeeeeneeeeeeeetaaeeeeeeeeaaees 4 60 B 29 Replace the Engine Oil and Filter Cummins Models cceeeeeeeeeeeeees 4 61 B 30 Inspect the Fuel Tank Cap Venting System cccccseeeeeeeeeeteeeeeteeeeeeeeees 4 62 B 31 Perform Hydraulic Oil Analysis ccccceeeeeee cesses eeceeeeeeeeeeeeaaeeeeeeeeeeeaeeee 4 63 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 vii First Edition First Printing E TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued C 1 Check the Engine Valve Clearances Deutz Models
357. shoot or consult Genie Industries Service Department Repair damage in circuit wiring Refer o electrical schematic to troubleshoot or consult Genie Industries Service Department SAFETY SWITCH P3 FAULT All functions inoperative Open circuit in tether Emergency stop wiring Repair damage in circuit wiring Refer o electrical schematic to troubleshoot or consult Genie Industries Service Department SAFETY SWITCH P6R1 FAULT Boom extend and boom down functions inoperative This fault creates Safety switch P9A P10 P11 and P18 fault Bad K4 relay inside turntable control box Replace K4 relay or consult Genie Industries Service Department SAFETY SWITCH P6R2 FAULT Engine cranks but won t start Bad K3 relay inside turntable control box Replace K3 relay or consult Genie Industries Service Department SAFETY SWITCH P7 FAULT SAFETY SWITCH P7R FAULT SAFETY SWITCH P9A FAULT SAFETY SWITCH P9B FAULT SAFETY SWITCH P10 FAULT SAFETY SWITCH P11 FAULT No boom functions Fault creates safety switch P7R P22 P14 P12 and P22R faults No boom functions Fault creates safety switch P22 P22R P14 and P12 faults Boom extend and boom down functions inoperative This fault creates Safety switch P10 and P18 faults Engine cranks but won t start Boom extend inoperative Boom up inoperative Bad K5 relay inside turntable control box or bad K1 relay inside platform
358. splay no Continued on the next page Activate the boom retract button Is there an audible beep when the button is pressed Replace the ground controls membrane decal See Repair Section OR consult the Genie Industries Service Department Recalibrate the joystick OR replace the boom extend retract joystick See Repair Section Check for damaged wires inside the platform control box from the boom extend retract joystick connector H2 to the circuit board P20 OR replace the boom extend retract joystick OR consult the Genie Industries Service Department Calibrate the boom extend threshold See Repair Section Chart 17 YSS yj Continued on page 5 71 PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 67 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 17 Continued from the previous page Is BOOM EXT RET FLOW VALVE FAULT present on the display no Continued on the next page Check for an open or short in the BK RD CO9PERF wire from pin 3 of the J4 connector at the ground controls to pin 1 of the DIN connector at the extend retract flow control valve coil item BB or item FB Check for an open or short in the BR VLVRET4 wire from pin 1 of the J4 connector at the ground controls to pin 2 of the DIN connector on the boom extend retract flow control valve coil item BB or item FB Check the resista
359. ss looking for Department Check for continuity pinch points and chafed between pin 5 and pin 8 or broken wires of the J20 connector Repair or replace the OR RD P63LS wire ae circuit OR repair or no continuity replace the RD WH P57PBD wire circuit Consult the Genie Industries Service Department Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 101 Section 5 Troubleshooting Flow Charts First Edition First Printing EE CHART 20 Fully extend the axles Visually check LSB3RS Replace and adjust Continued from page 5 89 Disconnect LSB3RS for damage and check bad LSB3RS See Repair and attempt to retract for debris under the limit Section OR remove the the axles switch debris Do the axles retract good Adjust LSB3RS See yes Repair Section Disconnect the J20 12 Visually inspect the ne Consult the Genie pin upper limit switch continuity lower limit switch wiring 96 Industries Service harness connector harness looking for Department Check for continuity pinch points and chafed between pin 3 and pin 4 or broken wires of the connector to LSB3RS damage found Repair or replace the OR S62BSTO wire circuit OR repair or no continuity replace the GR C61AXRT wire circuit Disconnect the J2 black Visually inspect the oe Consult the Genie 35 pin connector from Industries Service the ground controls TCON and disconnect LSB7DS Check for continuity betw
360. ss than 75 feet Start yes the engine Disconnect LSB4ES from the wiring harness Does the engine stop no Disconnect LSB8AS yes Does the engine stop no Disconnect the J20 e5 12 pin and J21 8 pin deutsch connectors inside the counterweight area of the machine Does the engine stop and does P9A P9B P10 P11 P12 P14 P18 and BOOM LENGTH FAULT appear on the display screen at the ground controls no Continued on the next page Section 5 Troubleshooting Flow Charts N Visually check LSB4ES for damage and check bad for debris under the limit switch good Adjust LSB4ES See Repair Section Visually check LSB8AS bad for damage See Repair Section Check for a short bad good Adjust LSB8AS See Repair Section between pin 1 and pin 8 of the J20 connector good Check for a short bad between pin 2 of the J20 connector and pin 1 of the J21 connector good Consult the Genie Industries Service Department CHART 21 Replace and adjust LSB4ES See Repair Section OR remove the debris Replace and adjust LSB8AS See Repair Section Repair the WH RD SJ1 wire OR repair the RD WH P57PBD wire Repair the BK RD SJ2 wire OR repair the RD BK P58LS wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 111 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21
361. st area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbol is selected then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line TABLE B PROCEDURES 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point 4 to 6 ft 1 2 to 1 8m Braking High range paved surface The brakes must be able to hold the machine on any slope it is able to climb Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES B 26 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines
362. st be performed according to a schedule daily quarterly six months annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 4 2 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Semi annual or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 hour I
363. sually check LSB4ES bad for damage See Repair Section Check for a short bad good Adjust LSB4ES See Repair Section between pin 1 and pin 8 of the J20 connector good Check for a short between pin 2 of the J20 connector and pin 3 of bad the J21 connector good Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department CHART 21 Replace and adjust LSB8AS See Repair Section OR remove the debris Replace and adjust LSB4ES See Repair Section Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the WH RD SJ1 wire OR repair the RD WH P57PBD wire Visually trace the limit switch upper wire harness from the J20 connector and the J21 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring and repair the BK RD SJ2 wire OR repair the RD BK P58LS wire Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 117 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 21 Check for a short between pin 1 of the P20 connector and pin 2 of the P21 connector Continued from the previous page Check for a short between pin 2 of the P20
364. sure the air intake system does not leak TABLE B PROCEDURES B 7 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns Cummins and Perkins models 1 Be sure that all fasteners are tight 2 Inspect all welds for cracks 2 Inspect for exhaust leaks i e carbon buildup around seams and joints Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES Deutz models 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine eh P es Des a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could resu
365. t L d HO OLS8Z9S GC 5 CH MYaNHO cA Sage ISS TER S Sa DES HWH9 XIXY099 5 _ HWwa9aanoess lt lt EE HMVH9 HENO6SS al o o N zd Wa u STeSd DI aa DC ORASd EEEAGSEE s0 zd lt aY AHd9SS SI E uv 9 H ES 5 pozd HWYS NIYSd ae 536 EI EI DC ME HM STeSd EES GY NOOdL d 7 7 BE Ya NOOGGND a EN z8 WE HO S1P90 4i 004 a Ze i a ad699 2 A oyzas i i a 5 oun US aune ers o LOL E A suzast Ha ONE d ME HM STeSd lt 5 5 e z 3 D D e S S a2 gfoES amp SZ 8 6ak 0 E B O D S d x o Sen g 9 BEZ g sg Sg SS ese2 se2r7oe Zz lt D D a Zo o o KK HR o oO 2 OfE gogo gt Ka E DS Do OOp Oo 6 18 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 6 Schematics ee Safety Circuit Schematic M L K J H G F E D C B A VR1 D23 d PWR D 1 P15 4 STAT ig To 4IN1 OUT 1 Tconw2 23 TURNTABLE FLOW CONTROL lt D14 5A ROTATE VALVE 30 86 CR12 30 86 E N2 OUT e We A SES aye 87 b85 87ae 87 485 Ea GND S AN OU
366. t Edition First Printing All Platform Steering and Axle Functions inoperative All Other Functions Operational Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the OPEN position Be sure the hydraulic tank is filled to the correct level Be sure the batteries are fully charged and properly connected 3000 psi or more Install a 0 to 5000 PSI 345 bar pressure gauge to the test port on the platform manifold Start the engine and activate the function enable high RPM button and the jib boom down button and check the hydraulic pressure less than 3000 psi Adjust the platform manifold system relief 3000 valve at the distribution psi or manifold item AC all more the way in clockwise counting the number of turns Activate the function enable high RPM button and the jib boom down button and check the hydraulic pressure less than 3000 psi Continued on the next page Section 5 Troubleshooting Flow Charts Troubleshoot platform functions individually OR consult the Genie Industries Service Department Activate the function enable high RPM button and the jib boom down button and adjust the relief pressure to 3000 psi 207 bar Check steering and axle functions no functions Activate the function enable high RPM button and the jib boom down button and check the 12V voltage on the multi function solenoid valve item AA o
367. t Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 14 Remove obstruction or repair mechanical Is there an obstruction or mechanical restriction Is BOOM DOWN Continued from the OVERLOAD FAULT previous page yes yes restriction present on the display preventing boom down function from operating no Test LSB20LO for bad prone operation See epair Section Replace LSB20LO good Check for proper bad _ Adjust LSB20LO See adjustment of LSB20LO Repair Section See Repair Section good Check for an open in the bad Repair or replace the RD BK C115LS wire RD BL C115LS wire from pin 17 of the J4 connector at the ground controls to LSB20LO good no Check for an open in the bad _ Repair or replace the BR VLVRET5 wire from BR VLVRET5 wire pin 14 of the J4 connector at the ground controls to LSB20LO good Consult the Genie Industries Service Department Continued on the next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 51 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 14 Continued from the previous page Is BOOM UP VALVE FAULT present on the Check for an open or short in the RD BK C02PBD wire from pin 8 of the J4 connector at the ground controls to yes display pin 1 of the DIN connector at the boom up valve coil item BD or item
368. t on the display screen at the ground controls extends Disconnect the J20 12 pin and J21 8 pin deutsch connectors inside the counterweight area of the machine Using auxiliary power attempt to extend the boom Does the boom extend and does P9A P9B P10 P11 P12 P14 P18 and BOOM LENGTH FAULT appear on the display screen at the ground controls extends Continued on the next page does not extend Visually check LSB6S bad for damage See Repair Section good Adjust LSB6S See Repair Section Physically pull the harness from the cable track and the internal cable track checking for pinch points and chafed and shorted wiring and repair or replace the upper cable break harness does not extend Visually trace the upper cable break harness from the J26 connector up the cable track to the breakout at the side of the boom checking for pinch points and chafed or shorted wiring does not good extend bad Repair the OR RD P63LS wire OR repair the GR WH S59CNBK wire CHART 21 Replace and adjust LSB6S See Repair Section Start troubleshooting from the beginning of the chart OR consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 115 Section 5 Troubleshooting Flow Charts First Edition First Printing E CHART 21 Check for a short Visually trace th
369. t the engine from the ground controls 5 Push one of the LCD screen buttons shown until engine rpm is displayed Result Low idle should be 1300 rpm Skip to step 7 if the low idle rpm is correct TABLE B PROCEDURES 6 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rom or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the e Perkins models ep Oo om low idle adjustment screw yoke lock nut solenoid boot high idle adjustment nut yoke low idle lock nut Cummins models yoke yoke lock nut solenoid boot high idle adjustment nut low idle adjustment screw oo Oo om Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 7 Push and hold the function enable high speed button Note the engine rpm on the display Result High idle should be 2350 rpm Skip to step 9 if the high idle rpm is correct 8 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle 9 Remove the engine pivot plate retaining fastener from the engine pivot plate a
370. t the terminal Install the secondary lock in to secure the terminal in place Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Continued from pages 5 75 and 5 76 Press amp keys together to access the status screen Scroll down until BOOM LENGTH is present on the display screen What boom length is shown on the display 100 Continued on the next page Section 5 Troubleshooting Flow Charts PE Disconnect LSB4EO Are the terminals no properly inserted into the deutsch connector yes Test LSB4EO for proper operation See Repair Section bad good Check for an open or bad short in C76PBE and C64LS wire circuits Trace the circuits back to the ground control box Check the wiring at the connector between the upper and lower limt switch harness Make sure the terminal 3 on J20 is properly inserted Are the wires good good Check pin 28 of the J2 connector at the ground bad controls to make sure the terminal is inserted properly good Check pin 13 of the J2 connector at the ground bad controls to make sure the terminal is inserted properly good Replace the ground control box OR consult the Genie Industries Service Department CHART 19 Remove the orange secondary lock and re insert the terminal Replace and adjust LSB4EO See Repair Section Repair or replace t
371. ted eet i eeds eae 2 6 Perkins Engine 1004 42 Specifications ccccceesccececeeeeeeeeeeeeeaeeseeeeeeeeaeeeteneeesenees 2 7 Cummins Engine B3 9L Specifications 2 00 2 cceeccececeeeeeeeeeeeeneeeeeeeeeeeeaeeseeeeseeneeeess 2 8 Deutz Engine FAL 913 Specifications cceceeccececeeeeeeeeeeeeeceeeeeeeeeeeeeaeeseeeeeeesaeeeeaas 2 9 Hydraulic Hose and Fitting Torque Specifications cceccseeeeeseeeeeeeeeeeeeeeeeeeeeees 2 10 Theory of Operation Theory of Operation isminin de dad idl eae ele 3 1 Scheduled Maintenance Procedures WIMMOCUCTION EE 4 1 Maintenance Inspection Report 00 0 0 eee ceeeeeeeeeeeeeeeaeeeeeeeeeaaeeeeeeeeaaeeeeeeseaaeeeeeeeeaas 4 3 A 1 Inspect the Manuals sssrensenotn ine 4 5 A 2 Inspect the Decals and Placards AA 4 5 A 3 Inspect for Damage and Loose or Missing Parts ccceeeeeeeseeeeeeeeeeetteeeeeeees 4 6 A 4 Check the Engine Oil Level ccccccceceeeeeeeeeeceeeeeeneeeesaaeeeseeaeeeeeaeeeessaeeenenees 4 6 Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 v First Edition First Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 5 Check the Engine Coolant Level Liquid Cooled Models cccceeeeeeees 4 7 A 6 Check the Engine Belt s Cummins Models cc ccccceeeceeeeeeeeeesttaeeeennees 4 8 A 7 Check the Engine Cooling Fan Liquid Cooled Modelen 4 9 A 8 Drainthe Inline Fuel Filter Water Sep
372. tend safety Boom 65 angle safety Boom 50 angle safety Boom 76 feet 23 2 m extend safety Drive enable mechanical Boom 10 mechanical Boom gt 100 feet 30 5 m retract proximity Boom gt 3 feet 0 9 m stowed mechanical Boom 75 feet 22 9 m extend proximity Boom 100 feet 30 5 m extend proximity Boom 53 angle proximity Boom 68 angle proximity Load moment mechanical Reverse load moment proximity Les S 120 and S 125 models only Numbering Legend Circuit number D Down AX Axle A Angle B Boom L Load moment T Turntable E Extend LS Limit switch R Retract O Operational J S Safety LSAN RO Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62445 First Edition First Printing Section 6 Schematics LIMIT SWITCHES 120 ft 36 6 m 110 ft 33 5 m 100 ft 30 5 m 90 ft 27 4 m 80 ft 24 4 m LSB8AS LSB13A0 50 53 70 ft 21 3 m LI J e L ps SB3E0 60 ft 18 3 m 23 m 22 9 m el 50 ft 15 2m 40 ft 12 2 m 30 ft 9 1m LSB7DS LSB7DS 11 LSB1DO 20 ft 6 1 m LSB1DO 11 gQ 10 10 g II e A 10ft 3m A LSB3RO CL EES SB3RO I LSB3RS LSB3 LSB3R LSB3RS 3 5 ft 1 1m 3ft
373. tend the Department axles Raise the boom to approximately 30 degrees Disconnect LSAX1ES Disconnect Continued from page 5 109 LSB3RS and install a wire jumper between terminal 3 and terminal 4 of the connector to LSB3RS Attempt to retract the axles Do the axles retract yes Extend the axles no Visually inspect bad Replace and adjust Disconnect LSB7DS LSB7DS for damage LSB7DS See Repair from the wiring harness Section Attempt to retract the good axles 9 Do the axles retract Adjust LSB7DS See Repair Section yes no damage Consult the Genie Disconnect the J2 black Industries Service 35 pin connector from the ground control box Check for continuity between pin 3 and pin 4 of the connector to LSB7DS damage found Visually inspect the lower limit switch harness looking for continuity Department pinch points and chafed or broken wires Repair or replace the RD S56PRV wire circuit D or the OR S62BSTO no continuity wire circuit Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 127 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 22 Turntable Rotate Clockwise Function Inoperative Be sure all other functions operate normally Be sure the axles are fully extended Be sure the batteries are fully charged and properly connected
374. the engine into high idle if the engine idle select rpm indicates that the rabbit and foot switch symbol is selected An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Turn the key switch to platform controls and pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Press down the foot switch and attempt to start the engine by pushing the engine start button Result The engine should not start 3 Do not press down the foot switch and start the engine 4 Do not press down the foot switch and test each machine function control handle toggle switch or button Result The machine functions should not operate Press down the foot switch 6 Activate each machine function control handle toggle switch or button Result All functions should operate through a full cycle Descent alarm if equipped should sound while boom is lowering 4 54 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 23 Test the Engine Idle Select A properly operating engine idle select function is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control multiple boom and or
375. ther functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency stop buttons pulled out to theon no position start the engine and push the steer mode select button for square end blue end steer Press down the foot switch and activate the steer function in both directions Are there any diagnostic codes present on the display at the ground controls yes Is STEERING JOYSTICK NOT CALIBRATED yes present on the display screen no Continued on the next page Stop the engine Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect no coupler on the steer axle manifold Start the engine and activate the steer functions in both directions Is the pressure less than 3000 psi 207 bar yes Exchange the square yes end yellow side steer valve item EA with the square end blue side steer valve item EB Start the engine and activate the steer function Does the circle end yellow side steering function in both directions Repair or replace the steer cylinder OR repair or replace the pilot operated check valves items EM and EBB OR consult the Genie Industries Service Department Recalibrate the steer joystick see Repair Section OR replace the steer joystick Chart 36 Check for mechanical restrictions keeping the steer function from moving
376. there an audible beep when button is pressed YSS aj Continued to page 5 63 Consult the Genie Industries Service Department The turntable membrane may need to be replaced Recalibrate the boom extend retract joystick see Repair Section OR the boom extend retract joystick may need to be replaced Check for damaged wires in internal PCON wire harness between ext ret joystick connector P2 and and board connector P20 or consult Genie industries service department or Boom ext ret joystick may need to be replaced Refer to Chart 18 Boom Envelope Operational Switch Failure S 100 S 105 models OR refer to Chart 19 Boom Envelope Operational Switch Failure 120 S 125 models Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 16 Is SAFETY SWITCH P10 Refer to Chart 18 Boom FAULT present on the Envelope Operational display Switch Failure S 100 S 105 models OR refer to Chart 19 Boom Envelope Operational Switch Failure 120 S 125 models Continued from the previous page Refer to Chart 12 Boom Angle switch Fault Is BOOM ANGLE SWITCHES FAULT present on the display Refer to Chart 15 Boom Length Switch Fault Is BOOM LENGTH SWITCHES FAULT present on the display Is BOOM EXT RET FLOW Re calibrate the boom VALVE NOT CALIBRATED extend joystick present on the d
377. tion First Printing CHART 31 Continued from the previous page Is JIB VALVE FAULT Check for an open or present on the display short in the GR BK C44JD wire from pin 6 of the J2 connector at the platform control box yes screen to pin 1 of the Din connector at the jib boom down valve coil item CL good Check for an open or short in the BR VLVRET wire from pin 1 of the J2 connector at the platform control box to pin 2 of the Din connector at the jib Ao boom down valve coil item CL good Check the resistance of jib boom down valve coil item CL 4 4 to 6 4 ohms bad 1 Repair or replace the GR BK C44JD wire bad __ Repair or replace the BR VLVRET wire Consult the Genie Industries Service Department 0 or infinite ohms Replace the valve coil If any other codes are on the display screen refer to the fault code chart for more information 5 162 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Chart 32 Auxiliariy With the key switch yes P turned to ground page 5 165 Fu nctions controls and both i Emergency Stop buttons Inoperative pulled out to the ON position activate Be sure all other function enable button functions operate sie Si e GC u g boom normally extend retract or boom up down Does the Be sure the batteries motor oper
378. to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Perkins models 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine s BS a a vent screw b fuel filter head c fuel filter a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 4 30 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures 5 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent If the drive cam of the fuel lift pump is at the point of maximum lift it will not be possible to operate the priming lever In this situation rotate the crankshaft one revolution a fuel lift pump 6 While continuing to operate the priming lever tighten the vent screw 7 Loosen the union nut on the fuel inlet pipe at the injection pump 8 Operate the priming lever of the fuel lift pump until fuel free from air comes from the connection 9 Tighten the union nut 10 Clean up any diesel fuel that may have spilled during the procedure TABLE B PROCEDURES 11 Start the engine and check for leaks ADANGER CAUTION CAUTION Explosion and fire ha
379. tools and working areas Be sure that your workshop or work area ET is properly ventilated and well lit Be sure any forklift overhead crane or le other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity ZA Be sure that fasteners intended for one OX time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time ay Be sure to properly dispose of old oil or ue other fluids Use an approved container Please be environmentally safe iv Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing Introduction Section One Section Two Section Three Section Four Table of Contents lmportant lit eu ul EE ii Safety Rules General Safety Rules cecceeeeeeeeeeeeeeeeceeeeeeeeeeeecaaaeeeeneeeeesaaeeecaaeeseceeeessaeeesnceeseennees iii Specifications Machine Specifications S120 and S 125 Models ccccsssceeesesseeeeeeesesneeeeeeeenaas 2 1 Performance Specifications S120 and S 125 Models sssssssssssnnnnnsnrnnnesennrrennenne 2 2 Machine Specifications S100 and S 105 Models cccccsseceeeseeseeeeeeeseseeeeeeeeaaas 2 3 Performance Specifications S100 and S 105 Models ssnnnnsssssnnnnnennrnnesennrnnnneene 2 5 Hydraulic SpecifiCations iiss iseinean a ae
380. tract Thresholds refer to repair section Refer to charts 16 and 17 to troubleshoot BOOM EXT VALVE FAULT Extend function inoperative Boom extend valve coil circuit open Refer to chart 16 to troubleshoot or shorted to ground or the coil itself is bad BOOM RET VALVE FAULT Retract function inoperative Boom retract valve coil circuit open or Refer to chart 17 to troubleshoot shorted to ground or the coil itself is bad LOCK OUT VALVE P1 FAULT Retract function inoperative when Boom retract lockout valve coil circuit Refer to chart 16 to troubleshoo boom length is lt 100 open or shorted to ground or the coil itself is bad LOCK OUT VALVE P2 FAULT Extend function inoperative when Boom extend lockout valve coil circuit Peter to chart 17 to troubleshoot boom length or gt 100 open or shorted to ground or the coil itself is bad BOOM LENGTH SWITCHES FAULT Extend up and down functions Boom length operational switches out Refer to chart 15 to troubleshoot inoperative of sequence TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Turntable rotate joystick not Calibrate turntable rotate joystick NOT CALIBRATED rom platform calibrated refer to repair section TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Open circuit between platform control Refer to charts 22 and 23 to SHORTED TO 0V rom platform card and turntable rotate joystick roubleshoot TURNTABLE ROTATE JOYSTICK Turntabl
381. trols membrane decal Department Make sure cam on key switch Contact BA switch is not damaged should be OPEN in the or stripped and repair or off position and replace OR replace CLOSED when the key contact BA is turned to platform controls or ground controls Continued from page 5 16 Key switch contact legend contact is open in any position Check the main key switch good Consult the Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 21 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 3 Engine Cranks Over But Will Not Start Be sure to check the fuel level and fill as needed Be sure the fuel system is properly bled Be sure the batteries are fully charged and With the key switch turned to ground yes controls and both Emergency Stop buttons pulled out to the on Check the engine manufacturer s manual for troubleshooting information position press the engine start button While the engine is cranking is exhaust smoke present no Is SAFETY SWITCH P9A es Refer to Chart 20 or 21 FAULT Or SAFETY SWITCH P9B FAULT properly connected present on the display screen at the ground controls no Push the engine start less Check battery condition button on the ground than 9V OR check alternator OR control box Check the check for short
382. ubleshoot SAFETY SWITCH P14 FAULT SAFETY SWITCH P18 FAULT Axle retract inoperative Boom extend inoperative Open in stowed safety circuit or limit switch LSB7DS has failed or limit switch LSB1DO has failed Open in axle safety switch circuit or limit switch LSB3RS LSAX1ES or LSAX2ES have failed or operational limit switch LSB3RO has failed Refer to chart 18 or 19 and chart 20 or 21 to troubleshoot Refer to chart 18 or 19 and chart 20 or 21 to troubleshoot SAFETY SWITCH P22 FAULT SAFETY SWITCH P22R FAULT DCON SAFETY SWITCH P7R FAULT PROX KILL SW FAULT PLTFRM OVERLOAD SEN FAULT Platform level inoperative Fault creates a safety switch P22R fault Platform level and Boom up down inoperative Steering and axle functions inoperative All functions inoperative unless spare membrane on platform control box is activated All functions inoperative red LED above spare membrane flashing Platform out of level gt 10degrees out of stowed position or platform level sensor is bad or there is an open in the platform level sensor circuit or limit switches LSB1DO or LSB3RO are bad Platform out of level gt 10degrees out of stowed position or platform level sensor is bad or there is an open in the platform level sensor circuit or limit switches LSB1DO or LSB3RO are bad Open in Red S56PRV wire circuit that runs from the turntable control box to the DCON control box Proximity Kill Bumper
383. ubleshooting Flow Charts First Edition First Printing Chart 42 Drive Mode Select Inoperative Be sure the boom is in the stowed position Be sure all other functions operate normally Be sure the batteries are fully charged and With the key switch turned to platform controls and both Emergency Stop buttons no pulled out to the on position activate drive mode select button Is there an audible beep yes Activate the drive mode yes select button Does the high drive mode LED turn on Consult the Genie Industries Service Department Platform membrane decal may need to be replaced Continued to page 5 207 properly connected Check the display Is BOOM LENGTH YSS l Refer to Chart 15 screen at the ground yes SWITCHES FAULT controls Are there present on the display codes present screen no Is BOOM ANGLE ES A Refer to Chart 12 SWITCHES FAULT present on the display screen no If any other codes are present on the display screen refer to the fault code chart for more no information Continued on the next page 5 204 Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 42 Turn the key switch to Using the display Consult the Genie le de the ground conirols Using ge screen activate the ae Industries Service previous page the display screen Boom an
384. uled Maintenance Procedures B 19 Test the Safety Envelope and Circuits Testing the machine safety envelope is critical to safe machine operation If the boom is allowed to operate when a safety switch is not functioning correctly the machine stability is compromised and may tip over 1 Raise the boom to approximately 60 For S 100 or S 105 models proceed to step 15 101 feet 30 8 m Length Safety Switch LSB2RS 2 Extend the boom to more than 80 feet 24 4 m 3 Disconnect the 68 proximity switch LSB14A0 and install a wire jumper between pin 3 and pin 4 of the deutsch connector Result gt 65 pec should be present on the display screen at the ground controls TABLE B PROCEDURES 4 Activate the function enable high RPM button and extend the boom to 101 feet 30 8 m Result The engine should stop and the boom extend function should be disabled Result If the engine does not stop and the boom continues to extend the LSB2RS switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING extends to more than 101 feet 30 8 m without stopping the engine stop immediately and retract the boom until the boom is extended to less than 100 feet 30 5 m Failure to retract the boom could result in death or serious injury 5 Using auxiliary power retract the boom until the boom is extended to ap
385. und under the platform and near the platform reference point selected Choose a point on the machine platform i e outside edge of the platform as a visual reference for use while performing this procedure Apply approximately 20 Ibs 89 N of side force to the platform moving the platform to one side as far as it will go Mark a reference point on the test line where the platform stops moving Apply approximately 20 Ibs 89 N of side force to the platform moving the platform in the opposite direction as far as it will go Mark a reference point on the test line where the platform stops moving Measure the distance on the test line between the two reference marks Result The platform movement should not exceed 2 inches 51 mm If the platform movement exceeds 2 inches 51 mm proceed to step 6 Turntable rotation gear backlash turntable rotation bearing Maximum side to side movement 2 inches at platform 51mm The 3 red painted gear teeth on the turntable rotation bearing are the teeth closest to the blue arrow side of the drive chassis Ir St C od U i eck et ch XY J Ne S a yellow arrow a blue arrow b red painted teeth Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 77 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE D PROCEDURES Adjusting the backlash 6 Remove the ground control side fixed turntable cover from the machine Ref
386. uture printings of this and other manuals Please write to the technical publications team in care of a i Genie Industries PO Box 97030 Redmond WA Genie Industries 98073 0069 U S A l Copyright 2001 by Genie Industries If you have any questions please contact Genie First Edition First Printing January 2001 Industries Genie and S are Registered Trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 5 1992 k Printed on recycled paper Printed in U S A il Genie S 100 amp S 105 amp S 120 amp S 125 PartNo 62401 First Edition First Printing Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 100 amp Genie S 105 Operator s Manual or the Genie S 120 amp 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 H You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop PartNo 62401 Genie S 100 amp S 105 a
387. ve chassis controller to pin 1 of the Din connector at the square end yellow side steer valve coil item EA good Check for an open or bad __ Repair or replace the short in the BRN BR VLVRET2 wire VLVRET2 wire from pin 14 of the J2 connector at the drive chassis controller to pin 2 of the Din connector at the square end yellow side steer valve coil item EA good Check the resistance of 4 8 to 6 8 Consult the Genie the square end yellow ohms Industries Service side steer valve coil itemEA Department 0 or infinite ohms Replace the valve coil PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 183 Section 5 Troubleshooting Flow Charts First Edition First Printing Chart 37 Yellow End Blue Side Steering Function Inoperative Be sure all other functions operate normally Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency stop buttons pulled out to theon position start the engine and push the steer mode select button for circle end yellow end steer Press down the foot switch and activate the steer function in both directions Are there any diagnostic codes present on the display at the ground controls no yes Is STEERING JOYSTICK NOT CALIBRATED yes present on the display screen no Continued on the next page Stop the
388. vot end of the engine pivot plate Install the bolt that was just removed into the anchor hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section A Scheduled Maintenance Procedures TABLE B PROCEDURES 4 Loosen the fuel filter water separator filter vent 11 Start the engine and inspect for leaks screw located on top of the fuel filter water Explosion and fire hazard If a fuel Seravalonnen ADANGER leak is discovered keep any a additional personnel from entering the area and do not operate the machine Repair the leak immediately Or Ri Component damage hazard l meg GY A l CAUTION Damage to the fuel injection pump Z S battery and starter motor can occur if the stater motor is used excessively to eliminate air from the fuel system Do not engage r e the starter motor for more than 30 oe Coe eee L seconds at a time Wait 120 EE EE seconds between starter motor engagements a filter head vent screw b fuel filter Component damage hazard S lift pump CAUTION Operate the engine at low idle speed for a minimum of two priming lever 5 Operate the priming lever on the fuel lift pump minutes immediately after air has until fuel free from air co
389. ween pin 3 and pin 4 of the deutsch connector LSB3EO is located on top of boom tube number 2 at the platform end of the machine 22 Start the engine and activate the function enable high RPM button and extend the boom to 76 feet 23 2 m Result The engine should stop and the boom extend function should be disabled Result If the engine does not stop and the boom continues to extend the LSB4ES switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired See Repair Section Bodily injury hazard If the boom AWARNING extends to more than 76 feet 23 2 m without stopping the engine stop immediately and retract the boom until the boom is extended to less than 75 feet 22 9 m Failure to retract the boom could result in death or serious injury 23 Using auxiliary power retract the boom until the boom is extended to less than 75 feet 22 9 m 24 Remove the wire jumper installed in step 21 and connect the harness plug to LSB3EO TABLE B PROCEDURES Cable Break Safety Switch LSB6S 25 Start the engine and activate the function enable high RPM button and retract the boom until the boom is extended to less than 2 feet 0 6 m 26 Remove the boom end cover from the pivot end of the boom 27 Remove the arm from the cable break limit switch LSB6S LSB6S is located at the end of the boom tubes at the pivot end of the boom 28 Using the arm just removed from LSB6S
390. welds 3 Check each lug nut for proper torque Tires and wheels Tire size 18 22 5 Tire ply rating 18 Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 433 9 Nm Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 4 39 First Edition First Printing Section Ae Scheduled Maintenance Procedures TABLE B PROCEDURES B 14 Check the Oil Level in the Drive Hubs Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at a drive hub plugs 2 Remove the plug located at 90 and check the oil level Result The oil level should be even with the bottom of the plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Install the plug into the drive hub When removing the drive hub plug on machines before serial number 158 replace the drive hub plug with the new O ring style drive hub plug Genie part number 75107 5 Repeat this procedure for each drive hub Drive hub oil Capacity 83 fl oz 2 5 liters Type SAE 80W 90 EP multipurpose gear oil Turntable Rotate Drive Hub The turntable rotate drive hub is located under a fixed turntable cover at the ground
391. wire Consult the Genie Industries Service Department 5 46 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 13 Is BOOM UP VALVE Check for an open or Repair or replace the eae We the FAULT present on the short in the RD CO1PBU RD CO1PBU wire display wire from pin 7 of the J4 connector at the ground controls to pin 1 of the DIN connector at the boom up valve item BD or item FD Check for an open or short in the BR VLVRET7 wire from pin 27 of the J4 connector at the ground controls to pin 2 of the DIN connector at the boom up valve Repair or replace the BR VLVRET7 wire Consult the Genie Industries Service Department Test the resistance of the boom up valve coil 0 or infinite ohms Replace the boom up valve coil If any other fault codes are on the display screen refer to the fault code chart for more information PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 47 Section 5 Troubleshooting Flow Charts First Edition First Printing CHART 13 Are there mechanical restrictions keeping the boom from raising Continued from page 5 45 Activate the function enable high RPM button and the boom up button Manually override the boom up directional valve by pushing in on the end of the valve spool fu
392. witch and pins 3 5 and 7 of the P20 connector at the circuit board good Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the platform function less than manifold and start the 3000 psi engine At the ground controls activate the function enable high RPM button and the platform level up button and check the pressure 3000 PSI or more Repair or replace the platform level valves OR repair or replace the cylinder counterbalance valve OR repair or replace the cylinder OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department Replace the toggle switch Repair or replace the internal platform wire harness Repair or replace the platform level valve item CH or item GH OR repair or replace the counterbalance valves OR repair or replace the cylinder OR the platform function manifold could have an internal fault Consult the Genie Industries Service Department 5 138 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts PE CHART 24 F Is PLATFORM LEVEL Check for an open or Replace the platform tilt Continued from the SENSOR DEGREES short in the ae circuit i OR cone the previous page SHORTED TO 0 VOLTS between pins 19 20 and Genie Industries Service OR PLATFORM LEVEL 21 of the J2 connector Department
393. wivel case or to return bad swivel to the BK wire at pin 2 of Genie Industries Service either of the P8 Department for repair connectors on the swivel not shorted Check for a short in the GR P53LS wire circuit from pin 6 of the J7 connector on the electric swivel to pin 1 of the deutsch connector at LSAX1ES to pin 3 of the J1 connector at the drive chassis controller DCON Repair short in the GR P53LS wire circuit Not shorted Check for a short in the Repair short in the BK WH P54ENG wire BK WH P54ENG wire circuit from pin 4 of the circuit J2 connector at the ground control box to pin 1 of the deutsch connector at LSB2RS to pin 1 of the deutsch connector at LSB9AS Not shorted Continued on the next page 5 14 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Check for a short in the RD S56PRV wire circuit from pin 5 of the J2 connector at the ground control box to pin 3 of the deutsch connector at LSB7DS to pin 1 of the deutsch connector at LSB3RO to pin 1 of the J8 connector at the electric swivel Repair or replace the RD S56PRV wire circuit Continued from the previous page Not shorted Check for a short in the If short is in cables of electric swivel from the electric swivel repair WH wire of pin 1 of the short If short is either of the P8 internal replace the connectors
394. x J1 connector Main Cable Harness 5 12 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts CHART 1 Check voltage at battery Repair or replace RD separator RD BATVLV BATVLV wire from 40A wire circuit breaker to battery separator Continued from the previous page Check voltage at the Repair or replace RD system battery 10 ga wire trom system battery to battery separator Check battery condition OR check altenator OR check battery cables OR replace battery OR consult Genie Industries Service Department PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 13 Section 5 Troubleshooting Flow Charts First Edition First Printing _ _ CHART 1 Check for a short in the Repair or replace the SEN WHIBK P53LS wire WHIBK P53LS wire pag circuit from pin 3 on the circuit J2 connector at the ground control box to pin 6 of the J7 connector on the electric swivel to pin 3 of the deutsch connector on LSB2RS to pin 3 of the deutsch connector at LSB9AS to pin 2 of the deutsch connector at LSB7DS not shorted Check for a short in the If the short is in the electric swivel from the cables of electric swivel GR wire at pin 6 of repair the short If the either of the P7 short is internal replace connectors to the the electric swivel and electric s
395. x or steering sensor may need to be replaced BLUE END BLUE SIDE STEER Blue end blue side steering functions Damaged circuit between blue end Peter to chart 35 to troubleshoot SENSOR VALUE TOO LOW inoperative blue side steering sensor and DCON box or steering sensor may need to be replaced BLUE END YELLOW SIDE STEER Blue end yellow side steering Open circuit between blue end yellow Refer to chart 36 to troubleshoot SENSOR SHORTED TO 0V functions inoperative side steering sensor and DCON box BLUE END YELLOW SIDE STEER Blue end yellow side steering Shorted circuit between blue end Refer to chart 36 to troubleshoot SENSOR SHORTED TO 5V functions inoperative yellow side steering sensor and DCON box Continued on next page PartNo 62401 Genie S 100 amp S 105 amp S 120 amp S 125 5 5 Section 5 Troubleshooting Flow Charts EE First Edition First Printing FAULT CODE CHART Diagnostic code displayed Condition Possible Causes Solution BLUE END YELLOW SIDE STEER Blue end yellow side steering Damaged circuit between blue end Refer to chart 36 to troubleshoot SENSOR VALUE TOO HIGH unctions inoperative yellow side steering sensor and DCON box or steering sensor may need to be replaced BLUE END YELLOW SIDE STEER Blue end yellow side steering Damaged circuit between blue end Refer to chart 36 to troubleshoot SENSOR VALUE TOO LOW unctions inope
396. xt page Press down the foot switch and activate the axle retract function Is there an audible beep yes Are there mechanical restrictions preventing the axle from retracting yes Remove or repair the mechanical restrictions Consult the Genie Industries Service Department OR the platform membrane decal may need to be replaced Check for an open or short in the GR V61AXRT wire from pin 3 of the J2 connector at the drive chassis controller to pin 1 of the Din connector at the axle extend valve coil item ES or item HS good Check for an open or short in the BR VLVRET wire from pin 1 of the J2 connecior at the drive chassis controller to pin 2 of the Din connector at the axle extend valve item ES or item HS good Check the resistance of the axle extend valve coil item ES 0 or infinite ohms Replace the valve coil 5 4 to 7 4 ohms Consult the Genie Industries Service Department OR the no platform membrane decal may need to be replaced Consult the Genie Industries Service Department bad_ Repair or replace GR V61AXRT wire bad Repair or replace BR VLVRET wire Consult the Genie Industries Service Department 5 174 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page Is SAFETY SWITCH P12
397. y and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Open the ground controls side cover and locate the tank breather filter The tank breather filter is located on top of the hydraulic tank 2 Remove the filter with an oil filter wrench 3 Apply teflon tape to the threads of the hydraulic tank filter mount 4 Install a new tank breather filter Genie part number 60559 onto the filter mount and tighten it securely by hand 5 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter Hydraulic tank breather filter Genie part number 60559 Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 10 Replace the Medium and High Pressure Hydraulic Filters Replacement of the medium and high pressure filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filters be replaced more often Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns The medium pressure filter is for the
398. y chock and lower the boom to the stowed position 10 Turn the engine off 11 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the boom Boom to platform cable harness Platform control box harness connectors Platform manifold wiring Genie S 100 amp S 105 amp S 120 amp S 125 Part No 62401 First Edition First Printing Section Ae Scheduled Maintenance Procedures B 12 Confirm the Proper Brake Configuration Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position ae disengage position s Leg a engage position TABLE B PROCEDURES B 13 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion The tires on these machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked
399. zard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Component damage hazard Damage to the fuel injection pump battery and starter motor can occur if the stater motor is used excessively to eliminate air from the fuel system Do not engage the starter motor for more than 30 seconds at a time Wait 120 seconds between starter motor engagements Component damage hazard Operate the engine at low idle speed for a minimum of two minutes immediately after air has been removed from the fuel system This will ensure that the pump is free of air and prevent any damage to the pumps by metal to metal contact If the engine does not start or runs erratically refer to the Perkins User s Handbook Perkins part number TPD 1349 Genie part number 62447 for additional information on the fuel system Part No 62401 Genie S 100 amp S 105 amp S 120 amp S 125 Section Ae Scheduled Maintenance Procedures First Edition First Printing TABLE B PROCEDURES 12 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 13 Swing the engine pivot plate in towards the machine 14 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate

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