S 100 Bef 136 S125 Bef 404

Introduction First Edition First Printing
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the Genie S-100 and
Genie S-105 Operator's Manual or the Genie S-
120 and Genie S-125 Operator's Manual before
attempting any maintenance or repair procedure.
This manual provides detailed scheduled

maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Copyright 2001 by Genie Industries

Contact Us: 62401 Rev A January 2001
First Edition, First Printing
http://www.genieindustries.com
e-mail: techsup@genieind.com "Genie" and "S" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
First Edition First Printing
INTRODUCTION
Serial Number Legend
Model: S120
Serial number: S12006-12345
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0427
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg S120 06 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 126 ft/ 38.6 m
Model Sequence
Maximum platform reach : 75ft/ 22.9 m number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Serial label
Serial number (located under cover)
(stamped on chassis)
PN - 77055
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 iii
This page intentionally left blank.
iv Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
First Edition First Printing Section 1 Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-100 & Genie S-105
Operator's Manual or the Genie S-120 & Genie
S-125 Operator's Manual will result in death or
serious injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 v
Section 1 - Safety Rules First Edition First Printing
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
Read each procedure thoroughly. This manual and placing loads. Always wear approved steel-toed
the decals on the machine, use signal words to shoes.
identify the following:
Workplace Safety
Safety alert symbolused to alert
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable
messages that follow this symbol and combustible materials like battery
to avoid possible injury or death. gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Used to indicate the presence of
an imminently hazardous situation Be sure that all tools and working areas
which, if not avoided, will result in are properly maintained and ready for
death or serious injury. use. Keep work surfaces clean and free of
Used to indicate the presence of a debris that could get into machine components and
potentially hazardous situation cause damage.
which, if not avoided, could result Be sure any forklift, overhead crane or
in death or serious injury. other lifting or supporting device is fully
With safety alert symbolused to capable of supporting and stabilizing the
indicate the presence of a weight to be lifted. Use only chains or straps that
potentially hazardous situation are in good condition and of ample capacity.
which, if not avoided, may cause Be sure that fasteners intended for one
minor or moderate injury. time use (i.e., cotter pins and self-locking
Used to indicate the presence of a nuts) are not reused. These components
potentially hazardous situation may fail if they are used a second time.
which, if not avoided, may result in
Be sure to properly dispose of old oil or
property damage.
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
vi Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One Safety Rules

General Safety Rules ..................................................................................................... iii
Section Two Specifications

Machine Specifications, S120 and S-125 Models ...................................................... 2 - 1
Performance Specifications, S120 and S-125 Models ............................................... 2 - 2
Machine Specifications, S100 and S-105 Models ...................................................... 2 - 3
Performance Specifications, S100 and S-105 Models ............................................... 2 - 5
Hydraulic Specifications ............................................................................................ 2 - 6
Perkins Engine 1004-42 Specifications ..................................................................... 2 - 7
Cummins Engine B3.9L Specifications ..................................................................... 2 - 8
Deutz Engine F4L 913 Specifications ........................................................................ 2 - 9
Hydraulic Hose and Fitting Torque Specifications ................................................... 2 - 10
Section Three Theory of Operation

Theory of Operation .................................................................................................. 3 - 1
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................. 4 - 3
A-1 Inspect the Manuals ........................................................................................ 4 - 5
A-2 Inspect the Decals and Placards ..................................................................... 4 - 5
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6
A-4 Check the Engine Oil Level ............................................................................. 4 - 6
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 vii
TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................. 4 - 7
A-6 Check the Engine Belt(s) - Cummins Models .................................................. 4 - 8
A-7 Check the Engine Cooling Fan - Liquid Cooled Models .................................... 4 - 9
A-8 Drain the Inline Fuel Filter/Water Separator ................................................... 4 - 10
A-9 Inspect the Engine Air Filter .......................................................................... 4 - 11
A-10 Check for Fuel Leaks .................................................................................... 4 - 12
A-11 Check the Hydraulic Oil Level ....................................................................... 4 - 12
A-12 Check for Hydraulic Leaks ............................................................................. 4 - 13
A-13 Check the Hydraulic Filter Condition Indicators .............................................. 4 - 13
A-14 Test the Platform and Ground Controls .......................................................... 4 - 15
A-15 Test the Auxiliary Power Operation .............................................................. 4 - 16
A-16 Test the Tilt Sensor and Alarm ...................................................................... 4 - 17
A-17 Test the Operating Envelope ......................................................................... 4 - 18
A-18 Perform 30 Day Service ................................................................................ 4 - 19
A-19 Check the Engine Fasteners - Deutz Models ................................................. 4 - 20
A-20 Check the Batteries ....................................................................................... 4 - 21
B-1 Check the Radiator - Liquid Cooled Models ................................................... 4 - 23
B-2 Check the Oil Cooler and Cooling Fins - Deutz Models .................................. 4 - 24
B-3 Check the Engine Belt(s) - Deutz and Perkins Models ................................... 4 - 25
B-4 Replace the Inline Fuel Filter/Water Separator Element ................................. 4 - 26
B-5 Replace the Air Filter ..................................................................................... 4 - 32
B-6 Inspect the Air Intake System ....................................................................... 4 - 33
B-7 Check the Exhaust System ........................................................................... 4 - 33
viii Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
TABLE OF CONTENTS

B-8 Replace the Hydraulic Tank Return Filters ..................................................... 4 - 35
B-9 Replace the Hydraulic Tank Breather Filter .................................................... 4 - 36
B10 Replace the Medium and High Pressure Hydraulic Filters .............................. 4 - 37
B-11 Inspect the Electrical Wiring .......................................................................... 4 - 38
B-12 Confirm the Proper Brake Configuration ......................................................... 4 - 39
B-13 Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 39
B-14 Check the Oil Level in the Drive Hubs ........................................................... 4 - 40
B-15 Check and Adjust the Engine RPM ............................................................... 4 - 41
B-16 Test the Key Switches .................................................................................. 4 - 44
B-17 Test the Emergency Stop Buttons ................................................................. 4 - 46
B-18 Test the Ground Control Override .................................................................. 4 - 46
B-19 Test the Safety Envelope and Circuits .......................................................... 4 - 47
B-20 Test the Platform Self-leveling ...................................................................... 4 - 53
B-21 Test the Horn ................................................................................................ 4 - 54
B-22 Test the Foot Switch ..................................................................................... 4 - 54
B-23 Test the Engine Idle Select ........................................................................... 4 - 55
B-24 Test the Drive Enable System ....................................................................... 4 - 56
B-25 Test the Drive Brakes .................................................................................... 4 - 57
B-26 Test the Drive Speed - Stowed Position ........................................................ 4 - 58
B-27 Test the Drive Speed - Raised or Extended Position ..................................... 4 - 58
B-28 Test the Alarm Package (if equipped) ............................................................ 4 - 60
B-29 Replace the Engine Oil and Filter - Cummins Models .................................... 4 - 61
B-30 Inspect the Fuel Tank Cap Venting System .................................................. 4 - 62
B-31 Perform Hydraulic Oil Analysis ...................................................................... 4 - 63
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 ix
TABLE OF CONTENTS

C-1 Check the Engine Valve Clearances - Deutz Models ..................................... 4 - 64
C-2 Clean the Fuel Pump Strainer - Perkins Models ............................................ 4 - 64
C-3 Replace the Fuel Filter Element - Perkins and Cummins Models ................... 4 - 66
C-4 Replace the Engine Oil and Filter - Deutz and Perkins Models ...................... 4 - 68
C-5 Check the Specific Gravity of the Coolant - Liquid Cooled Models ................. 4 - 70
C-6 Inspect the Boom Extend/Retract Cables ...................................................... 4 - 71
D-1 Check the Boom Wear Pads ......................................................................... 4 - 73
D-2 Check the Extendable Axle Wear Pads ......................................................... 4 - 74
D-3 Check the Free-wheel Configuration .............................................................. 4 - 75
D-4 Check the Turntable Rotation Bearing Bolts .................................................. 4 - 76
D-5 Check the Turntable Rotation Gear Backlash ................................................ 4 - 77
D-6 Grease the Turntable Rotation Bearing and Rotate Gear ................................ 4 - 78
D-7 Replace the Drive Hub Oil ............................................................................. 4 - 78
D-8 Inspect the Engine Belt(s) - Cummin Models ................................................. 4 - 82
D-9 Replace the Fuel Filter/Water Separator - Deutz Models ................................ 4 - 84
D-10 Check the Engine Valve Clearances - Perkins and Cummins Models ............ 4 - 85
E-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 86
E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models ................ 4 - 89
E-3 Change the Fuel Hoses ................................................................................. 4 - 90
E-4 Check the Engine Valve Clearances - Cummins Models ............................... 4 - 92
E-5 Check the Fuel Injectors - Deutz Models ....................................................... 4 - 92
E-6 Replace the Boom Extend/Retract Cables (REV B)......................................... 4 - 93
x Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1
Fault Code Chart ....................................................................................................... 5 - 3
1 Display Not Active ......................................................................................... 5 - 11
2 Engine Will Not Crank Over ........................................................................... 5 - 16
3 Engine Cranks Over But Will Not Start .......................................................... 5 - 22
4 Engine Starts and Runs for 3 Seconds and Dies ........................................... 5 - 25
5 Engine High Idle Inoperative .......................................................................... 5 - 28
6 Engine Low Idle Inoperative ........................................................................... 5 - 30
7 All Functions Inoperative, Engine Starts and Runs ........................................ 5 - 31
8 Boom Up/Down, Extend/Retract, Turntable Rotate and
Platform Functions Inoperative,
Drive, Steer and Axle Extend/Retract Functions Operational ......................... 5 - 32
9 All Platform, Steering and Axle Functions Inoperative,
All Other Functions Operational ..................................................................... 5 - 33
10 Ground Controls Inoperative, Platform Controls Operate Normally ................. 5 - 38
11 Platform Controls Inoperative, Ground Controls Operate Normally ................. 5 - 40
12 Boom Angle Switch Fault .............................................................................. 5 - 42
13 Boom Up Function Inoperative ...................................................................... 5 - 45
14 Boom Down Function Inoperative .................................................................. 5 - 49
15 Boom Length Switch Fault ............................................................................. 5 - 54
16 Boom Extend Function Inoperative ................................................................ 5 - 58
17 Boom Retract Function Inoperative ............................................................... 5 - 67
18 Boom Envelope Operational Switch Failure, S-100 and S-105 Models ........... 5 - 72
19 Boom Envelope Operational Switch Failure, S-120 and S-125 Models ........... 5 - 77
20 Boom Envelope Safety Switch Failure, S-100 and S-105 Models .................. 5 - 86
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 xi
TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued

21 Boom Envelope Safety Switch Failure, S-120 and S-125 Models ................. 5 - 104
22 Turntable Rotate Clockwise Function Inoperative ......................................... 5 - 128
23 Turntable Rotate Counter Clockwise Function Inoperative ............................ 5 - 133
24 Platform Level Function Inoperative ............................................................. 5 - 138
25 Platform Level Up Function Inoperative ........................................................ 5 - 140
26 Platform Level Down Function Inoperative .................................................... 5 - 144
27 Platform Level Safety Fault .......................................................................... 5 - 148
28 Platform Rotate Clockwise Function Inoperative ........................................... 5 - 151
29 Platform Rotate Counter Clockwise Function Inoperative .............................. 5 - 154
30 Jib Up Function Inoperative .......................................................................... 5 - 157
31 Jib Down Function Inoperative ...................................................................... 5 - 160
32 Auxiliariy Functions Inoperative .................................................................... 5 - 163
33 Axle Extend Function Inoperative ................................................................. 5 - 168
34 Axle Retract Function Inoperative ................................................................. 5 - 174
35 Blue End Blue Side Steering Function Inoperative ........................................ 5 - 178
36 Blue End Yellow Side Steering Function Inoperative .................................... 5 - 181
37 Yellow End Blue Side Steering Function Inoperative .................................... 5 - 184
38 Yellow End Yellow Side Steering Function Inoperative ................................. 5 - 187
39 Drive Forward Function Inoperative .............................................................. 5 - 190
40 Drive Reverse Function Inoperative .............................................................. 5 - 196
41 Drive Enable Fault ........................................................................................ 5 - 202
42 Drive Mode Select Inoperative ...................................................................... 5 - 204
43 Engine Start Assist Inoperative .................................................................... 5 - 210
44 Auxiliary Drive Function Inoperative ............................................................. 5 - 213
xii Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
TABLE OF CONTENTS
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Wire Circuit Legend ................................................................................................... 6 - 4
Limit Switches .......................................................................................................... 6 - 8
Relay Layout ........................................................................................................... 6 - 10
Drive Chassis Controller Pin Legend ....................................................................... 6 - 11
Platform Controller Pin Legend ................................................................................ 6 - 12
Turntable Controller Pin Legend .............................................................................. 6 - 13
Electrical Schematic Legend -
Drive Chassis (DCON) and Platform Controls (PCON) ............................................ 6 - 14
Electrical Schematic Legend - Ground Controls (TCON) ......................................... 6 - 15
Electric Symbols Legend ........................................................................................ 6 - 16
Electrical Schematic -
Drive Chassis and Platform Controls (Sheet 1 of 2) ................... located at end of manual
Ground Controls (Sheet 2 of 2) ................................................... located at end of manual
Limit Switch Harness Schematic, S-100 & S-105 Models ....................................... 6 - 17
Limit Switch Harness Schematic, S-120 & S-125 Models ....................................... 6 - 18
Safety Circuit Schematic ........................................................................................ 6 - 19
Electrical Schematic - Generators ........................................................................... 6 - 20
Electrical Schematic - Deutz Models ...................................................................... 6 - 21
Electrical Schematic - Cummins and Perkins Models ............................................. 6 - 22
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 xiii
TABLE OF CONTENTS
Section Six Schematics, continued

Hydraulic Symbols Legend ...................................................................................... 6 - 24
Hydraulic Schematic, S-100 Models with 2 Wheel Steer ......................................... 6 - 25
Hydraulic Schematic, S-120 Models ....................................................................... 6 - 33
Hydraulic Schematic, S-125 Models ....................................................................... 6 - 35
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Display Module ......................................................................................................... 7 - 2
Platform Controls
1-1 Circuit Boards .................................................................................................. 7 - 5
1-2 Membrane Decal ............................................................................................. 7 - 6
1-3 Joystick Controllers ......................................................................................... 7 - 7
1-4 Foot Switch ................................................................................................... 7 - 14
1-5 Toggle Switches ............................................................................................ 7 - 15
Platform Components
2-1 Platform ........................................................................................................ 7 - 16
2-2 Platform Leveling Cylinder ............................................................................. 7 - 16
2-3 Platform Rotator ............................................................................................ 7 - 18
2-4 Platform Overload System ............................................................................ 7 - 21
xiv Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
TABLE OF CONTENTS
Section Seven Repair Procedures, continued

Jib Boom Components, S-105 and S-125 Models
3-1 Jib Boom, S-105 and S-125 Models .............................................................. 7 - 24
3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models ........................................... 7 - 26
Boom Components
4-1 Cable Track ................................................................................................... 7 - 29
4-2 Boom ............................................................................................................ 7 - 32
4-3 Boom Lift Cylinder ......................................................................................... 7 - 43
4-4 Extension Cylinders ...................................................................................... 7 - 45
4-5 Boom Extend/Retract Cables ........................................................................ 7 - 49
Turntable Covers
5-1 Turntable Covers ........................................................................................... 7 - 53
Engines
6-1 RPM Adjustment ........................................................................................... 7 - 55
6-2 Flex Plate ...................................................................................................... 7 - 55
6-3 Oil Pressure and Coolant Temperature Sending Units,
Cummins and Perkins Models ....................................................................... 7 - 57
6-4 Oil Pressure and Temperature Sending Units, Deutz Models ......................... 7 - 57
Ground Controls
7-1 Circuit Boards ................................................................................................ 7 - 58
7-2 Membrane Decal ........................................................................................... 7 - 59
7-3 Control Relays ............................................................................................... 7 - 60
Limit Switches
8-1 Limit Switches ............................................................................................... 7 - 63
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 xv
TABLE OF CONTENTS

Hydraulic Pumps
9-1 Function Pumps ............................................................................................ 7 - 70
9-2 Drive Pump ................................................................................................... 7 - 71
9-3 Auxiliary Pump .............................................................................................. 7 - 74
9-4 Power Relay .................................................................................................. 7 - 75
Manifolds
10-1 Function Manifold Components, S-100 and S-105 Models ............................. 7 - 76
10-2 Valve Adjustments - Function Manifold, S-100 and S-105 Models ................. 7 - 80
10-3 Proportional Valves - Function Manifold ........................................................ 7 - 81
10-4 Function Manifold Components, S-120 and S-125 Models ............................. 7 - 82
10-5 Valve Adjustments - Function Manifold, S-120 and S-125 Models ................. 7 - 86
10-6 Proportional Valves - Function Manifold ........................................................ 7 - 87
10-7 Distribution Manifold Components ................................................................. 7 - 88
10-8 Valve Adjustments - Distribution Manifold ..................................................... 7 - 90
10-9 Platform Manifold Components, S-100 and S-120 Models ............................. 7 - 92
10-10 Platform Manifold Components, S-105 and S-125 Models ............................. 7 - 94
10-11 Proportional Valves - Platform Manifolds ....................................................... 7 - 96
10-12 Platform Rotate Counterbalance Valve Manifold ............................................ 7 - 96
10-13 Turntable Rotation Manifold Components ...................................................... 7 - 97
10-14 Steer and Axle Extend/Retract Manifold Components - View 1 ...................... 7 - 98
10-15 Steer and Axle Extend/Retract Manifold Components - View 2 ..................... 7 - 102
10-16 Valve Adjustments - Steer and Axle Extend/Retract Manifold ...................... 7 - 106
10-17 Drive Manifold Components .......................................................................... 7 - 108
10-18 Valve Adjustments - Drive Manifold .............................................................. 7 - 112
10-19 Valve Coils ................................................................................................... 7 - 112
xvi Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
TABLE OF CONTENTS

. Fuel and Hydraulic Tanks
11-1 Fuel Tank ..................................................................................................... 7 - 115
11-2 Hydraulic Tank ............................................................................................. 7 - 116
Turntable Rotation Components
12-1 Turntable Rotation Hydraulic Motor and Drive Hub ........................................ 7 - 118
Axle Components
13-1 Steer Sensors .............................................................................................. 7 - 122
13-2 Yoke and Hub ............................................................................................... 7 - 124
13-3 Drive Motor ................................................................................................... 7 - 126
13-4 Drive Hub ..................................................................................................... 7 - 127
13-5 Steering Cylinders ........................................................................................ 7 - 128
13-6 Extendable Axles ......................................................................................... 7 - 129
Appendix Electrical Schematic , Genie part number 62304

Drive Chassis and Platform Control ............................................................... Sheet 1 of 2
Ground Controls ............................................................................................ Sheet 2 of 2
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 xvii
xviii Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
First Edition First Printing Section 2 Specifications
Specifications
Machine Specifications, Turning radius, inside, 16 ft 4 in 16 ft 4 in
S-120 and S-125 Models axles retracted 4.9 m 4.9 m
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 12.17 m axles extended 3.1 m 3.1 m
Length, stowed 42 ft 8 in 46 ft Turntable rotation (degrees) 360 continuous

13 m 14 m
Platform rotation 160
Width, axles retracted 8 ft 6 in 8 ft 6 in
259 cm 259 cm Maximum allowable 150 lbs
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 lbs
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 lbs 44,640 lbs Platform dimensions

20,112 kg 20,248 kg
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 125 ft 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
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 lb 500 lb 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 ft 4 in 24 ft 4 in 433.9 Nm
axles retracted 7.4 m 7.4 m
Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 2-1
Section 2 Specifications First Edition First Printing
SPECIFICATIONS
Fluid capacities Performance Specifications,

Hydraulic tank capacity 55 gallons S-120 and S-125 Models
208 liters
Drive speeds, maximum
Hydraulic system capacity 80 gallons
(including tank) 303 liters Drive speed, stowed 3 mph 4.8 km/h
40 ft/9.1 sec 12.2 m/9.1 sec
Fuel tank capacity 40 gallons
151 liters Drive speed, 0.7 mph 1.1 km/h
raised or extended 40 ft/40 sec 12.2 m/40 sec
Airborne noise emissions 80 dB
Maximum sound level at normal operating workstations Drive speed, 0.4 mph 0.6 km/h
(A-weighted) fully extended 40 ft/70 sec 12.2 m/70 sec
Gradeability (boom stowed) 40%

Continuous improvement of our products is a
Genie policy. Product specifications are subject to Boom function speeds, maximum
change without notice. from platform controls
Jib boom up (S-125 models) 28 to 32 seconds
Jib boom down (S-125 models) 28 to 32 seconds
Boom up
Boom fully retracted 80 to 88 seconds

Boom extended to >4 ft (>1.2 m) 100 to 110 seconds
(time between fully lowered and
a fully raised position)
(time between 53 envelope
limit and a fully raised position)
Boom down

(time between fully raised and
a fully lowered position)
the 50 envelope limit)
2-2 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401
SPECIFICATIONS
Boom extend Machine Specifications,

horizontal, 0 to 80 ft (0 to 24.4 m)
vertical, 0 to 120 ft (0 to 36.6 m)
75 to 83 seconds
170 to 190 seconds
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
vertical, 120 ft to 0 (36.6 m to 0) 170 to 190 seconds Length, transport position 39 ft 11 in 39 ft 11 in
12.17 m 12.17 m
Turntable rotate, 360
boom horizontal and Length, stowed 42 ft 8 in 46 ft
fully retracted 170 to 190 seconds 13 m 14 m
Turntable rotate, 360 Width, axles retracted 8 ft 6 in 8 ft 6 in

boom horizontal and 259 cm 259 cm
extended >0 ft (>0 m) 285 to 315 seconds Width, axles extended 11 ft 6 in 11 ft 6 in
Turntable rotate, 360 351 cm 351 cm
boom horizontal and Height, stowed maximum 10 ft 1 in 10 ft 1 in
extended >80 ft (>24.4 m) 490 to 540 seconds 308 cm 308 cm
Platform rotate, 160 18 to 22 seconds Weight 39,700 lbs 40,000 lbs
18,007 kg 18,143 kg
Ground clearance 151/2 in 151/2 in

39 cm 39 cm
Operational dimensions
Platform height, maximum 100 ft 105 ft

30.5 m 32 m
Working height, maximum 106 ft 111 ft

32.3 m 33.8 m
Horizontal reach maximum 75 ft 80 ft

22.9 m 24.4 m
Maximum load capacity 750 lb 500 lb

340 kg 227 kg
Turntable tailswing, 66 in 66 in
axles retracted 168 cm 168 cm
Turntable tailswing 48 in 48 in
axles extended 122 cm 122 cm
Wheelbase 12 ft 12 ft
366 cm 366 cm
Turning radius, outside, 24 ft 4 in 24 ft 4 in

Turning radius, inside, 16 ft 4 in 16 ft 4 in

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 3.1 m 3.1 m
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 lbs
side force (ANSI and CSA) 667 N Airborne noise emissions 80 dB
Maximum sound level at normal operating workstations
Maximum allowable 90 lbs (A-weighted)
side force (CE) 400 N
Continuous improvement of our products is a
Controls 12V DC proportional Genie policy. Product specifications are subject to
change without notice.
Platform dimensions
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 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
SPECIFICATIONS
Performance Specifications, Boom extend, boom fully raised

S-100 and S-105 Models 0 to 100 ft (0 to 30.5 m) 120 to 140 seconds
Boom retract, boom fully raised

Drive speeds, maximum 100 ft to 0 (30.5 m to 0) 120 to 140 seconds
Drive speed, stowed 3 mph 4.8 km/h Turntable rotate, 360

40 ft/9.1 sec 12.2 m/9.1 sec boom horizontal and
fully retracted 170 to 190 seconds
Drive speed, 0.7 mph 1.1 km/h
raised or extended 40 ft/40 sec 12.2 m/40 sec Turntable rotate, 360
Drive speed, 0.4 mph 0.6 km/h boom horizontal and
fully extended 40 ft/70 sec 12.2 m/70 sec extended >0 ft (>0 m) 285 to 315 seconds
Gradeability (boom stowed) 42% Turntable rotate, 360

boom fully raised and
Boom function speeds, maximum extended >80 ft (>24.4 m) 490 to 540 seconds
from platform controls
Platform rotate, 160 18 to 22 seconds
Jib boom up (S-105 models) 28 to 32 seconds
Jib boom down (S-105 models) 28 to 32 seconds
Boom up

(time between fully lowered and
a fully raised position)
Boom down

a fully lowered position)
SPECIFICATIONS
Hydraulic Specifications Function pump
Hydraulic fluid Dexron equivalent Type: two-section gear pump
Drive pump Displacement (Pump 1) 1.75 cu in

28.7 cc
Type: bi-directional, variable displacement piston pump
Displacement @ 2350 rpm (Pump 1) 17.8 gpm
Displacement @ 2350 rpm 28 gpm 67.4 L/min
106 L/min
Displacement (Pump 2) 1 cu in
Maximum drive pressure 4250 psi 16.4 cc
293 bar
Displacement @ 2350 rpm (Pump 2) 10.2 gpm
Charge pump 38.5 L/min
Type: gear Auxiliary pump
Displacement @ 2350 rpm 5.2 gpm Type: two section gear pump
19.7 L/min
Displacement (Section 1) 0.159 cu in
Charge pump pressure 290 psi 2.61 cc
20 bar
Displacement @ 2687 rpm (Section 1) 1.85 gpm
Function manifold 7 L/min
Function relief 2600 psi Displacement (Section 2) 0.051 cu in

valve pressure 179.3 bar 0.84 cc
Boom extend relief 1800 psi Displacement @ 2687 rpm (Section 2) 0.59 gpm
valve pressure 124.1 bar 2.2 L/min
Four wheel steer and axle extend/retract manifold Auxiliary pump relief pressure
Section 1 2500 psi 172.4 bar
Steer/axle extend 3 gpm Section 2 3000 psi 206.8 bar
flow regulator 11.4 L/min
Hydraulic filters
Drive manifold
High pressure filter B3-200
Brake relief pressure 250 psi
17.2 bar High pressure filter 100 psi
bypass pressure 6.9 bar
Drive motors
Medium pressure filter B3-200
Displacement 0.73 to 2.75 cu in
per revolution, variable 12 cc to 45 cc Medium pressure filter 87 psi
bypass pressure 6 bar
Hydraulic tank circuit 10 micron with 25 psi

return line filter (1.7 bar) bypass
Drive motor case drain filter 10 micron
SPECIFICATIONS
Perkins Engine 1004-42 Injection system
Displacement 258 cu in Injection pump make Zexel

4.23 liters Injector opening pressure 2204 psi
Number of cylinders 4 152 bar
Bore & stroke 4.06 x 5 inches Fuel requirement

103.1 x 127 mm Summer grade diesel number 2-D
Horsepower 81 @ 2200 rpm Winter grade At operating temperatures below
32F (0C), use a special winter fuel.
Firing order 1-3-4-2
Alternator output 55A, 12V
Compression ratio 18.5:1
Battery - System
Compression pressure
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
0.20 mm AH rating 190AH
Cold cranking ampere 1020A
Exhaust 0.018 in Reserve capacity @ 25A rate 325 minutes
0.45 mm
Cooling system
Lubrication system
Engine capacity 9.5 quarts
Oil pressure 51 psi 9 liters
3.45 bar
System capacity 20 quarts
Oil capacity 8.9 quarts 18.9 liters
(including filter) 8.4 liters
Fan belt deflection 3 /8
to 1/2 inch
Oil viscosity requirements 9 to 12 mm
below 32F / 0C 0W
-13F to 68F / -25C to 20C 5W-20
10F to 104F / -12C to 40C 10W-30
14F to 122F / -10C to 50C 15W-40
above 23F / -5C 20W-50
Engine oil should have properties of API classification

CF4 grade OR ACEA classification E3.
SPECIFICATIONS
Cummins Engine B3.9L Injection system
Displacement 238 cu in Injection pump make Bosch

3.9 liters Injection pump pressure 5500 psi
Number of cylinders 4 379.2 bar
Bore and stroke 4.02 x 4.72 inches Injector opening pressure 3480 psi
102 x 120 mm 240 bar
Horsepower 75 @ 2200 rpm Fuel requirement diesel number 2-D
Firing order 1-3-4-2 Alternator output 63A, 12V
Compression ratio 16.5:1 Battery - System
Compression pressure Type 12V, Group 27TM

pressure (psi or bar) of the lowest cylinder must be at Quantity 1
least 75% of the highest cylinder. AH rating 109AH
Low idle - no load 1300 rpm Reserve capacity @ 25A rate 160 minutes
High idle - no load 2350 rpm Battery - Engine starting
Valve clearance, cold Type 12V, Group 4D

Quantity 1
Intake 0.010 in AH rating 190AH
0.254 mm Cold cranking ampere 1020A
Exhaust 0.020 in
0.508 mm Cooling system
Lubrication system Engine capacity 8.8 quarts
8.3 liters
Oil pressure 50 psi
3.45 bar System capacity 20 quarts
18.9 liters
Oil capacity 9.5 quarts
(including filter) 9 liters
Oil viscosity requirements
below 68F / 20C 5W-30
-10 to 68F / -23 to 20C 10W-30
above 15F / -9C 15W-40
Use oils meeting API classification CE (labeled CE/SG).
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 3626 psi
102 x 125 mm 250 bar
Horsepower 77 @ 2200 rpm Fuel requirement diesel number 2-D
Firing order 1-3-4-2 Alternator output 55A, 12V
Compression ratio 18:1 Battery - System
Compression pressure Type 12V, Group 27TM

pressure (psi or bar) of the lowest cylinder must be at Quantity 1
least 75% of the highest cylinder. AH rating 109AH
Low idle - no load 1300 rpm Reserve capacity @ 25A rate 160 minutes
High idle - no load 2350 rpm Battery - Engine starting
Valve clearance, cold Type 12V, Group 4D

Quantity 1
Intake 0.006 in AH rating 190AH
0.15 mm Cold cranking ampere 1020A
Exhaust 0.006 in
0.15 mm Fan belt deflection 3 /8
to 1/2 inch
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 60F / 15.5C (synthetic) 5W-30
-10F to 90F / -23C to 32C 10W-40
above -4F / -34C 15W-40

CC/SE or CC/SF grades OR ACEA classification E1-96.
SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok O-ring face seal fittings and hose ends. Machines that
utilize Parker Seal-Lok O-ring face seal hoses and fittings require that the fittings and hose ends be
torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port - tube fitting Seal-Lok - hose end
SAE Dash Installing SAE Dash
Size into... ft. lbs. Nm Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1
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
4 Position the tube and nut squarely on the face
hose end has been tightened beyond finger
seal end of the fitting and tighten the nut finger
tight.
tight.
The O-rings used in the Parker
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 & S-105 & S-120 & S-125 Part No. 62401
First Edition First Printing Section 3 Theory of Operation
Theory of Operation
Power Source The boom lift cylinder, boom extend cylinders,
platform leveling slave cylinder, platform rotator
The Genie S-100, S-105, S-120 and S-125 are and jib boom cylinder (S-105 and S-125 models)
powered by one of three diesel engines: incorporate counterbalance valves to prevent
the Cummins B3.9L, the Deutz F4L 913 and the movement in the event of a hydraulic line failure.
Perkins 1004-42.
Auxiliary power is supplied by a hydraulic pump A regeneration circuit is used to increase the
powered by a 12V battery. performance of the primary boom extension
function. This circuit transfers hydraulic fluid from
Hydraulic System one end of the primary cylinder into the other end
when the cylinder is extending or retracting.
All machine functions are performed by the
hydraulic system. The hydraulic system can be The auxiliary pump is a two-section gear pump.
divided into two groups: Boom and Steer/Axle One section is rated at 1.85 gpm (7 L/min) and the
functions and Drive functions. other is rated at 0.59 gpm (2.2 L/min).
The 1.7 gpm (7 L/min) section is supplied with a
Boom and Steer/Axle functions are powered by 2500 psi (172.4 bar) relief valve and the 0.59 gpm
two-section gear pumps, rated at 17 gpm (64.4 L/ (2.2 L/min) section is supplied with a 3000 psi
min) and 10 gpm (37.9 L/min). When the engine is (206.8 bar) relief valve.
running, these pumps supply hydraulic fluid under
pressure to function manifolds, where the Electrical System
directional and flow control valves are located. To
protect from over-pressurization of the systems, Two separate 12V batteries are used for this
each manifold is provided with a pressure relief system. The larger, Group 4D, battery is used to
valve. The Steer and Axle extend/retract manifold start the engine and power the auxiliary pump. The
relief valve is set at 3000 psi (206.8 bar); the smaller, Group 31, battery is used to power the
Function manifold relief valve is set at 2600 psi three Electronic Control Modules (ECM's) which
(179.3 bar); the Platform manifold relief valve is manage boom functions and engine controls. The
located in the Distribution manifold and is set at batteries are charged through a common engine
3000 psi (206.8 bar). driven alternator. A battery separator is used to
charge the smaller battery before charging the
Drive functions are powered by a bi-directional, larger battery. The control system is protected by
variable displacement piston pump rated at 28 gpm two circuit breakers that may be manually reset.
(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.
Section 3 Theory of Operation First Edition First Printing
THEORY OF OPERATION
Service Bypass/Recovery A series of proximity switches and mechanical limit

switches provide information to the controllers.
Key Switch These proximity and mechanical switches maintain
The Service Bypass/Recovery key switch is only to and define the safe operating parameters of the
be used by properly trained service personnel. machine. In addition, there is a back-up safety
system using mechanical limit switches which will
When the Service Bypass/Recovery key switch is cut power to selected portions of the controllers
turned to the service bypass position, the boom should the operational system fail to operate
can be raised while the axles are retracted. This properly.
feature of the machine is especially helpful for
storage purposes or when loading the machine for The ground controls (TCON) have membrane
transport. When the boom is raised with the axles operated switches. They are non-tactile touch
retracted, the boom cannot be rotated past either switches for greater durability. When one button is
circle-end wheel. pressed there is an audible beep indicating
operation. In addition, there is a display on the
When the Service Bypass/Recovery key switch is ground control box that is used to show fault
turned and held to the recovery position, the codes, engine condition, machine status and
auxiliary power unit will turn on and fully retract the setup, and the display language selected. Boom
boom, and then lower the boom to a stowed speeds, turntable rotation and ramp rates are
position. This feature of the machine is especially adjustable. Also, various options and operating
helpful if the operator in the platform cannot lower limitations can be programmed. For example, the
the boom, if the platform controls become boom extension can be limited to 80 ft (24.4 m) or
inoperative or for returning the machine to a safe 100 ft (30.5 m).
position when the safety switches have been
tripped. The platform controls (PCON) has three joystick
controllers for operational control. Drive and steer
Machine Controls functions are controlled through one dual-axis
joystick, boom up/down and turntable rotate
Three ECMs manage the boom functions. They functions are controlled through another dual-axis
are located at the turntable (ground controls or joystick, and the boom extend/retract functions are
TCON), the platform (platform controls or PCON) controlled through a single axis joystick. Standard
and the drive chassis (drive chassis controller or toggle switches are used to control the platform
DCON). Communication between the controllers is level up/down, platform rotate and jib boom up/
maintained via a high speed data bus (CAN bus). down functions (S-105 and S-125 models).
For example, steering inputs from PCON are sent Membrane type switches are used to select the
to DCON via the high speed data bus using various steering and operating modes.
multiplexed signals.
First Edition First Printing Section 3 Theory of Operation
THEORY OF OPERATION
The drive chassis controller (DCON) has no

operator accessible controls. The various steering
controls, axle status, brake and motor speed is
managed by this controller. There are status LED's
on this module to indicate power, data link
communications, system fault and sensor power.
Platform leveling is accomplished with
electrohydraulic controls. An angle sensor is
mounted on the platform rotator which senses the
level of the platform. This signal is processed by
PCON and sent to TCON using the data bus. The
signal from the tilt sensor on the turntable is
compared to the PCON signal and adjustments are
made to level the platform.
For safety, machine drive speed is reduced relative

to the steer angle of the wheels and boom length.
Steering is accomplished using hydraulic cylinders

at each wheel. Correct steering geometry is
maintained through the use of four steering
sensors, one at each wheel. Steering angles are
sent from the primary steering sensor to DCON
and the appropriate adjustments are made to the
other three wheels to correspond with the steer
mode selected. If the machine is equipped with
four wheel steering, there are four steering modes
available: 2 wheel front steer, 2 wheel rear steer, 4
wheel coordinated steer and crab steer. Having
independent control over each wheel allows the
machine to determine the correct wheel geometry
in each steering mode.
Washing electronic components is
not suggested. Instead, use low
pressure compressed air to
remove debris from these
components.
Section 3 Theory of Operation First Edition First Printing
First Edition First Printing Section 4 Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbolused to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
Redused to indicate the
annually and every 2 years as specified on the
presence of an imminently
Maintenance Inspection Report.
hazardous situation which, if not
Failure to perform each procedure avoided, will result in death or
as presented and scheduled could serious injury.
result in death, serious injury or
Orangeused to indicate the
substantial damage.
presence of a potentially
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
Repair any machine damage or malfunction
before operating the machine. Yellow with safety alert symbol
used to indicate the presence of a
Keep records on all inspections for three years. potentially hazardous situation
which, if not avoided, may cause
Machines that have been out of service for a
minor or moderate injury.
period longer than 3 months must complete the
quarterly inspection. Yellow without safety alert
symbolused to indicate the
Unless otherwise specified, perform each
presence of a potentially
maintenance procedure with the machine in the hazardous situation which, if not
following configuration: avoided, may result in property
Machine parked on a flat, level surface damage.
Boom in stowed position Greenused to indicate operation
Turntable rotated with the boom between or maintenance information.
the circle-end (yellow arrow) wheels
Indicates that a specific result is expected after
Turntable secured with the turntable rotation performing a series of steps.
lock
Key switch in the OFF position with the
key removed
Wheels chocked
Section 4 Scheduled Maintenance Procedures First Edition First Printing
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Maintenance Schedule

The following symbols have been There are five types of maintenance inspections
used in this manual to help that must be performed according to a schedule
communicate the intent of the daily, quarterly, six months, annual, and two year.
instructions. When one or more of The Scheduled Maintenance Procedures Section
the symbols appear at the and the Maintenance Inspection Report have been
beginning of a maintenance divided into five subsectionsA, B, C, D and E.
procedure, it conveys the meaning Use the following chart to determine which
below. group(s) of procedures are required to perform a
scheduled inspection.
Indicates that tools will be required to Inspection Table or Checklist

perform this procedure.
Daily or every 8 hours A
Indicates that new parts will be required Quarterly or every 250 hours A+B
to perform this procedure.
Semi-annually or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D

Indicates that a cold engine will be
required to perform this procedure. Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report

Indicates that a warm engine will be
required to perform this procedure. The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
Indicates that dealer service will be
to use for each inspection. Store completed forms
required to perform this procedure.
for three years.
Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Manuals B-1 Check radiator -
Serial number Liquid cooled models
A-2 Decals and placards
B-2 Oil cooler and fins -
Date A-3 Damage and loose or
Deutz models
missing parts
Hour meter B-3 Engine belt(s) - Deutz
A-4 Engine oil level
and Perkins models
Machine owner A-5 Engine coolant level -
B-4 Replace inline fuel
Liquid cooled models
filter/water separator
Inspected by (print) A-6 Engine belt(s) -
B-5 Replace air filter
Cummins models
Inspector signature A-7 Engine cooling fan - B-6 Air intake system
Liquid cooled models B-7 Exhaust system
Inspector title A-8 Drain inline fuel B-8 Hydraulic tank return
filter/water separator filters
Inspector company
A-9 Inspect air filter B-9 Hydraulic tank
A-10 Fuel leaks breather filter
Instructions
Make copies of this report to use for A-11 Hydraulic oil level B-10 Medium and high
each inspection. pressure filters
A-12 Hydraulic leaks
Select the appropriate checklist(s) for B-11 Electrical wiring
A-13 Hydraulic filter
the type of inspection to be condition indicators B-12 Brake configuration
performed. B-13 Tires and wheels
A-14 Platform and
Daily or 8 hour ground controls B-14 Drive hub oil level
Inspection: A A-15 Auxiliary power B-15 Engine RPM
Quarterly or 250 hour A-16 Tilt sensor and alarm B-16 Key switches
Inspection: A+B B-17 Emergency Stop
A-17 Operating envelope
Semi-annual or 500 hour B-18 Ground control override
Inspection: A+B+C Perform after 40 hours:
A-18 Perform 30 day service B-19 Safety envelope
Annual or 1000 hour B-20 Platform self leveling
Inspection: A+B+C+D A-19 Engine fasteners -
Deutz models B-21 Horn
2 Year or 2000 hour
Perform every 125 hours: B-22 Foot switch
Inspection: A+B+C+D+E
A-20 Batteries B-23 Engine idle select
Place a check in the appropriate box B-24 Drive enable system
after each inspection procedure is
B-25 Drive brakes
completed.
Use the step-by-step procedures in B-26 Drive speed - stowed
this section to learn how to perform B-27 Drive speed - raised or
these inspections. extended
If any inspection receives an N, tag B-28 Alarm package
and remove the machine from B-29 Engine oil and filter -
service, repair and re-inspect it. After Cummins models
repair, place a check in the R box.
B-30 Fuel tank cap vent
Legend B-31 Hydraulic oil analysis
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
MAINTENANCE INSPECTION REPORT
Model Checklist C Y N R Checklist E Y N R

Refer to Table C Refer to Table E
Serial number C-1 Valves - Deutz models E-1 Hydraulic oil
C-2 Fuel pump strainer - E-2 Engine coolant-
Date
Perkins models Liquid cooled models
Hour meter C-3 Fuel filter element - E-3 Fuel hoses
Perkins and Cummins E-4 Valves -
Machine owner C-4 Engine oil and filter - Cummins models
Deutz and Perkins Perform every 3000 hours:
Inspected by (print) C-5 Check the coolant - E-5 Fuel injectors-
Liquid cooled models Deutz models
Inspector signature C-6 Boom extend/retract Perform every 7 years:
cables
E-6 Replace the
Inspector title
boom extend/retract
Checklist D Y N R cables
Inspector company
Refer to Table D
Instructions D-1 Boom wear pads
Make copies of this report to use for D-2 Axle wear pads
each inspection. D-3 Free-wheel configuration
Select the appropriate checklist(s) for D-4 Turntable bearing bolts
the type of inspection to be D-5 Turntable gear backlash
performed.
D-6 Grease rotation bearing
Daily or 8 hour D-7 Drive hub oil
Inspection: A D-8 Engine Belt(s) -
Quarterly or 250 hour Cummins models
Inspection: A+B D-9 Fuel filter - Deutz models
Semi-annual or 500 hour D-10 Valves -
Inspection: A+B+C Cummins and Perkins
Annual or 1000 hour
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E
Place a check in the appropriate box

after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an N, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Table A Procedures
A-1 A-2
Inspect the Manuals Inspect the
Maintaining the operators and safety manuals in Decals and Placards
good condition is essential to safe machine Maintaining all of the safety and instructional
operation. Manuals are included with each decals and placards in good condition is
machine and should be stored in the container mandatory for safe machine operation. Decals
provided in the platform. An illegible or missing alert operators and personnel to the many possible
manual will not provide safety and operational hazards associated with using this machine. They
information necessary for a safe operating also provide users with operation and maintenance
condition. information. An illegible decal will fail to alert
1 Check to be sure that the storage container is personnel of a procedure or hazard and could
present and in good condition. result in unsafe operating conditions.
2 Check to make sure that the operator's, 1 Refer to the Decals section in the Genie S-100 &
responsibilities and safety manuals are present Genie S-105 Operator's Manual or the Genie
and complete in the storage container in the S-120 & Genie S-125 Operator's Manual and
platform. use the decal list and illustrations to determine
that all decals and placards are in place.
3 Examine the pages of each manual to be sure
that they are legible and in good condition. 2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
4 Always return the manuals to the storage immediately.
container after use.
Contact your authorized Genie
Contact your authorized Genie distributor or Genie Industries if
distributor or Genie Industries if replacement decals are needed.
replacement manuals are needed.
TABLE A PROCEDURES
A-3 A-4
Inspect for Damage and Loose or Check the Engine Oil Level
Missing Parts
Maintaining the proper engine oil level is essential

Daily machine condition inspections are essential to good engine performance and service life.
to safe machine operation and good machine Operating the machine with an improper oil level
performance. Failure to locate and repair damage, can damage engine components.
and discover loose or missing parts may result in Check the oil level with the
an unsafe operating condition. engine off.
1 Visually inspect the entire machine for damage 1 Check the engine oil dipstick. Add oil as
and improperly installed or missing parts needed.
including:
Cummins models:
Electrical components, wiring and electrical Result: The oil level should be within the "L" and
cables "H" marks on the dipstick.
Hydraulic hoses, fittings, cylinders and Deutz models:
manifolds Result: The oil level should be within the two
Fuel and hydraulic tanks marks on the dipstick.
Drive and turntable motors and drive hubs Perkins models:
Boom and axle wear pads Result: The oil level should be within the two
notches on the dipstick.
Dents or damage to machine
Tires and wheels Cummins B3.9L Engine 11.5 quarts
Engine and related components Oil capacity (including filter) 10.9 liters
Limit switches and horn Cummins B3.9L Engine

Alarms and beacon (if equipped) Engine oil viscosity requirements
Nuts, bolts and other fasteners
below 68F / 20C 5W-30
Platform entry mid-rail or gate
Cracks in welds or structural components -13 to 68F / -25 to 20C 10W-30
Compartment covers and latches above 15F / -9C 15W-40
Use oils meeting API classification CE (labeled CE/SG).
TABLE A PROCEDURES
Deutz F4L 913 Engine 14.3 quarts A-5

Oil capacity (including filter) 13.5 liters
Check the Engine Coolant Level -
Deutz F4L 913 Engine Liquid Cooled Models
Engine oil viscosity requirements
below 60F / 15.5C (synthetic) 5W-30
-10F to 90F / -23C to 32C 10W-40 Maintaining the engine coolant at the proper level
is essential to engine service life. Improper coolant
above -4F / -34C 15W-40 level will affect the engine's cooling capability and
can damage engine components. Daily checks will
Engine oil should have properties of API classification allow the inspector to identify changes in coolant
CC/SE or CC/SF grades OR ACEA classification E1-96. level that might indicate cooling system problems.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed.
Perkins 1004-42 Engine 8.9 quarts
Result: The fluid level should be in the
Oil capacity (including filter) 8.4 liters
NORMAL range.
Perkins 1004-42 Engine Bodily injury hazard. Fluids in the

Engine oil viscosity requirements radiator are under pressure and
extremely hot. Use caution when
below 32F / 0C 0W removing cap and adding fluids.
-13F to 68F / -25C to 20C 5W-20
10F to 104F / -12C to 40C 10W-30
14F to 122F / -10C to 50C 15W-40
above 23F / -5C 20W-50

TABLE A PROCEDURES
A-6 2 Locate the engine pivot plate anchor hole at the

pivot end of the engine pivot plate.
Check the Engine Belt(s) -
3 Install the bolt that was just removed into the
Cummins Models anchor hole to secure the engine pivot plate
from moving.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
Maintaining the engine belt(s) is essential to good
to secure it from moving could
engine performance and service life. The machine
result in death or serious injury.
will not operate properly with a loose or defective
belt(s) and continued use may cause component 4 Inspect the engine belt for:
damage.
Cracking
Bodily injury hazard. Do not Glazing
inspect while the engine is
Separation
running. Remove the key to
secure from operation. Breaks
Bodily injury hazard. Beware of 5 Replace the belt if any damage is found. See
hot engine components. Contact D-8, Inspect the Engine Belt(s).
with hot engine components may 6 Inspect the generator belt (if equipped) for:
cause severe burns.
Cracking
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away Glazing
from the machine. Separation
Breaks
a b
a engine pivot plate anchor hole

b engine pivot plate retaining fastener a generator (option)
b generator belt
TABLE A PROCEDURES
7 Replace the belt if any damage is found. See A-7

D-8, Inspect the Engine Belt(s).
Check the Engine Cooling Fan -
Cummins engines are equipped
with a serpentine belt and
Liquid Cooled Models
incorporate a self-adjusting pulley
tensioner. No adjustment is
required.
Maintaining the engine cooling fan is essential to
8 Remove the engine pivot plate retaining good engine performance and service life. The
fastener from the engine pivot plate anchor hole machine will not operate properly with a loose or
at the pivot end of the engine pivot plate. defective cooling fan and continued use may
9 Swing the engine pivot plate in towards the cause component damage.
machine.
Bodily injury hazard. Do not
10 Install the bolt that was just removed into the inspect while the engine is
original hole to secure the engine pivot plate. running. Remove the key to
secure from operation.
the bolt into the engine pivot plate Bodily injury hazard. Beware of
to secure it from moving could hot engine components. Contact
result in death or serious injury. with hot engine components may
cause severe burns.
Belts - Genie part numbers 1 Open the engine side turntable cover and locate
the engine cooling fan.
Cummins engine belt 62437
Cummins generator belt 60725 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.
TABLE A PROCEDURES
A-8 2 Loosen the vent plug located on the fuel filter/

water separator head.
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 a head bolt

fuels are combustible. Perform this b vent plug
c drain plug
procedure in an open, well- d filter bowl
ventilated area away from heaters, e filter element
sparks, flames and lighted f separator head
tobacco. Always have an
3 Loosen the drain plug located at the bottom of
approved fire extinguisher within
the bowl. Allow the water to drain into a suitable
easy reach.
container until fuel starts to come out.
Poor fuel quality or very wet Immediately tighten the drain plug.
conditions may necessitate
Do not completely drain the fuel
performing this procedure more
bowl.
often.
4 Tighten the vent plug.
Perform this procedure with the
engine off. 5 Clean up any diesel fuel that may have spilled
during the procedure.
1 Open the engine side turntable cover and locate
the fuel filter/water separator. 6 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
If the engine will not start or runs
erratically, the fuel system may
need to be bled. Refer to B-4,
Replace The Fuel Filter/Water
Separator.
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. 6 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 clamp
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 & S-105 & S-120 & S-125 4 - 11
TABLE A PROCEDURES
A-10 A-11
Check for Fuel Leaks Check the Hydraulic Oil Level
Failure to detect and correct fuel leaks will result in Maintaining the hydraulic oil at the proper level is
an unsafe condition. An explosion or fuel fire could essential to machine operation. Improper hydraulic
result in death or serious injury. oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil
Explosion and fire hazard. Engine level that might indicate the presence of hydraulic
fuels are combustible. Inspect the system problems.
machine in an open, well-
ventilated area away from heaters, Perform this procedure with the
sparks, flames and lighted boom in the stowed position and
tobacco. Always have an the axles extended.
1 Visually inspect the sight gauge located on the
easy reach.
side of the hydraulic oil tank.
1 Perform a visual inspection around the following
Result: The hydraulic oil level should be 3/4 inch
areas:
(19 mm) from the top of the sight gauge.
Fuel tank, shutoff valve, hoses and fittings,
fuel pump, fuel filter, fuel injection pumps and Hydraulic oil specifications
fuel injectors.
Hydraulic oil type Dexron equivalent
Explosion and fire hazard. If a fuel
leak is discovered, keep any Tank capacity 55 gallons
additional personnel from entering 208 liters
the area and do not operate the Hydraulic system 80 gallons
machine. Repair the leak (including tank) 303 liters
immediately.
TABLE A PROCEDURES
A-12 A-13
Check for Hydraulic Leaks Check the Hydraulic Filter
Condition Indicators
Detecting hydraulic fluid leaks is essential to

operational safety and good machine performance.
Maintaining the hydraulic filters in good condition is
Undiscovered leaks can develop into hazardous
essential to good system performance and safe
situations, impair machine functions and damage
machine operation. The filter condition indicators
machine components.
will show when the hydraulic flow is bypassing a
1 Inspect for hydraulic oil puddles, dripping or clogged filter. If the filters are not frequently
residue on or around the following areas: checked and replaced, impurities will remain in the
hydraulic system and cause component damage.
Hydraulic tankfilter, fittings, hoses,
auxiliary power unit and turntable surface There are five hydraulic filters
located on the machine. There is
Engine compartmentfittings, hoses,
two tank return filters, one medium
pumps, filters and turntable surface
pressure filter and two high
All hydraulic cylinders pressure filters. All the filters have
All hydraulic manifolds condition indicators on them,
except the drive motor case drain
Boom
return filter.
The underside of the turntable
1 Start the engine from the platform controls.
The underside of the drive chassis
Axles
Ground area under the machine
TABLE A PROCEDURES
2 Change the engine idle to high rpm (rabbit Medium and High Pressure Filters
symbol).
The medium and high pressure
a b c 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 foot switch activated high idle

indicator light b
b low idle indicator light
c high idle indicator light
d engine idle speed select button
Press the engine idle speed select a

button until the indicator light next c
to foot switch activated high idle
(rabbit symbol) is on.
Tank Return Filter a high pressure filters
b filter condition indicators
3 Inspect the filter condition indicator gauge. c medium pressure filter
Result: The filter condition indicators should be

operating with the plungers in the green area. If
a
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.
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.
TABLE A PROCEDURES
A-14 3 Push and hold a function enable/speed select

button and push the boom up button.
Test the Platform and
Result: The boom should raise to 10 above
Ground Controls horizontal and then stop. The boom should not
Testing the machine functions and the Emergency raise above the limit switch unless both axles
Stop buttons for malfunctions is essential for safe are extended.
machine operation. An unsafe working condition 4 Push and hold a function enable/speed select
exists if any function fails to operate properly or button and push the boom down button.
either Emergency Stop button fails to stop all the
machine functions and shut off the engine. Each Result: The boom should lower and return to
function should activate, operate smoothly and be the stowed position.
free of hesitation, jerking and unusual noise.
5 Push and hold a function enable/speed select
Tip-over hazard. Do not raise or button and press the boom extend button.
extend the boom unless both Result: The boom will extend approximately 3
axles are extended. If the axle feet (1 m) and stop. The boom should not
extension system is not operating extend further unless both axles are extended.
correctly, the stability of the
machine is compromised and it 6 Push and hold a function enable/speed select
may tip over. button and push the boom retract button.
Be sure the axles are retracted Result: The boom should retract.
before performing this procedure. 7 Turn the key switch to platform controls.
1 Turn the key switch to ground controls and pull 8 Press down the foot switch.
out the Emergency Stop button to the ON
position at both the ground and platform 9 Move the drive control handle in the forward
controls. direction and push the extend axle button.
Result: The LCD screen will come on and Result: The machine should drive and the axles
display no error messages. The beacon should extend. The indicator light will flash
(if equipped) should flash. while the axles are moving and stay on when
the axles are fully extended.
In cold climates, the LCD readout
screen will need to warm up The extend axle function will only
before the display appears. work while the machine is moving.
2 Start the engine.
TABLE A PROCEDURES
10 Stop the machine when the axles are fully A-15

extended.
Test the Auxiliary Power
Test the Ground Controls
Operation
11 Turn the key switch to ground controls.
Detection of auxiliary power system malfunctions is
12 Do not press and hold a function enable/speed essential for safe machine operation. An unsafe
select button. Attempt to activate each boom working condition exists if the auxiliary powered
and platform function button. functions do not operate in the event of a main
power loss. When operating the machine on
Result: No boom and platform functions should
engine power, selecting auxiliary power will stop
operate.
the engine immediately. Auxiliary power is
13 Press and hold a function enable/speed select designed for short term use only and excessive
button and activate each boom and platform use will result in battery drain and component
function button. damage.
Result: All boom and platform functions should Perform this procedure with the
operate through a full cycle. Descent alarm axles extended and the engine off.
(if equipped) should sound while boom is
1 Turn the key switch to ground control and pull
lowering.
Test the Platform Controls position at both the ground and platform
controls.
14 Turn the key switch to platform controls.
2 Simultaneously push and hold the auxiliary
15 Do not press down the foot switch. power button and push each boom function
16 Attempt to activate each machine function button.
control handle, toggle switch or button. To conserve battery power, test
Result: No boom and platform functions should each function through a partial
operate. cycle.
17 Press down the foot switch. Result: All boom functions should operate.
18 Activate each machine function control handle, 3 Turn the key switch to platform controls.
toggle switch or button. 4 Press down the foot switch.
Result: All functions should operate through a 5 Simultaneously press and hold the auxiliary
full cycle. Descent alarm (if equipped) should power button and activate each function control
sound while boom is lowering. handle, toggle switch or button.
To conserve battery power, test
each function through a partial
cycle.
Result: All boom functions should operate.
TABLE A PROCEDURES
A-16 4 Push one of the LCD

screen buttons shown until
Test the Tilt Sensor and Alarm PLATFORM LEVEL
The tilt sensor sounds an alarm located in the appears.
platform when the incline of the turntable exceeds Result: The LCD screen should display the
the rating on the serial plate. angle in degrees.
Select a level test area. The tilt 5 Turn the key switch to platform controls.
alarm should not be sounding prior
to the test. 6 Push a button, such as the engine RPM button
or the fuel select button.
Be sure the engine is off.
Result: The alarm should sound at the platform
controls.
1 Turn the key switch to ground controls and pull
out the Emergency Stop buttons out to the ON
position at both the ground and platform
controls.
2 Push one of the LCD
TURNTABLE LEVEL X
AXIS appears.
Result: The LCD screen should display the
angle in degrees.
TURNTABLE LEVEL Y
AXIS appears.
Result: The LCD screen should display the
angle in degrees.
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 >0
to safe machine operation. If the boom is allowed >80
to operate outside of the operating envelope, the = 100
machine stability is compromised and may tip over. >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 8 Lower the boom.
controls.
2 Simultaneously push the
LCD screen buttons
shown to activate status
mode.
BOOM ANGLE is
displayed.
4 Raise the boom and observe the LCD screen.
Result: The LCD screen should display:
<10
>10
>50
>65
BOOM LENGTH is
displayed.
TABLE A PROCEDURES
A-18 Cummins models:

A-3 Inspect for Damage and Loose or
Perform 30 Day Service Missing Parts
A-5 Check the Engine Coolant Level -
Liquid Cooled Models
B-5 Replace the Air Filter
The 30 day maintenance procedure is a one-time
sequence of procedures to be performed after the B-8 Replace the Hydraulic Tank Return
first 30 days or 40 hours of usage. After this Filters
interval, refer to the maintenance tables for B-13 Inspect the Tires and Wheels
continued scheduled maintenance. (including lug nut torque)
C-3 Replace the Fuel Filter Element -
1 Perform the following maintenance procedures:
Perkins and Cummins Models
Deutz models:
C-6 Inspect the Boom Extend/Retract
A-3 Inspect for Damage and Loose or Cables
Missing Parts
D-4 Check the Turnable Rotation Bearing
A-19 Check the Engine Fasteners - Bolts
Deutz Models
D-8 Check the Engine Belt(s) -
B-3 Check the Engine Belt(s) - Deutz and Cummins Models
Perkins Models
D-10 Check the Engine Valve Clearances -
B-5 Replace the Air Filter Cummins and Perkins Models
B-8 Replace the Hydraulic Tank Return B-15 Check and Adjust the Engine RPM
Filters
B-28 Replace the Engine Oil and Filter -
B-13 Inspect the Tires and Wheels Cummins Models
(including lug nut torque)
C-1 Check the Engine Valve Clearances -
Deutz Models
Cables
D-4 Check the Turnable Rotation Bearing
Bolts
D-9 Replace the Fuel Filter/Water
Separator - Deutz Models
B-15 Check and Adjust the Engine RPM
C-4 Replace the Engine Oil and Filter -
Deutz and Perkins Models
TABLE A PROCEDURES
Perkins models: A-19

A-3 Inspect for Damage and Loose or
Missing Parts
Check the Engine Fasteners -
A-5 Check the Engine Coolant Level - Deutz Models
Liquid Cooled Models Engine specifications require that
B-3 Check the Engine Belt(s) - Deutz and this procedure be performed after
Perkins Models 40 hours of use.
B-5 Replace the Air Filter
B-8 Replace the Hydraulic Tank Return
Filters
B-13 Inspect the Tires and Wheels Properly torqued engine fasteners are essential to
(including lug nut torque) good engine performance and operational safety.
C-3 Replace the Fuel Filter Element - Loose or improperly torqued fasteners can result in
Perkins and Cummins Models engine component damage and hazardous
conditions.
Cables 1 Remove the engine pivot plate retaining
D-4 Check the Turnable Rotation Bearing fastener. Swing the engine pivot plate out away
Bolts from the machine.
D-10 Check the Engine Valve Clearances -
Cummins and Perkins Models
B-15 Check and Adjust the Engine RPM
C-4 Replace the Engine Oil and Filter -
a b

b engine pivot plate retaining fastener
2 Locate the engine pivot plate anchor hole at the

TABLE A PROCEDURES
3 Install the bolt that was just removed into the A-20
anchor hole to secure the engine pivot plate
from moving. Check the Batteries
Crushing hazard. Failure to install Genie specifications require that
the bolt into the engine pivot plate this procedure be performed every
to secure it from moving could 125 hours.
4 Tighten all valve cover retaining fasteners.
Torque to 108 in-lbs (12 Nm).
Proper battery condition is essential to good
5 Tighten all air intake pipe clamps. Torque to 108 engine performance and operational safety.
in-lbs (12 Nm). Improper fluid levels or damaged cables and
connections can result in engine component
6 Tighten all intake manifold retaining fasteners. damage and hazardous conditions. There are 2
Torque to 17 ft-lbs (23 Nm). batteries on the machine. One is used for starting
7 Tighten all exhaust manifold retaining fasteners. the engine and the other is used to power the
Torque to 30 ft-lbs (40 Nm). control system. The two batteries are charged by
the alternator through a battery separator.
8 Tighten all engine mounting fasteners. Torque
engine to bracket mounting fasteners to 54 ft- Electrocution hazard. Contact with
lbs (73 Nm) and bracket to engine pivot plate hot or live circuits could result in
mounting fasteners to 175 ft-lbs (237 Nm). death or serious injury. Remove all
rings, watches and other jewelry.
fastener from the engine pivot plate anchor hole Bodily injury hazard. Batteries
at the pivot end of the engine pivot plate. contain acid. Avoid spilling or
contacting battery acid. Neutralize
10 Swing the engine pivot plate in towards the battery acid spills with baking soda
machine. and water.
11 Install the bolt that was just removed into the 1 Put on protective clothing and eye wear.
original hole to secure the engine pivot plate.
2 Be sure that the battery cable connections are
Crushing hazard. Failure to install free of corrosion.
to secure it from moving could 3 Be sure that the battery hold downs and cable
result in death or serious injury. connections are tight.
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.
Table B Procedures
B-1 2 Locate the engine pivot plate anchor hole at the
Check the Radiator -
Liquid Cooled Models anchor hole to secure the engine pivot plate
from moving.
Maintaining the radiator in good condition is
essential for good engine performance. Operating
a machine with a damaged or leaking radiator may
result in engine damage. Also, restricting air flow 4 Inspect the radiator for leaks and physical
through the radiator (i.e., dirt or debris) will affect damage.
the performance of the cooling system. A frequent
5 Clean the radiator fins of debris and foreign
check allows the inspector to identify changes in
materials.
the condition of the radiator that might indicate
cooling system problems. 6 Remove the engine pivot plate retaining
fastener from the engine pivot plate anchor hole
at the pivot end of the engine pivot plate.
running. Remove the key to 7 Swing the engine pivot plate in towards the
secure from operation. machine.
Bodily injury hazard. Beware of 8 Install the bolt that was just removed into the
hot engine parts and coolant. original hole to secure the engine pivot plate.
Contact with hot engine parts and/
or coolant may cause severe
burns.
1 Remove the engine pivot plate retaining result in death or serious injury.
fastener. Swing the engine pivot plate out away
from the machine.
a b

TABLE B PROCEDURES
B-2 5 Clean the fan blower fins of debris and foreign

material.
Check the Oil Cooler and
6 Inspect the cylinder head cooling passages and
Cooling Fins - Deutz Models fins for physical damage or foreign material,
using a flashlight.
7 Clean the cylinder head cooling passages of
debris and foreign material.
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. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
Oil Cooler
1 Open the latches from the engine side cover.

Remove the cover.
2 Inspect the oil cooler for leaks and physical
damage.
3 Clean the oil cooler of debris and foreign
material.
Cooling and Fan Blower Fins
4 Inspect the fan blower fins for physical damage.
TABLE B PROCEDURES
B-3 3 Install the bolt that was just removed into the
Check the Engine Belt(s) - from moving.
Deutz and Perkins Models Crushing hazard. Failure to install
Maintaining the engine belt(s) is essential to good
Deutz models:
engine performance and service life. The machine
will not operate properly with a loose or defective 4 Remove the front engine access cover
belt and continued use may cause component mounting fasteners and remove the front
damage. engine access cover.
Bodily injury hazard. Do not All models:
inspect while the engine is 5 Inspect the engine belt for:
secure from operation. Cracking
Glazing
Burn injury hazard. Beware of hot
engine components. Contact with Separation
hot engine components may Breaks
cause severe burns.
6 Replace the belt if any damage is found.
7 Inspect the generator belt (if equipped) for:
from the machine. Cracking
Glazing
Separation
Breaks
a b

a
Perkins engine Deutz engine
a generator belt
TABLE B PROCEDURES
8 Check the engine belt(s) for proper tension. B-4

Replace the Inline Fuel Filter/
Water Separator Element
Replacing the inline fuel filter/water separator

element is essential for good engine performance
Perkins engine Deutz engine and service life. A dirty or clogged filter may cause
Deutz models: the engine to perform poorly and continued use
may cause component damage. Extremely dirty
9 Install the front engine access cover mounting
conditions may require that the filter be replaced
fasteners and install the front engine access
more often.
cover.
All models: Explosion and fire hazard. Engine
fuels are combustible. Perform this
10 Remove the engine pivot plate retaining procedure in an open, well-
fastener from the engine pivot plate anchor hole ventilated area away from heaters,
at the pivot end of the engine pivot plate. sparks, flames and lighted
11 Swing the engine pivot plate in towards the tobacco. Always have an
machine. approved fire extinguisher within
easy reach.
original hole to secure the engine pivot plate. Perform this procedure with the
engine off.
the bolt into the engine pivot plate 1 Tag, disconnect and plug the fuel line from the
to secure it from moving could fuel tank at the inline fuel filter/water separator
result in death or serious injury. head.
Belts - Genie part numbers
Deutz Engine Belt 62431

Deutz Generator Belt 75053
Perkins Engine Belt 62428
Perkins Generator Belt 75053
Belt deflection 3 /8inch to 1/2 inch

9 mm to 12 mm
TABLE B PROCEDURES
2 Loosen the vent plug located on the inline fuel 10 Tighten the head bolt to 65 in-lbs (7.3 Nm).
filter/water separator head.
11 Tighten the vent plug.
12 Clean up any diesel fuel that may have spilled
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 -

a head bolt Genie part number 62433
b vent plug
c drain plug
d filter bowl
e filter element Bleed the fuel system:
f fuel filter/water separator head
Before bleeding the fuel system,
3 Place a suitable container under the filter bowl. be sure the fuel tank is full.
4 Loosen the drain plug located at the bottom of Deutz models:
the bowl. Completely drain the fuel from the
bowl. 1 Loosen the overflow valve at the injector pump.
5 Loosen the head bolt. Rotate the filter bowl

counterclockwise and remove it from the
element.
6 Install the bowl onto the new inline filter element
(Genie part number 62433). Tighten the drain
plug.
7 Fill the element and bowl with clean diesel fuel.
8 Apply a thin layer of oil onto the element gasket.
9 Install the filter/bowl assembly onto the filter
head and tighten it securely by hand.
a overflow valve
The filter/bowl assembly must be b fuel lift pump priming lever
full of fuel when it is installed onto c oil filter
d filter head
the filter head or the fuel system e fuel filter
will have to be bled.
TABLE B PROCEDURES
2 Operate the priming lever of the fuel lift pump Cummins models:
until fuel, free from air, comes from the vent.
Controlled venting is provided at
3 While continuing to operate the priming lever, the injection pump. Small amounts
tighten the overflow valve. of air introduced by changing the
filters or injection pump supply line
4 Clean up any diesel fuel that might have spilled
will be vented automatically. If the
fuel filter is changed in accordance
5 Start the engine and inspect for leaks. with instructions, no manual
bleeding of the fuel system is
Explosion and fire hazard. If a fuel needed.
leak is discovered, keep any
additional personnel from entering 1 Remove the engine pivot plate retaining
the area and do not operate the fastener. Swing the engine pivot plate out away
machine. Repair the leak from the machine.
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 a b
seconds between starter motor a engine pivot plate anchor hole
engagements. b engine pivot plate retaining fastener
Component damage hazard. 2 Locate the engine pivot plate anchor hole at the
Operate the engine at low idle pivot end of the engine pivot plate.
speed for a minimum of two
minutes immediately after air has
been removed from the fuel
from moving.
system. This will ensure that the
pump is free of air and prevent Crushing hazard. Failure to install
any damage to the pumps by the bolt into the engine pivot plate
metal to metal contact. to secure it from moving could
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.
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
separator head.
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
seconds at a time. Wait 120
seconds between starter motor
engagements.
a filter head vent screw
b fuel filter Component damage hazard.
c lift pump Operate the engine at low idle
d priming lever
5 Operate the priming lever on the fuel lift pump minutes immediately after air has
until fuel, free from air, comes out from the vent been removed from the fuel
screw. system. This will ensure that the
pump is free of air and prevent
6 While continuing to operate the priming lever, any damage to the pumps by
tighten the vent screw. Torque the vent screw metal to metal contact.
to 80 in-lbs (9 Nm).
If the engine does not start or runs
10 Clean up any diesel fuel that may have spilled erratically, refer to the Cummins
during the procedure. Operation and Maintenance
Manual, Cummins part number
3810205 (Genie part number
62448) for additional information
on the fuel system.
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 Crushing hazard. Failure to install
machine. the bolt into the engine pivot plate
4 Loosen the fuel filter/water separator filter vent
screw, located on top of the fuel filter/water
separator head.
Perkins models:
from the machine.
a vent screw
b fuel filter head
a b c fuel filter


TABLE B PROCEDURES
5 Operate the priming lever of the fuel lift pump 11 Start the engine and check for leaks.
until fuel, free from air, comes from the vent.
If the drive cam of the fuel lift leak is discovered, keep any
pump is at the point of maximum additional personnel from entering
lift, it will not be possible to the area and do not operate the
operate the priming lever. In this machine. Repair the leak
situation, rotate the crankshaft one immediately.
revolution.
seconds at a time. Wait 120
seconds between starter motor
engagements.
Operate the engine at low idle
minutes immediately after air has
a fuel lift pump been removed from the fuel
system. This will ensure that the
6 While continuing to operate the priming lever, pump is free of air and prevent
tighten the vent screw. any damage to the pumps by
7 Loosen the union nut on the fuel inlet pipe at the metal to metal contact.
injection pump. If the engine does not start or runs
8 Operate the priming lever of the fuel lift pump erratically, refer to the Perkins
until fuel, free from air, comes from the User's Handbook, Perkins part
connection. number TPD 1349 (Genie part
number 62447) for additional
9 Tighten the union nut. information on the fuel system.
10 Clean up any diesel fuel that may have spilled
TABLE B PROCEDURES
12 Remove the engine pivot plate retaining B-5

at the pivot end of the engine pivot plate. Replace the Air Filter
13 Swing the engine pivot plate in towards the
machine.
14 Install the bolt that was just removed into the Maintaining the engine air filter in good condition is
original hole to secure the engine pivot plate. essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
to secure it from moving could Perform this procedure with the
result in death or serious injury. engine off.
1 Open the evacuator valve located on the air
cleaner cap by squeezing the sides together
with your fingers.
2 Open the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
3 Remove the filter element.
4 Clean the inside of the air cleaner canister and
end cap with a damp cloth.
5 Install the new filter element.
6 Replace the end cap on the canister.
Be sure the evacuator valve is
pointing in the down direction.
Air filter - Genie part number 62425
TABLE B PROCEDURES
B-6 B-7
Inspect the Air Intake System Check the Exhaust System
Maintaining the air intake system in good condition Maintaining the exhaust system is essential to
is essential to good engine performance and good engine performance and service life. Running
service life. Failure to perform this procedure can the engine with a damaged or leaking exhaust
lead to poor engine performance and component system can cause component damage and unsafe
damage. operating conditions.
Perform this procedure with the Bodily injury hazard. Do not
engine off. inspect while the engine is
1 Inspect the intake piping for cracked hoses,
loose clamps or punctures which can allow dirt
and debris to enter the engine. Bodily injury hazard. Beware of
hot engine components. Contact
2 Tighten or replace parts as necessary to make
with hot engine components may
sure the air intake system does not leak.
cause severe burns.
Cummins and Perkins models:
1 Be sure that all fasteners are tight.
2 Inspect all welds for cracks.
3 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
TABLE B PROCEDURES
Deutz models: 7 Remove the engine pivot plate retaining

from the machine. 8 Swing the engine pivot plate in towards the
machine.
a b


from moving.
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.
TABLE B PROCEDURES
B-8 2 Place a suitable container under the hydraulic

tank return filters.
Replace the Hydraulic Tank
3 Remove each filter with an oil filter wrench.
Return Filters
4 Apply a thin layer of clean oil to the new oil filter
gaskets.
5 Install the new system return filter (Genie part
Replacement of the hydraulic tank return filter is number 61326) and tighten it securely by hand.
essential for good machine performance and
6 Install the drive motor case drain return filter
service life. A dirty or clogged filter may cause the
(Genie part number 44207) and tighten it
machine to perform poorly and continued use may
securely by hand.
cause component damage. Extremely dirty
conditions may require that the filter be replaced 7 Clean up any oil that may have spilled during
more often. the procedure.
Burn hazard. Beware of hot oil. 8 Use a permanent ink marker to write the date
Contact with hot oil may cause and number of hours from the hour meter on
severe burns. the filters.
Perform this procedure with the 9 Start the engine from the ground controls.
engine off.
10 Inspect the filters and related components to
There are two return filters on the be sure that there are no leaks.
machine. One is the system return
filter and the other one is the Hydraulic tank return filters -
return filter for the drive motor Genie part numbers
case drains.
System return filter 61326
1 Open the ground controls side turntable side Drive motor case drain return filter 44207
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
B-9 5 Use a permanent ink marker to write the date

Replace the Hydraulic Tank the filter.
Breather Filter
Hydraulic tank breather filter
Genie part number 60559
Replacement of the hydraulic tank breather filter is

service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
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.
TABLE B PROCEDURES
B-10 2 Place a suitable container under the filters.

Replace the Medium and 3 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housing.
High Pressure Hydraulic Filters
4 Remove the filter element from the housing.
5 Inspect the housing seal and replace it if
necessary.
Replacement of the medium and high pressure
6 Install the new medium pressure filter element
filters is essential for good machine performance
into the housing (Genie part number 60858)
and service life. A dirty or clogged filter may cause
and tighten it securely.
the machine to perform poorly and continued use
may cause component damage. Extremely dirty 7 Install the new high pressure filter elements into
conditions may require that the filters be replaced the housings (Genie part number 60857) and
more often. tighten them securely.
Burn hazard. Beware of hot oil. 8 Clean up any oil that may have spilled during
Contact with hot oil may cause the installation procedure.
severe burns.
The medium pressure filter is for and number of hours from the hour meter on
the charge pump and the high the oil filter housings.
pressure filters are for the drive
10 Start the engine from the ground controls.
circuit.
11 Inspect the filter housings and related
components to be sure that there are no leaks.
engine off.
1 Open the engine side turntable cover and locate Medium and high pressure filters -
the three filters mounted to the bulkhead. Genie part numbers
Medium pressure filter 60858

High pressure filter 60857
a
b
a high pressure filters

b medium pressure filter
TABLE B PROCEDURES
B-11 5 Turn the engine off.

Inspect the Electrical Wiring 6 Remove the boom storage area cover retaining
fasteners and remove the boom storage area
Maintaining electrical wiring in good condition is cover.
essential to safe operation and good machine
performance. Failure to find and replace burnt, 7 Inspect the turntable area for burnt, chafed and
chafed, corroded or pinched wires could result in pinched cables.
unsafe operating conditions and may cause 8 Install the boom storage area cover and install
component damage. the boom storage area cover retaining
Electrocution hazard. Contact with fasteners.
hot or live circuits could result in 9 Raise the boom to a horizontal position.
death or serious injury. Remove all
rings, watches and other jewelry. 10 Remove the safety chock and lower the boom
to the stowed position.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires: 10 Turn the engine off.
Engine wiring harness 11 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
Ground control box harness connectors
Cable track on the boom
Turntable manifold wiring
Boom to platform cable harness
2 Start the engine from the platform controls and
extend the axles. Platform control box harness connectors
3 Turn the key switch to ground control and raise Platform manifold wiring
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
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).
TABLE B PROCEDURES
B-12 B-13
Confirm the Proper Inspect the Tires and Wheels
Brake Configuration (including lug nut torque)
Proper brake configuration is essential to safe Maintaining the tires and wheels in good
operation and good machine performance. condition is essential to safe operation and good
Hydrostatic brakes and hydraulically-released, performance. Tire and/or wheel failure could result
spring-applied individual wheel brakes can appear in a machine tip-over. Component damage may
to operate normally when they are actually not fully also result if problems are not discovered and
operational. repaired in a timely fashion.
1 Check each drive hub disconnect cap to be The tires on these machines are
sure it is in the engaged position. foam filled and do not need air
added to them.
disengage position
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
engage position cracked 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
TABLE B PROCEDURES
B-14 4 Install the plug into the drive hub.

Check the Oil Level in the When removing the drive hub plug
on machines before serial number
Drive Hubs 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.
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage. Drive hub oil
Drive Hubs Capacity 83 fl oz

2.5 liters
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at Type: SAE 80W-90 EP multipurpose gear oil
90.
Turntable Rotate Drive Hub

a
The turntable rotate drive hub is
located under a fixed turntable
cover at the ground controls side
of the machine. The cover has to
be removed before the following
procedure can be completed.
a drive hub plugs 1 Remove the power to platform plug panel upper
retaining fasteners and loosen the lower
2 Remove the plug located at 90 and check the retaining fasteners. Do not disconnect the
oil level. wiring.
Result: The oil level should be even with the 2 Support the cover with a suitable lifting device.
bottom of the plug hole. Protect the cover from damage.
3 If necessary, remove the top plug and add oil 3 Remove the cover retaining fasteners. Remove
until the oil level is even with the bottom of the the cover from the machine.
side plug hole.
Crushing hazard. The turntable
cover may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported.
TABLE B PROCEDURES
4 Remove the plug located on the top of the drive B-15

brake and check the oil level.
Check and Adjust the
Result: The oil level should be even with the
bottom of the plug hole.
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
c
a operate properly if the rpm is incorrect and
continued use may cause component damage.
Deutz models:
b
engine rpm is displayed.
Result: Low idle should be 1300 rpm.
Skip to step 11 if the low idle rpm is correct.
a plug
b turntable rotate drive hub 3 Remove the secondary idle adjustment screw
c drive brake
cap from the secondary idle adjustment screw
5 If necessary, add oil until the oil level is even on the injection pump. Loosen the locknut.
with the bottom of the plug hole.
6 Install the plug into the drive hub.
Turntable rotate drive hub oil
Capacity (approximately) 92 fl oz
2.7 liters
Type SAE 80W-90 EP multipurpose gear oil
Deutz engine
a primary idle adjustment screw
b secondary idle adjustment screw
TABLE B PROCEDURES
4 Turn the secondary adjustment screw 12 Loosen the yoke lock nut. Turn the high idle
counterclockwise until the adjustment screw is adjustment nut and solenoid boot
loose. Tighten the locknut. counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
Be sure the adjustment screw is
yoke lock nut and recheck the rpm.
loosened until there is no spring
tension felt. Be sure the solenoid fully retracts
when activating high idle.
5 Remove the primary idle adjustment screw cap
from the primary idle adjustment screw on the
injection pump. Loosen the locknut. Deutz models
6 Adjust the primary idle adjustment screw until Low idle 1300 rpm
low idle is 1250 rpm. Tighten the locknut.
High idle 2350 rpm
7 Install the primary idle adjustment screw cap
and tighten. Do not over tighten.
8 Loosen the secondary idle adjustment screw Cummins and Perkins models:
locknut.
9 Adjust the secondary adjustment screw until the fastener. Swing the engine pivot plate out away
low idle is 1300 rpm. Tighten the locknut. from the machine.
10 Install the secondary idle adjustment screw cap
and tighten. Do not over tighten.
11 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Result: High idle should be 2350 rpm.
If the high idle is correct, disregard adjustment a b
step 12. a engine pivot plate anchor hole

TABLE B PROCEDURES
3 Install the bolt that was just removed into the 6 Loosen the low idle lock nut. Turn the low idle
anchor hole to secure the engine pivot plate adjustment screw clockwise to increase the rpm
from moving. or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
5 Push one of the LCD screen buttons shown
until engine rpm is
displayed.
Result: Low idle should be
1300 rpm.
Skip to step 7 if the low idle rpm is correct.
Perkins models
a low idle adjustment screw
b yoke lock nut
c solenoid boot
d high idle adjustment nut
e yoke
f low idle lock nut
Cummins models
a yoke
b yoke lock nut
c solenoid boot
d high idle adjustment nut
e low idle adjustment screw
TABLE B PROCEDURES
7 Push and hold the function enable/high speed B-16

button. Note the engine rpm on the display.
Test the Key Switches
Result: High idle should be 2350 rpm.
Proper key switch action and response is essential
Skip to step 9 if the high idle rpm is correct. to safe machine operation. Failure of either key
switch to function properly could cause a
8 Loosen the yoke lock nut. Turn the high idle
hazardous operating situation.
adjustment nut and solenoid boot
counterclockwise to increase the rpm or There are two key switches on the machine - the
clockwise to decrease the rpm. Tighten the Main key switch and the Service Bypass/Recovery
yoke lock nut and recheck the rpm. key switch.
Be sure the solenoid fully retracts The Main key switch controls machine operation
when activating high idle. 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
10 Swing the engine pivot plate in towards the feature of the machine is especially helpful for
machine. 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
Cummins and Perkins models helpful if the operator in the platform cannot lower
the boom, if the platform controls become
Low idle 1300 rpm
inoperative or for returning the machine to a safe
position when the safety switches have been
High idle 2350 rpm
tripped.

axles retracted.
1 Open the ground controls side turntable side
cover.
TABLE B PROCEDURES
2 Pull out the Emergency Stop button to the ON 12 Remove the key from the main key switch and
position at both the ground and platform insert the key into the service bypass/recovery
controls. key switch.
3 At the ground controls, turn the service The key switch should remain in
bypass/recovery key switch to the RUN position. the GROUND CONTROL position.
4 Turn the main key switch to ground control, 13 Turn the service bypass/recovery key switch to
start the engine and then turn the key switch to the SERVICE BYPASS position.
platform control.
14 Raise the boom.
5 Check any machine function from the ground
Result: The boom should raise.
controls.
15 Remove the key from the service
Result: The machine functions should not
bypass/recovery key switch and insert the key
operate.
into the main key switch.
6 Turn the main key switch to ground control.
16 Turn the main key switch to the OFF position.
7 Check any machine function from the platform
17 Remove the key from the main key switch and
controls.
insert the key into the service bypass/recovery
Result: The machine functions should not key switch.
operate.
18 Turn and hold the service bypass/recovery key
8 Turn the main key switch to the OFF position. switch to the RECOVERY position.
Result: The engine should stop and no Result: The boom should return to the stowed
functions should operate. position.
9 Open the ground controls side turntable side 19 Turn the service bypass/recovery key switch to
cover. the run position.
10 Turn the main key switch to ground control and 20 Remove the key from the service
start the engine. bypass/recovery key switch and insert the key
into the main key switch.
11 Raise the boom.
21 Turn the main key switch to the OFF position.
Result: The boom should raise to 10 above
horizontal and then stop. The boom should not 22 Close the turntable side cover.
raise above the limit switch unless both axles
are extended.
TABLE B PROCEDURES
B-17 B-18
Test the Emergency Test the Ground Control Override
Stop Buttons A properly functioning ground control override is
Properly functioning Emergency Stop buttons essential to safe machine operation. The ground
are essential for safe machine operation. An control override function is intended to allow
improperly operating Emergency Stop button ground personnel to operate the machine from the
will fail to shut off power and stop all machine ground controls whether or not the Emergency
functions, resulting in a hazardous situation for Stop button on the platform controls is in the ON or
OFF position. This function is particularly useful if
ground and platform personnel.
the operator at the platform controls cannot return
As a safety feature, selecting the boom to the stowed position.
and operating the ground controls
will override the platform controls, 1 Push in the platform Emergency Stop button
including the Emergency Stop to the OFF position.
button. 2 Start the engine from the ground controls.
1 Start the engine from the ground controls. 3 Operate each boom function through a
2 Push in the Emergency Stop button to the OFF partial cycle.
position. Result: All boom functions should operate.
Result: The engine should shut off and no
machine functions should operate.
4 Push down the Emergency Stop button to the
OFF position.
Result: The engine should shut off and no

machine functions should operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch
is switched to platform control.
TABLE B PROCEDURES
B-19 4 Activate the function enable/high RPM button

and extend the boom to 101 feet (30.8 m).
Test the Safety Envelope and
Result: The engine should stop and the boom
Circuits extend function should be disabled.
Testing the machine safety envelope is critical to Result: If the engine does not stop and the
safe machine operation. If the boom is allowed to boom continues to extend, the LSB2RS switch
operate when a safety switch is not functioning is out of adjustment or the wiring circuit is faulty
correctly, the machine stability is compromised and and will need to be replaced or repaired. See
may tip over. Repair Section.
1 Raise the boom to approximately 60. Bodily injury hazard. If the boom
For S-100 or S-105 models, extends to more than 101 feet
proceed to step 15. (30.8 m) without stopping the
engine, stop immediately and
101 feet (30.8 m) Length Safety Switch, retract the boom until the boom is
LSB2RS extended to less than 100 feet
(30.5 m). Failure to retract the
2 Extend the boom to more than 80 feet (24.4 m).
boom could result in death or
3 Disconnect the 68 proximity switch LSB14AO serious injury.
and install a wire jumper between pin 3 and pin
5 Using auxiliary power, retract the boom until the
4 of the deutsch connector.
boom is extended to approximately 95 feet
Result: ">65 DEG" should be present on the (29 m).
display screen at the ground controls.
6 Remove the wire jumper installed in step 3 and
connect the deutsch connector to LSB14AO.
65 Angle Safety Switch,
LSB9AS
7 Raise the boom to the maximum angle.

8 Fully extend the boom.
9 Disconnect the 68 proximity switch LSB14AO
and install a wire jumper between pin 3 and pin
4 of the deutsch connector.
TABLE B PROCEDURES
10 Start the engine and activate the function 16 Disconnect the 53 proximity switch LSB13AO
enable/high RPM button and lower the boom to and install a wire jumper between pin 3 and pin
65. 4 of the deutsch connector.
Result: The engine should stop and the boom 17 Activate the function enable/high RPM button
down function should be disabled. and lower the boom to 50.
Result: If the engine does not stop and the Result: The engine should stop and the boom
boom continues to lower to less than 65, the down function should be disabled.
LSB9AS switch is out of adjustment or the
Result: If the engine does not stop and the
wiring is faulty and will need to be replaced or
boom continues to lower to less than 50, the
repaired. See Repair Section.
LSB8AS switch is out of adjustment or the
Bodily injury hazard. If the boom wiring circuit is faulty and will need to be
lowers to less than 65 without replaced or repaired. See Repair Section.
stopping the engine, stop
Bodily injury hazard. If the boom
immediately and raise the boom
lowers to less than 50 without
until the boom is elevated to
stopping the engine, stop
greater than 68. Failure to raise
immediately and raise the boom
the boom could result in death or
until the boom is elevated to
serious injury.
greater than 53. Failure to raise
11 Measure the angle of the boom. the boom could result in death or
serious injury.
Result: The angle of the boom should be
greater than 65. 18 Measure the angle of the boom.
12 Using auxiliary power, raise the boom until the Result: the angle of the boom should be greater
boom angle is greater than 68. than 50.
13 Remove the wire jumper installed in step 9 and 19 Using auxiliary power, raise the boom until the
connect the deutsch connector to LSB14AO. boom angle is greater than 53.
50 Angle Safety Switch, 20 Remove the wire jumper installed in step 16 and
LSB8AS connect the deutsch connector to LSB13AO.
14 Raise the boom to approximately 60.

15 Extend the boom to approximately
95 feet (24.4 m).
TABLE B PROCEDURES
76 feet (30.8 m) Length Safety Switch, Cable Break Safety Switch,

LSB4ES LSB6S
21 Disconnect the 75 feet (22.9 m) proximity switch 25 Start the engine and activate the function
LSB3EO and install a wire jumper between pin enable/high RPM button and retract the boom
3 and pin 4 of the deutsch connector. until the boom is extended to less than 2 feet
(0.6 m).
LSB3EO is located on top of boom
tube number 2 at the platform end 26 Remove the boom end cover from the pivot end
of the machine. of the boom.
22 Start the engine and activate the function 27 Remove the arm from the cable break limit
enable/high RPM button and extend the boom switch LSB6S.
to 76 feet (23.2 m).
LSB6S is located at the end of the
Result: The engine should stop and the boom boom tubes at the pivot end of the
extend function should be disabled. boom.
Result: If the engine does not stop and the 28 Using the arm just removed from LSB6S, rotate
boom continues to extend, the LSB4ES switch the head of the switch 45 degrees clockwise
is out of adjustment or the wiring circuit is faulty and activate the function enable/high RPM
and will need to be replaced or repaired. See button and attempt to extend the boom.
Repair Section.
Result: The boom extend function should be
Bodily injury hazard. If the boom disabled.
extends to more than 76 feet
Result: If the boom extends, the LSB6S switch
(23.2 m) without stopping the
or wiring circuit is faulty and will need to be
engine, stop immediately and
replaced or repaired. See Repair Section.
retract the boom until the boom is
extended to less than 75 feet (22.9 Bodily injury hazard. If the boom
m). Failure to retract the boom extends at all, stop immediately
could result in death or serious and retract the boom until the
injury. boom is extended to less than 2
feet (0.6 m). Failure to retract the
23 Using auxiliary power, retract the boom until the
boom is extended to less than 75 feet (22.9 m).
serious injury.
connect the harness plug to LSB3EO.
TABLE B PROCEDURES
29 Activate the function enable/high RPM button Axle Extend Safety Switch,
and attempt to retract the boom. LSAX1ES and LSAX2ES
and
Result: The boom retract function should be
enabled. 3 feet (0.9 m) Safety Switch,
LSB3RS
Result: If the boom does not retract, the LSB6S
and
switch or wiring circuit is faulty and will need to
be replaced or repaired. See Repair Section. 11 Angle Safety Switch,
30 Using the arm just removed from LSB6S, rotate LSB7DS
the head of the switch 90 degrees counter 33 Fully retract and lower the boom to the stowed
clockwise and activate the function enable/high position.
RPM button and attempt to extend the boom.
34 Retract both axles approximately 1 foot (0.3 m).
Result: The boom extend function should be
disabled. 35 Remove the access cover from each axle.
Result: If the boom extends, the LSB6S switch 36 Disconnect the square-end axle extend safety
or wiring circuit is faulty and will need to be switch LSAX1ES and install a wire jumper
replaced or repaired. See Repair Section. between pin 3 and pin 4 of the deutsch
connector.
extends at all, stop immediately 37 Place a metal washer over the target area of
and retract the boom until the the axle extend proximity switch LSAX1EO and
boom is extended to less than 2 place a metal washer over the target area of the
feet (0.6 m). Failure to retract the axle extend proximity switch LSAX2EO to close
boom could result in death or the contacts.
serious injury.
Result: The axle extend indicator light at the
31 Activate the function enable/high RPM button ground and platform controls should be
and attempt to retract the boom. illuminated.
a
Result: The boom retract function should be
disabled.
Result: If the boom retracts, the LSB6S switch
or wiring circuit is faulty and will need to be
32 Rotate the head of the switch 45 degrees
clockwise and install the arm onto LSB6S. Proximity switch
a target area
TABLE B PROCEDURES
38 Activate the function enable/high RPM button 40 Remove the wire jumper installed in step 36 and
and attempt to extend the boom. connect the deutsch connector to LSAX1ES.
Result: The boom should not extend to more 41 Disconnect the circle-end axle extend safety
than 3 feet (0.9 m). switch LSAX2ES and install a wire jumper
between pin 3 and pin 4 of the deutsch
Result: If the boom extends to more than 3 feet
connector.
(0.9 m), the LSAX1ES or LSAX2ES switch are
out of adjustment or the wiring circuit is faulty 42 Activate the function enable/high RPM button
and will need to be replaced or repaired. See and attempt to extend the boom.
Repair Section.
Result: The boom should not extend to more
Bodily injury hazard. If the boom than 3 feet (0.9 m).
Result: If the boom extends to more than 3 feet
(0.9 m), stop immediately and
(0.9 m), the LSAX1ES or LSAX2ES switch are
out of adjustment or the wiring circuit is faulty
extended to less than 2 feet
and will need to be replaced or repaired. See
(0.6 m). Failure to retract the
Repair Section.
serious injury. Bodily injury hazard. If the boom
39 Activate the function enable/high RPM button
(0.9 m), stop immediately and
and attempt to raise the boom.
Result: The boom should not raise to more extended to less than 2 feet
than 11. (0.6 m). Failure to retract the
Result: If the boom continues to raise, the
serious injury.
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.
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
43 Activate the function enable/high RPM button 47 Activate the function enable/high RPM button
and attempt to raise the boom. and extend the boom until ">0" is present on
the display screen at the ground controls.
Result: The boom should not raise to more
than 11. Result: The alarm should sound and "REVERSE
LOAD MOMENT FAULT" should be present on the
Result: If the boom continues to raise, the
display screen at the ground controls.
LSAX1ES or LSAX2ES switch are out of
adjustment or the wiring circuit is faulty and will Result: If the alarm does not sound or if
need to be replaced or repaired. See Repair "REVERSE LOAD MOMENT FAULT" is not present on
Section. 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
raises to more than 11, stop
immediately and lower the boom
until the boom is less than 11. Bodily injury hazard. If the alarm
Failure to lower the boom could does not sound or if "REVERSE LOAD
result in death or serious injury. MOMENT FAULT" is not present on the
display screen at the ground
controls, stop immediately and
connect the deutsch connector to LSAX2ES.
fully retract the boom. Failure to
Reverse Load Moment Switch, retract the boom could result in
LSB20LO death or serious injury.
and fully retract the boom. and raise the boom to clear the alarm.
and lower the boom onto the boom rest pad and lower the boom to the stowed position.
and continue to hold the boom lower function 50 Turn the key switch to the OFF position.
button for 5 seconds.
TABLE B PROCEDURES
B-20 5 Push and hold a function enable/speed select

button and fully raise the boom.
Test the Platform Self-leveling
Result: The platform should remain level at
Automatic platform self-leveling throughout all times to within 2 degrees.
the full cycle of boom raising and lowering is
essential for safe machine operation. The If the platform becomes out of
platform is maintained level by the communication level, the tilt alarm will sound and
between the platform level sensor and the the Platform Not Level Indicator
turntable level sensor. If the platform becomes out will flash at the ground controls.
of level, the computer at the ground controls will The platform level up/down
open the appropriate solenoid valve(s) at the buttons will only work in the
platform manifold to maintain a level platform. direction that will level the
A platform self-leveling failure creates an unsafe platform. Level the platform until
working condition for platform and ground the indicator light turns off.
personnel. 6 Push and hold a function enable/speed select
1 Start the engine from the platform controls and button and fully lower the boom.
extend the axles. Result: The platform should remain level at
2 Turn the key switch to ground controls. all times to within 2 degrees.
3 Push and hold a function enable/speed select If the platform becomes out of
button and fully retract the boom. level, the tilt alarm will sound and
the Platform Not Level Indicator
4 Push and hold a function enable/speed select will flash at the ground controls.
button and adjust the platform to a level position The platform level up/down
using the platform level up/down buttons. buttons will only work in the
direction that will level the
platform. Level the platform until
the indicator light turns off.
TABLE B PROCEDURES
B-21 B-22
Test the Horn Test the Foot Switch
A functional horn is essential to safe machine A properly functioning foot switch is essential to
operation. The horn is activated at the platform safe machine operation. Machine functions should
controls and sounds at the ground as a warning to activate and operate smoothly as long as the foot
ground personnel. An improperly functioning horn switch is pressed down, and promptly stop when
will prevent the operator from alerting ground the foot switch is released. Pressing down the foot
personnel of hazards or unsafe conditions. switch will also shift the engine into high idle if the
engine idle select (rpm) indicates that the rabbit
1 Turn the key switch to platform control and and foot switch symbol is selected. An improperly
pull out the Emergency Stop button to the functioning foot switch can cause an unsafe
ON position at both the ground and
working condition and endanger platform and
platform controls. ground personnel.
2 Push down the horn button at the platform
The engine should not start if the
controls.
foot switch is pressed down.
Result: The horn should sound.
1 Turn the key switch to platform controls and pull
If necessary, the horn can be out the Emergency Stop button to the ON
adjusted to obtain the loudest position at both the ground and platform
volume by turning the adjustment controls.
screw near the wire terminals on 2 Press down the foot switch and attempt to start
the horn. the engine by pushing the engine start button.
Result: The engine should not start.
3 Do not press down the foot switch and start the
engine.
4 Do not press down the foot switch and test each
machine function control handle, toggle switch
or button.
Result: The machine functions should not
operate.
5 Press down the foot switch.
6 Activate each machine function control handle,
toggle switch or button.
Result: All functions should operate through a
full cycle. Descent alarm (if equipped) should
sound while boom is lowering.
TABLE B PROCEDURES
B-23 6 Turn the key switch to platform controls.

Test the Engine Idle Select 7 At the platform controls, press the engine idle
select button until high idle (rabbit symbol) is
A properly operating engine idle select function selected.
is essential to good engine performance and safe
machine operation. There are three settings. Result: The engine should change to high idle.
Low idle (turtle symbol) allows the operator a b c

to control multiple boom and/or 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.
d
Foot switch activated high idle (rabbit and foot
switch symbols) should be used for normal a foot switch activated high idle
machine operation. This selection activates high indicator light
b low idle indicator light
idle only when the foot switch is pressed down. c high idle indicator light
d engine rpm select button
1 Turn the key switch to ground controls.
8 Press the engine idle select button until low idle
2 Pull out the Emergency Stop button to the
(turtle symbol) is selected.
ON position at both the ground and platform
controls. Result: The engine should change to low idle.
3 Start the engine from the ground controls. 9 Press the engine idle select button until the foot
switch activated high idle (rabbit and foot switch
4 Push and hold the high speed function enable/
symbol) is selected.
speed select button (rabbit symbol).
Result: The engine should not change to
Result: The engine should change to high idle.
high idle.
5 Release the high speed function enable/speed
10 Press down the foot switch.
select button.
Result: The engine should change to high idle.
Result: The engine should return to low idle.
TABLE B PROCEDURES
B-24 5 Push the drive enable button and slowly move

the drive/steer control handle off center.
Test the Drive Enable System
Result: The drive function should operate.
Proper drive enable system operation is
essential to safe machine operation. An improperly Collision hazard. Always use the
functioning drive enable system may allow the color-coded direction arrows on
machine to be moved into an unsafe position. the platform control panel and the
When the boom is rotated past one of the circle- drive chassis to identify which
end wheels while the machine is moving, the direction the machine will travel.
indicator light will illuminate and the drive function
will continue to operate until the drive control
Blue
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
Yellow
moved.
When the boom is rotated past one of the circle-
end wheels and the machine is not moving, the
When the drive enable system is
indicator light will illuminate and the drive function
in use, the machine may drive in
is turned off.
the opposite direction that the
1 Start the engine from the platform controls. drive and steer control handle is
moved.
2 Press down the foot switch and lower the boom
to the stowed position. If the drive/steer control handle is
not moved within two seconds of
3 Rotate the turntable until pushing the drive enable button,
the boom moves past the drive function will not operate.
one of the circle-end
tires.
Result: The drive enable indicator light should
come on while the boom is anywhere in the
range shown.
4 Move the drive/steer control handle off center.
Result: No drive function should operate.
TABLE B PROCEDURES
B-25 5 Bring the machine to top drive speed before

reaching the test line. Release the drive joystick
Test the Drive Brakes when your reference point on the machine
crosses the test line.
6 Measure the distance between the test line and
your machine reference point.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
Braking, High range 4 to 6 ft
smoothly, free of hesitation, jerking and unusual
paved surface 1.2 to 1.8 m
noise. Hydrostatic brakes and hydraulically-
released individual wheel brakes can appear to
operate normally when they are actually not fully
operational. The brakes must be able to hold
the machine on any slope it is able
Collision hazard. Be sure that the to climb.
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 test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
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
B-26 B-27
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised or Extended Position
Proper drive function movement is essential to Proper drive function movement is essential to
safe machine operation. The drive function should safe machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of Drive performance should also be free of
hesitation, jerking and unusual noise over the hesitation, jerking and unusual noise over the
entire proportionally controlled speed range. entire proportionally controlled speed range.
Select a test area that is firm, level Select a test area that is firm, level
and free of obstructions. and free of obstructions.
1 Create start and finish lines by marking two 1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart. lines on the ground 40 feet (12.2 m) apart and
two lines on the ground 10 feet (3 m) apart.
3 Press the engine rpm select button until the foot
switch activated high idle (rabbit and foot switch 3 Press the engine idle select button until the foot
symbol) is selected, then lower the boom into switch activated high idle (rabbit and foot switch
the stowed position. symbol) is selected.
4 Choose a point on the machine; i.e., contact 4 Raise the boom until the engine rpm switches to
patch of a tire, as a visual reference for use low speed.
when crossing the start and finish lines.
5 Bring the machine to top drive speed before patch of a tire, as a visual reference for use
reaching the start line. Begin timing when your when crossing the start and finish lines.
reference point on the machine crosses the
6 Bring the machine to top drive speed before
start line.
reaching the start line. Begin timing when your
6 Continue at full speed and note the time when reference point on the machine crosses the
the machine reference point crosses the finish start line.
line.
Drive speed: 40 ft/9.1 sec

stowed position 12.2 m/9.1 sec
TABLE B PROCEDURES
7 Continue at full speed and note the time when 16 Bring the machine to top drive speed before
the machine reference point crosses the finish reaching the start line. Begin timing when your
line. reference point on the machine crosses the
start line.
Drive speed: 40 ft/40 sec 17 Continue at full speed and note the time when
raised position 12.2 m/40 sec
the machine reference point crosses the finish
line.
8 Lower the boom below horizontal.

Drive speed: 10 ft/18 sec
9 Extend the boom approximately 4 feet (1.2 m). fully extended position 3 m/18 sec

11 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
12 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
Drive speed: 40 ft/40 sec

extended position 12.2 m/40 sec
13 Raise the boom to a horizontal position.

14 Extend the boom until the raise boom LED and
envelope alarm are activated.
TABLE B PROCEDURES
B-28 3 Turn the key switch to platform control.

Test the Alarm Package Result: The flashing beacon should be on
and flashing.
(if equipped)
4 Press down the foot switch. Move the boom
The alarm package includes: control handle to the DOWN position, hold for a
Travel alarm moment and then release it.
Descent alarm Result: The descent alarm should sound when
Travel and descent alarm the control handle is held down.
Motion alarm 5 Press down the foot switch. Move the drive
control handle off center, hold for a moment
Flashing beacon
and then release it. Move the drive control
Alarms and a beacon are installed to alert handle off center in the opposite direction, hold
operators and ground personnel of machine for a moment and then release it.
proximity and motion. The alarm package is
Result: The travel alarm should sound when the
installed on the turntable covers.
drive control handle is moved off center in
The alarms and beacon will either direction.
operate with the engine
running or not running.
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.
TABLE B PROCEDURES
B-29 3 Remove the drain plug from the oil pan and
allow all of the oil from the engine to drain into a
Replace the Engine Oil and suitable container.
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. Cummins Model
a filter head
Bodily injury hazard. Beware of b oil filter
hot engine parts and oil. Contact c oil filler cap
with hot engine oil and/or engine 4 Install the drain plug into the engine and tighten.
parts may cause severe burns.
5 Use an oil filter wrench and remove the oil filter.
Perform this procedure after
warming the engine to normal 6 Clean inside the filter head.
operating temperature. 7 Fill the filter with clean engine oil.
1 Remove the oil filler cap from the valve cover. 8 Apply a thin layer of clean oil to the new filter
2 Place a suitable container under the engine gasket (Genie part number 62436). Install the
tray. See capacity specifications. filter and tighten it securely by hand.
9 Clean up any oil that may have spilled during
the procedure.
the filter.
TABLE B PROCEDURES
11 Fill the engine with new oil per specifications B-30

and install the oil filler cap.
Inspect the Fuel Tank Cap Venting
12 Start the engine from the ground controls and
allow the engine to run for 30 seconds. Stop the
System
engine.
13 Check the oil filter and oil drain plug for leaks.
14 Wait 15 minutes after stopping the engine and A free-breathing fuel tank cap is essential for good
check the engine oil level on the dipstick. Add engine performance and service life. A dirty or
oil if needed. clogged fuel tank cap may cause the engine to
perform poorly and continued use may cause
15 Dispose of the used oil and filter properly. component damage. Extremely dirty conditions
may require that the cap be inspected more often.
Cummins B3.9L Engine 11.5 quarts
Oil capacity (including filter) 10.9 liters Explosion and fire hazard. Engine
fuels are combustible. Perform this
Oil filter - Genie part number 62436 procedure in an open, well-
ventilated area away from heaters,
Cummins B3.9L Engine sparks, flames and lighted
Engine oil viscosity requirements tobacco. Always have an
below 68F / 20C 5W-30 easy reach.
-13 to 68F / -25 to 20C 10W-30 Perform this procedure with the
engine off.
above 15F / -9C 15W-40
1 Remove the cap from the fuel tank.
Use oils meeting API classification CE (labeled CE/SG). 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.
TABLE B PROCEDURES
If the fuel tank cap vent is working properly, B-31

proceed to step 5.
Perform Hydraulic Oil Analysis
3 Using a mild solvent, carefully wash the fuel
tank cap. Dry the cap using low pressure
compressed air.
4 Repeat step 2. See E-1, Test or Replace the Hydraulic Oil.
5 Install the fuel tank cap onto the fuel tank.
Table C Procedures
C-1 C-2
Check the Engine Valve Clean the Fuel Pump Strainer -
Clearances - Perkins Models
Deutz Models
Cleaning the fuel pump strainer is essential to

Complete information to perform this procedure is good engine performance and service life. A dirty
available in the Deutz 913 Operation Manual, or clogged strainer may cause the engine to
Deutz part number 0297 9690 (Genie part number perform poorly and continued use may cause
62446). component damage. Extremely dirty conditions
may require that the strainer be cleaned more
often.
Explosion and fire hazard. Engine
fuels are combustible. Replace the
fuel filter in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
easy reach.
engine off.
1 Tag, disconnect and plug the fuel line from the
fuel tank at the inline fuel filter/water separator
head.
TABLE C PROCEDURES
2 Remove the engine pivot plate retaining 5 Locate the fuel lift pump.
from the machine.
a b

a fuel lift pump
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.
from moving.
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
TABLE C PROCEDURES
7 Remove the strainer from the fuel lift pump. C-3

8 Using a mild solvent, carefully wash the inside Replace the Fuel Filter Element -
of the fuel lift pump body.
Perkins and Cummins Models
9 Using a mild solvent, clean the strainer, the seal
and the lift pump cover.
10 Install the strainer and seal onto the fuel lift
pump body. Replacing the diesel fuel filter element is essential
for good engine performance and service life. A
11 Install the cover onto the fuel lift pump. Tighten dirty or clogged filter may cause the engine to
the fuel lift pump cover retaining fastener. perform poorly and continued use may cause
Be sure that the lift pump body component damage. Extremely dirty conditions
and cover are installed correctly. may required that the filter be replaced more often.
An incorrect fit will let air into the Explosion and fire hazard. Engine
fuel system. fuels are combustible. Perform this
12 Clean up any fuel that might have spilled during procedure in an open, well-
the procedure. ventilated area away from heaters,
13 Bleed the fuel system. See Maintenance tobacco. Always have an
Procedure B-4, Replace the Inline Fuel Filter/ approved fire extinguisher within
Water Separator Element. easy reach.
Before bleeding the system, fill the Perform this procedure with the
fuel tank. 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.
TABLE C PROCEDURES
2 Remove the engine pivot plate retaining 6 Remove the fuel filter element and dispose of
fastener. Swing the engine pivot plate out away properly.
from the machine.
7 Clean the inside surfaces of the filter head.
8 Fill the new fuel filter element with clean diesel
fuel. Lightly lubricate the O-ring with clean
diesel fuel and install the element into the filter
head.
Failure to fill the fuel filter element
with clean diesel fuel before
installation will require bleeding
a b
the fuel system.
b engine pivot plate retaining fastener 9 Clean up any fuel that may have spilled during
this procedure.
pivot end of the engine pivot plate. 10 Use a permanent ink marker to write the date
4 Install the bolt that was just removed into the the filter.
from moving. 11 Install the fuel tank line onto the inline fuel filter/
the bolt into the engine pivot plate 12 Bleed the fuel system. See Maintenance
to secure it from moving could Procedure B-4, Replace the Inline Fuel Filter/
result in death or serious injury. Water Separator Element.
5 Locate the fuel filter. Thoroughly clean the Before bleeding the system, fill the
outside surfaces of the fuel filter assembly. fuel tank.
Fuel filter elements -

Genie part numbers
Perkins models 62426

Cummins models 62435
Cummins model
a fuel filter
b lift pump
TABLE C PROCEDURES
C-4 4 Use an oil filter wrench to remove the oil filter.

Replace the Engine Oil and
Filter -
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 Deutz model
anticipate and perform oil and filter changes at a oil filler cap
b oil filter
the 500 hour interval. c filter head
d fuel filter
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. Perkins model
a oil filler cap
3 Install the sealing washer onto the drain plug b oil filter
and tighten the drain plug. c filter head
TABLE C PROCEDURES
5 Clean inside the filter head. 14 Dispose of the used oil and filter properly.
6 Fill the filter with clean engine oil.
Deutz F4L 913 Engine 14.3 quarts
7 Apply a thin layer of clean engine oil to the new Oil capacity (including filter) 13.5 liters
filter gasket. Install the filter and tighten it
securely by hand. Deutz F4L 913 Engine
8 Clean up any oil that may have spilled during
this procedure. below 60F / 15.5C (synthetic) 5W-30
-10F to 90F / -23C to 32C 10W-40
the filter.
above -4F / -20C 15W-40
10 Fill the engine with new oil per specifications
and install the oil filler cap. Engine oil should have properties of API classification
CC/SE or CC/SF grades OR ACEA classification E1-96.
allow the engine to run for 30 seconds. Stop the Oil filter - Genie part number 62430
engine.
12 Check the oil filter and oil drain plug for leaks.
13 Wait 15 minutes after stopping the engine and Perkins 1004-42 Engine 8.9 quarts
check the engine oil level on the dipstick. Add Oil capacity (including filter) 8.4 liters
oil if needed.
Perkins 1004-42 Engine
below 32F / 0C 0W
-13F to 68F / -25C to 20C 5W-20
10F to 104F / -12C to 40C 10W-30
14F to 122F / -10C to 50C 15W-40
above 23F / -5C 20W-50

Oil filter - Genie part number 62427
TABLE C PROCEDURES
C-5 5 Remove the radiator filler cap. Inspect the cap

for wear. Replace as necessary.
Check the Specific Gravity of the
Burn hazard. Allow any pressure
Coolant - to dissipate gradually before
Liquid Cooled Models removing the radiator cap.
6 Drain some coolant from the cooling system
into a suitable container.
The quality of the coolant which is used can have a 7 Use a special coolant hydrometer to check the
great effect on the efficiency and life of the cooling temperature and the specific gravity of the
system. Old or dirty coolant may cause the engine coolant.
to perform poorly and continued use may cause 8 Adjust the mixture of the coolant as necessary
engine damage. to protect the engine to -34F (-37C).
Burn injury hazard. Beware of hot 9 Install the radiator filler cap.
engine parts and coolant. Contact
with hot engine parts and/or
coolant may cause severe burns.
machine on level ground.
engine off.
1 Put on protective clothing and eyewear.
2 Operate the engine until it is warm enough to
open the thermostat. Continue to run the engine
until the coolant has circulated the cooling
system.
3 Stop the engine.
4 Allow the engine to cool until the temperature of
the coolant is below 140 F (60 C).
Burn hazard. Beware of hot
coolant. Contact with hot coolant
may cause severe burns.
TABLE C PROCEDURES
C-6 2 Remove the retaining fasteners from the access

covers located on the side of the boom at the
Inspect the Boom Extend/Retract platform end of the machine. Remove the
Cables covers.
3 Visually inspect the cables and components
through both inspection holes for the following:
Frayed or broken wire strands
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom Kinks or crushed cables
tube. Inspecting for foreign objects, damage and/or Corrosion
improper adjustment of the boom extend/retract
Paint or foreign materials on the cables
cables on a regular basis is essential to good
machine performance and safe machine operation. Split or cracked cable ends
The boom extend and retract functions should
Cables are on all pulleys
operate smoothly and be free of hesitation, jerking
and unusual noise. Cables have equal tension
Perform this procedure with the Cables at end of adjustment range

boom in the stowed position and No Broken or damaged pulleys
the engine off.
No Unusual or excessive pulley wear
1 Remove the boom end cover from the pivot end All fasteners in place and secure
of the boom.
A flashlight and inspection mirror
may be necessary to thoroughly
inspect the above items.
A pulley groove gauge should be
used to check the condition of the
pulleys.
4 Replace the cables if any damage is found.
5 At the pivot end of the boom, visually inspect for
a boom end cover
the following:
b side access covers The red locking bracket is securely installed
c cable ends (located
underneath the boom) over the cable adjustment bolts
6 Install the plastic cover at the pivot end of the
boom and access panels on the sides of the
boom.
TABLE C PROCEDURES
8 Extend the boom approximately 2 feet (0.6 m).

9 Retract the boom. While retracting the boom,
visually inspect the number 2 and number 3
boom tubes.
Result: The number 2 should not move more
than 1/2 inch (13 mm) before the number 3
boom tube begins to retract.
If the number 2 boom tube moves
more than 1/2 inch (13 mm) before
the number 3 boom tube begins to
retract, the boom extend/retract
cables need to be adjusted. See
Repair Procedure 4-5, How to
Adjust the Boom Extend/Retract
Cables.
Table D Procedures
D-1 7 Remove the boom side inspection cover
retaining fasteners from the boom at the pivot
Check the Boom Wear Pads end of the boom. Remove the boom inspection
Maintaining the boom wear pads in good condition cover from the machine.
is essential to safe machine operation. Wear pads 8 Repeat step 7 until all boom inspection covers
are placed on boom tube surfaces to provide a low at the pivot end of the boom are removed.
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued 9 Measure each wear pad at the pivot end of the
use of worn out wear pads may result in boom.
component damage and unsafe operating
conditions. Boom wear pad specifications 1/2 inch
Minimum thickness 12.7 mm
2 Raise the end of the boom to a comfortable
working height (chest high). Stop the engine. 10 Replace any wear pad if it is less than
specification. If a wear pad is not less than
3 Remove the protective covers from the platform specification, shim as necessary to obtain zero
end of each boom tube. clearance.
4 Measure each wear pad. 11 Extend and retract the boom through the entire
range of motion to check for tight spots that
Boom wear pad specifications 1/2inch may cause binding of the boom tubes.
Always maintain squareness
between the outer and inner
boom tubes.
5 Replace any wear pad if it is 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
D-2 4 Extend and retract the axles through the entire

range of motion to check for tight spots that
Check the Extendable Axle may cause binding or scraping of the axle
Wear Pads tubes.
between the outer and inner
axle tubes.
Maintaining the axle wear pads in good condition is
essential to safe machine operation. Wear pads
are placed on axle tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in
component damage and unsafe operating
conditions.
Be sure that the axles are fully
extended before attempting this
procedure.
1 Start the engine from the platform controls and
extend the axles.
2 Measure each wear pad.
Extendable axle wear pad specifications 7/16 inch

3 Replace any wear pad if it is 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.
TABLE D PROCEDURES
D-3 5 Manually rotate each wheel at the square-end

of the machine.
Check the Free-wheel
Result: Each wheel at the square-end of the
Configuration 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
Proper use of the free-wheel configuration is
remove the blocks. Lower the machine.
essential to safe machine operation. The
free-wheel configuration is used primarily for Collision hazard. Failure to
towing. A machine configured to free-wheel without re-engage the drive hubs could
operator knowledge may cause death or serious result in death or serious injury
injury and property damage. and property damage.
Collision hazard. Select a work 7 Chock both of the wheels at the square-end of
site that is firm and level. the machine to prevent the machine from
rolling.
1 Chock both of the wheels at the circle-end of
the machine to prevent the machine from 8 Center a lifting jack of ample capacity
rolling. (30,000 lbs/15000 kg) under the drive chassis
between the wheels at the circle-end of the
2 Center a lifting jack of ample capacity machine.
(30,000 lbs/15000 kg) under the drive chassis
between the wheels at the square-end of the 9 Lift the wheels off the ground and place jack
machine. stands under the drive chassis for support.
3 Lift the wheels off the ground and place blocks 10 Disengage the drive hubs by turning over the
under the drive chassis for support. drive hub disconnect caps on each wheel hub
at the circle-end of the machine.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each wheel hub 11 Manually rotate each wheel at the circle-end of
at the square-end of the machine. the machine.
disengage position 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
engage position check for engagement. Lift the machine and
remove the jack stands. Lower the machine.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury
and property damage.
TABLE D PROCEDURES
D-4 3 Be sure that each turntable rotation bearing

mounting bolt above the turntable is torqued in
Check the Turntable Rotation sequence to 190 ft-lbs (258 Nm).
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.
2 Install a safety chock (Genie part number
75097) onto the hydraulic lift cylinder extension
rod. Carefully lower the boom onto the lift
cylinder safety chock.
Crushing hazard. Keep hands
away from the cylinder and all
moving parts when lowering the
boom.
The lift cylinder safety chock is Bolt torque sequence
available through Genie (Genie
part number 75097). 4 Raise the boom to a horizontal position.
5 Remove the safety chock and lower the boom
to the stowed position.
6 Be sure that each turntable rotation bearing
mounting bolt under the drive chassis is
torqued in sequence to 190 ft-lbs (258 Nm).
The turntable rotation bearing bolt
torque sequence is the same from
above the turntable and below the
drive chassis.
TABLE D PROCEDURES
D-5 2 Mark a test line approximately two feet long

(0.6 m), perpendicular to the length to the
Check the Turntable Rotation boom, on the ground under the platform and
Gear Backlash 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
Properly adjusted turntable rotation gear backlash use while performing this
is essential for good machine performance and procedure.
service life. Improperly adjusted turntable rotation
3 Apply approximately 20 lbs (89 N) of side force
gear backlash will cause the machine to perform
to the platform, moving the platform to one side
poorly and continued use will cause component
as far as it will go. Mark a reference point on
damage. The turntable rotation drive hub is
the test line where the platform stops moving.
mounted on the swing chassis behind the fixed
side cover at the ground controls side. 4 Apply approximately 20 lbs (89 N) of side force
to the platform, moving the platform in the
Be sure to check the backlash opposite direction as far as it will go. Mark a
with the machine fully stowed and reference point on the test line where the
the counterweight at the square platform stops moving.
end of the machine.
5 Measure the distance on the test line between
Select a test area that is firm, level the two reference marks.
and free of obstructions.
Result: The platform movement should not
This procedure may require two exceed 2 inches (51 mm). If the platform
people. movement exceeds 2 inches (51 mm), proceed
1 Rotate the turntable in a clockwise direction to step 6.
until the turntable rotation motor pinion gear is
directly over the 3 red-painted gear teeth on the Turntable rotation gear backlash
turntable rotation bearing. Maximum side to side movement 2 inches
at platform 51 mm
The 3 red-painted gear teeth on
the turntable rotation bearing are
the teeth closest to the blue arrow
side of the drive chassis.
a yellow arrow
a blue arrow
b red painted teeth
TABLE D PROCEDURES
Adjusting the backlash: 10 Tighten the turntable drive hub adjustment bolt
until the turntable drive hub gear is fully
6 Remove the ground control side fixed turntable
engaged and tight into the turntable rotate gear.
cover from the machine. Refer to Repair
Section 5-1, How to Remove a Fixed Turntable 11 Turn the adjustment bolt 1/4 turn
Cover. counterclockwise. Tighten the lock nut on the
adjustment bolt.
7 Loosen the turntable drive hub mounting bolts.
Do not remove them. 12 Rotate the drive hub away from the turntable
until it contacts the adjustment bolt. Torque the
It may be necessary to raise the
drive hub mounting bolts to 210 ft-lbs (283 Nm).
boom slightly to access all the
turntable drive hub mounting bolts. 13 Torque the turntable rotate pivot bolt to
210 ft-lbs (283 Nm).
14 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
15 Install the ground control side fixed turntable
cover onto the machine and tighten the
retaining fasteners.
a motor
b brake
c drive hub
d pivot bolt
e mounting bolt
f adjustment bolt with lock nut
8 Loosen the turntable drive hub pivot bolt. Do not

remove it.
9 Loosen the lock nut on the turntable drive hub
adjustment bolt.
TABLE D PROCEDURES
D-6 D-7
Grease the Turntable Rotation Replace the Drive Hub Oil
Bearing and Rotate Gear
Replacing the drive hub oil is essential for good

Yearly application of lubrication to the turntable machine performance and service life. Failure to
bearing and rotate gear is essential to good replace the drive hub oil at yearly intervals may
machine performance and service life. Continued cause the machine to perform poorly and
use of an improperly greased bearing and gear will continued use may cause component damage.
result in component damage. Drive Hubs:
1 Remove the turntable rotation gear cover 1 Select the drive hub to be serviced. Drive the
retaining fasteners and remove the gear cover machine until one of the two drain plugs is at
from the machine. the lowest point.
2 Open the ground controls side turntable side 2 Remove both plugs and drain the oil into a
cover. suitable container.
3 Locate the grease fitting below the ground 3 Drive the machine until one plug hole is at the
control box. top and the other is at 90.
4 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5
inches (10 to 13 cm) at a time and repeat this a
step until the entire bearing has been greased.
5 Apply grease to each tooth of the drive gear,
located under the turntable.
6 Install the turntable rotation gear cover and
retaining fasteners onto the machine.
Bodily injury hazard. Contact with a drive hub plugs
the turntable rotation gear could
4 Fill the hub with oil from the top hole until the oil
result in serious injury. Do not
level is even with the bottom of the side hole.
operate the machine if the
turntable rotation gear cover is not
installed.
Grease type Multi-purpose grease
TABLE D PROCEDURES
5 Install the plug into the drive hub. 2 Remove the ground control side fixed turntable
cover. Refer to Repair Section 5-1, How to
When removing the drive hub plug
Remove a Fixed Turntable Cover.
158, replace the drive hub plug 3 Tag, disconnect and plug the turntable rotate
with the new O-ring style drive hub drive motor hoses at the turntable rotate drive
plug (Genie part number 75107). motor and the turntable rotate drive brake
hoses at the turntable rotate drive brake. Cap
6 Repeat steps 1 through 5 for all the other drive
the fittings.
hubs.
Bodily injury hazard. Spraying
Drive hub oil hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Capacity 83 fl oz connections very slowly to allow
2.5 liters the oil pressure to dissipate
gradually. Do not allow oil to squirt
Type: SAE 80W-90 EP multipurpose gear oil or spray.
Hoses can be damaged if they are
Turntable Rotate Drive Hub: kinked or pinched.
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.
a drive motor
b drive brake
c brake drain plug
unlocked locked d drive hub
e pivot bolt
f mounting bolt
g adjustment bolt with lock nut
h drive hub drain plug
TABLE D PROCEDURES
4 Remove the turntable rotate drive hub mounting 9 Install the drive hub onto the machine. Install
bolts and pivot bolt. Remove the turntable the pivot bolt and the mounting bolts and
rotate drive hub with a suitable lifting device of tighten the bolts until they are finger tight.
ample capacity.
10 Install the turntable rotate drive motor hoses
Crushing hazard. The turntable into the turntable rotate drive motor and install
rotate drive hub may become the turntable rotate drive brake hose into the
unbalanced and fall when it is turntable rotate drive brake.
removed from the machine if it is
not properly supported. Component damage hazard.
Hoses can be damaged if they are
5 Remove the drive brake drain plug from the kinked or pinched.
side of the drive brake and drain the oil from the
drive brake into a suitable container. See 11 Adjust the turntable rotation gear backlash. See
capacity specifications. D-5, Check the Turntable Rotation Gear
Backlash.
6 Remove the drive hub drain plug from the side
of the drive hub and drain the oil from the drive 12 Install the ground control side fixed turntable
hub into a suitable container. See capacity cover onto the machine and tighten the
specifications. retaining fasteners.
7 Fill the drive hub with oil until the oil is level Turntable rotate drive hub oil
with the bottom of the threads. Install the drain
plug and tighten. Capacity 92 fl oz
2.7 liters
When removing the drive brake
plug on machines before serial
Type: SAE 80W-90 EP multipurpose gear oil
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
158, replace the drive hub plug
with the new O-ring style drive hub
plug (Genie part number 75107).
TABLE D PROCEDURES
D-8 2 Locate the engine pivot plate anchor hole at the

Inspect the Engine Belt(s) -
Cummins Models anchor hole to secure the engine pivot plate
from moving.
Maintaining the engine belt is essential to good the bolt into the engine pivot plate
engine performance and service life. The machine anchor hole to secure it from
will not operate properly with a loose or defective moving could result in death or
belt and continued use may cause component serious injury.
damage. If the machine is not equipped with the
generator option, proceed to step 7.
inspect while the engine is 4 Loosen the generator and remove the generator
running. Remove the key to belt.
5 Inspect the generator belt for:
hot engine components. Contact Cracking
with hot engine components may Glazing
cause severe burns. Separation
1 Remove the engine pivot plate retaining Breaks
from the machine. a
a b a generator (option)
b generator belt
TABLE D PROCEDURES
6 Replace the belt if any damage is found. 15 Install the bolt that was just removed into the
7 Lift the belt tensioner and remove the engine
belt. Crushing hazard. Failure to install
8 Inspect the engine belt for:
Cracking result in death or serious injury.
Glazing
Belts - Genie part numbers
Separation
Breaks Cummins Engine Belt 62437
9 Replace the belt if any damage is found. Cummins Generator Belt 60725
10 Check the torque of the belt tensioner retaining Generator belt deflection 3 /8inch to 1/2 inch
fastener. Torque to 32 ft-lbs (43 Nm). 9 mm to 12 mm
11 Lift the belt tensioner and install the engine belt.

Cummins engines are equipped
with a serpentine belt and
incorporate a self adjusting pulley
tensioner. No adjustment is
required.
If the machine is not equipped with the
generator option, proceed to step 13.
12 Install the generator belt.

machine.
TABLE D PROCEDURES
D-9 2 Place a suitable container beneath the fuel filter.

Replace the Fuel Filter -
Deutz Models
Replacing the diesel fuel filter is essential to good

engine performance and service life. A dirty or
clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
a overflow valve
fuels are combustible. Replace the b fuel lift pump priming lever
fuel filter in an open, well- c oil filter
ventilated area away from heaters, d filter head
sparks, flames and lighted e fuel filter
tobacco. Always have an 3 Loosen the fuel filter with a filter wrench and
approved fire extinguisher within drain the fuel into a suitable container. Remove
easy reach. the fuel filter from the machine when the fuel
Perform this procedure with the flow has slowed or stopped.
engine off. 4 Apply a thin layer of clean diesel fuel to the new
Immediately clean up any fuel that fuel filter gasket (Genie part number 29560).
may have spilled during this 5 Install the new filter and tighten it securely by
procedure. hand.
1 Tag, disconnect and plug the fuel hose from the 6 Clean up any diesel fuel that might have spilled
fuel tank at the inline fuel filter/water separator during the procedure.
head.
the filter.
TABLE D PROCEDURES
8 Install the fuel tank hose onto the inline fuel D-10
filter/water separator head. Tighten the hose
clamp. Check the Engine Valve
9 Bleed the fuel system. See Maintenance
Clearances -
Procedure B-4, Replace the Inline Fuel Filter/ Perkins and Cummins Models
Water Separator Element.
Before bleeding the system, fill the
fuel tank.
Perkins models:
Complete information to perform this procedure is

available in the Perkins User's Handbook,
Perkins part number TPD 1349
(Genie part number 62447).
Cummins models:

available in the Cummins Operation and
Maintenance Manual, Cummins part number
3810205 (Genie part number 62448).
Table E Procedures
E-1 2 Close the three hydraulic shutoff valves located
at the hydraulic tank.
Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil is

service life. Dirty oil and suction strainers may
cause the machine to perform poorly and open closed
continued use may cause component damage.
Extremely dirty conditions may require oil changes Component damage hazard. The
to be performed more frequently. engine must not be started with
the hydraulic tank shutoff valves in
The machine uses Dexron the CLOSED position or component
equivalent hydraulic oil. Before damage will occur. If the tank
replacing the hydraulic oil, the oil valves are closed, remove the key
may be tested by an oil distributor from the key switch and tag the
for specific levels of contamination machine to inform personnel of the
to verify that changing the oil is condition.
necessary. If the hydraulic oil is
not replaced at the two year 3 Remove the drain plug from the hydraulic tank
inspection, test the oil quarterly. and allow all of the oil from the tank to drain into
Replace the oil when it fails the a suitable container. See capacity
test. specifications.
Perform this procedure with the 4 Remove the ground controls support bracket
boom in the stowed position and retaining fasteners and remove the ground
the axles extended. control box assembly from the machine.
When removing a hose assembly Component damage hazard.

or fitting, the O-ring on the fitting Be sure to properly support the
and/or hose end must be replaced ground control box. Do not allow
and then torqued to specification the ground control box to hang by
during installation. the wiring or cables.
Refer to Section Two, Hydraulic 5 Tag and disconnect the wires from the horn.
Hose and Fitting Torque Remove the horn retaining fasteners and
Specifications. remove the horn from the machine.
1 Remove the ground controls side turntable side
Remove a Hinged Turntable Cover.
TABLE E PROCEDURES
6 Tag, disconnect and plug the two suction hoses 15 Remove the case drain filter from the case drain
that are attached to the hydraulic tank shutoff filter head.
valves. Cap the fittings.
16 Remove the suction strainers from the tank and
7 Tag, disconnect and plug the supply hose for clean them using a mild solvent.
the auxiliary power unit. Cap the fitting on the
17 Rinse out the inside of the tank using a mild
hydraulic tank.
solvent.
8 Tag, disconnect and plug the case drain hose at
18 Install the suction strainers using Loctite 567
the return filter. Cap the fitting on the return
on the pipe threads.
filter head.
Always use Loctite 567 on all
9 Disconnect and plug the T-fitting located at the pipe threads.
return filter with the 2 hoses connected to it.
Cap the fitting on the return filter head. 19 Install the drain plug using Loctite 567 on the
pipe threads.
10 Remove the hydraulic tank breather filter from
the tank. Always use Loctite 567 on all
pipe threads.
11 Remove the hydraulic tank strap retaining
fasteners and remove the hydraulic tank straps 20 Install the hydraulic tank onto the machine.
from the machine. 21 Install the hydraulic tank retaining straps and
12 Support the hydraulic tank with 2 lifting straps. install the hydraulic tank retaining fasteners.
Place one lifting strap at each end of the tank 22 Install the horn and horn retaining fasteners
and attach the lifting straps to an overhead onto the machine. Connect the wiring.
crane.
23 Install the ground control box assembly and
13 Remove the hydraulic tank from the machine. assembly retaining fasteners onto the machine.
Crushing hazard. The hydraulic 24 Install the two suction hoses and the supply
tank could become unbalanced hose for the auxiliary power unit onto the
and fall if it is not properly machine.
supported and secured to the
25 Install the case drain hose onto the return filter
overhead crane when it is
head.
removed from the machine.
26 Install the T-fitting and 2 hoses connected to it
14 Remove the hydraulic tank return filter from the
to the hydraulic tank return filter head.
hydraulic tank return filter head.
TABLE E PROCEDURES
27 Fill the tank with hydraulic oil until the level is 3/4 36 Open the hydraulic tank shutoff valves.
inch (19 mm) from the top of the sight gauge.
Do not overfill.
Be sure to open the two hydraulic
28 Apply teflon tape to the threads of the hydraulic tank shutoff valves and prime the
tank filter mount. pump after installing the hydraulic
tank.
29 Install a new tank breather filter (Genie part
Refer to Repair Section 10-2, How
number 60559) onto the filter mount and tighten
to Prime the Pump.
Use only Dexron equivalent
hydraulic fluid.
the filter. 37 Install the turntable side cover.
31 Install a new tank case drain return filter (Genie
part number 44207) onto the filter mount and Hydraulic system
tighten it securely by hand.
Hydraulic tank capacity 55 gallons
32 Use a permanent ink marker to write the date 208 liters
the filter. Hydraulic system 80 gallons
capacity (including tank) 303 liters
33 Install a new tank return filter (Genie part
number 61326) onto the filter mount and tighten Hydraulic fluid Dexron equivalent
Hydraulic tank return filters -
Genie part numbers
the filter. Hydraulic tank breather filter 60559
35 Clean up any oil that may have spilled during System return filter 61326
the procedure. Drive motor case drain return filter 44207
TABLE E PROCEDURES
E-2 2 Locate the engine pivot plate anchor hole at the

Change or Recondition the
Engine Coolant - anchor hole to secure the engine pivot plate
Liquid Cooled Models from moving.
Replacing or reconditioning the engine coolant is result in death or serious injury.
essential to good engine performance and service
life. Old or dirty coolant may cause the engine to 4 Put on protective clothing and eye wear.
perform poorly and continued use may cause 5 Disconnect the coolant return hose at the
engine damage. Extremely dirty conditions may radiator and drain the coolant return tank into a
require coolant to be changed more frequently. suitable container. See capacity specifications.
Bodily injury hazard. Beware of 6 Slowly remove the radiator cap from the
hot engine parts and coolant. radiator.
Contact with hot engine parts
Bodily injury hazard. Allow any
and/or coolant will cause severe
pressure to dissipate gradually
burns.
before removing the radiator cap.
7 Open the drain valve on the radiator and allow
engine off and cooled.
the coolant to drain into a suitable container.
8 After all the coolant has drained, close the drain
valve.
from the machine.
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
a b
(coolant and water) for your climate until it is
full.
TABLE E PROCEDURES
13 Fill the coolant recovery tank to the COLD FULL E-3

line on the tank.
Change the Fuel Hoses
14 Clean up any coolant that may have spilled
during this procedure.
let it run until the engine is up to operating Maintaining the fuel hoses in good condition is
temperature. Continue to run the engine until essential to safe operation and good engine
the coolant has circulated the cooling system. performance. Failure to detect a worn, cracked or
leaking fuel hose may cause an unsafe operating
16 Stop the engine.
condition.
17 Allow the engine to cool.
18 Remove the engine pivot plate retaining fuels are combustible. Replace the
fastener from the engine pivot plate anchor hole fuel lines in an open, well-
at the pivot end of the engine pivot plate. ventilated area away from heaters,
machine.
20 Install the bolt that was just removed into the easy reach.
Bodily injury hazard. Fuel may be
Crushing hazard. Failure to install expelled under pressure. Wrap a
the bolt into the engine pivot plate cloth around fuel hoses to absorb
to secure it from moving could leaking fuel before disconnecting
result in death or serious injury. them.
21 Check the coolant level in the coolant recovery Immediately clean up any fuel that
tank. Add coolant if needed. may have spilled during this
procedure.
Coolant capacity 20 quarts 18.9 liters Perform this procedure with the
engine off.
Deutz models:
1 Remove the engine side turntable fixed side
TABLE E PROCEDURES
2 Tag, disconnect and plug the fuel line from the 2 Remove the engine pivot plate retaining
fuel tank at the inline fuel filter/water separator fastener. Swing the engine pivot plate out away
head. from the machine.
3 Remove and replace the following fuel line
hoses and clamps:
Hose from the fuel tank to the inline fuel
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 a b
pump
Hose from the fuel injectors to the fuel tank
3 Clean up any fuel that may have spilled during
this procedure. 3 Locate the engine pivot plate anchor hole at the
water separator head. Tighten the hose clamp. 4 Install the bolt that was just removed into the
5 Install the ground control side fixed turntable from moving.
cover onto the machine and tighten the
retaining fasteners. Crushing hazard. Failure to install
6 Bleed the fuel system. See B-4, Replace the to secure it from moving could
Inline Fuel Filter/ Water Separator Element. result in death or serious injury.
Before bleeding the system, fill the 5 Tag, disconnect and plug the fuel line from the
fuel tank. fuel tank at the inline fuel filter/water separator
Perkins and Cummins models: head.
1 Remove the engine side turntable fixed side

TABLE E PROCEDURES
6 Remove and replace the following fuel line E-4

hoses and clamps:
Check the Engine Valve
Perkins models:
Clearances -
Hose from the fuel tank to the inline fuel Cummins Models
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: available in the Cummins Operation and
Hose from the fuel tank to the inline fuel Maintenance Manual, Cummins part number
filter/water separator 3810205 (Genie part number 62448).
Hose from the inline fuel filter/water separator
to the fuel lift pump
Hose from the fuel injectors to the fuel tank E-5
7 Clean up any fuel that may have spilled during
Check the Fuel Injectors -
this procedure. Deutz Models
9 Install the ground control side fixed turntable Engine specifications require
cover onto the machine and tighten the that this procedure be performed
retaining fasteners. at 3000 hours.
10 Bleed the fuel system. See Maintenance Complete information to perform this procedure is
Procedure B-4, Replace the Inline Fuel Filter/ available in the Deutz Workshop Manual, Deutz
Water Separator Element. part number 297-7293 (Genie part number 62434).
Before bleeding the system, fill the
fuel tank.
Printing (February 2009) Section 4 Scheduled Maintenance Procedures
REV B TABLE E PROCEDURES
E-6
Replace the Boom Extend/
Retract Cables
Genie specifications require that

this procedure be performed every
7 years.
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. Replacement of the boom extend/retract
cables is essential to good machine performance
and safe machine operation. The boom extend/
retract functions should operate smoothly and be
1 Replace the boom extend cables. Refer to

Repair Procedure 4-5, How to Replace the
Boom Extend/Retract Cables.
First Edition First Printing Section 5 Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Genie S-100
and Genie S-105 Operator's Manual or the Genie
S-120 and Genie S-125 Operator's Manual.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropiate flow chart thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Crushing hazard. When testing
before operating the machine. or replacing any hydraulic
component, always support
Unless otherwise specified, perform each the structure and secure it
repair procedure with the machine in the from movement.
following configuration:
Electrocution hazard. Contact
Machine parked on a flat, level surface
with electrically charged circuits
Boom in stowed position could result in death or serious
Turntable rotated with the boom between injury. Remove all rings, watches
the circle-end wheels and other jewelry.
Turntable secured with the turntable Bodily injury hazard. Spraying
rotation lock pin hydraulic oil can penetrate and
Key switch in the OFF position with the burn skin. Loosen hydraulic
key removed connections very slowly to allow
the oil pressure to dissipate
Welder disconnected from the machine
gradually. Do not allow oil to
(if equipped with the weld cable to
squirt or spray.
platform option)
Perform all troubleshooting on a
Wheels chocked
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Section 5 Troubleshooting Flow Charts First Edition First Printing
TROUBLESHOOTING FLOW CHARTS
About This Section General Repair Process
When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are requiredvoltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved
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.
Fault Code Chart

Diagnostic code displayed Condition Possible Causes Solution
AXLE EXT/RET BUTTONS FAULT Axles will not extend or retract. Shorted axle extend or retract Consult Genie Industries Service
membrane on platform membrane Department. The platform membrane
panel. panel may need to be replaced.
AXLE VALVE FAULT Axle extend or axle retract Axle extend or axle retract valve coils Refer to charts 33 and 34 to
inoperative. circuits open or shorted to ground or troubleshoot.
the coils are bad.
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. troubleshoot.
UP/DOWN JOYSTICK SHORTED Up/down 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 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.
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 to repair section.
valve defaults set from display. Refer
to Display module section.
BOOM UP/DOWN FLOW VALVE No movement on up/down functions Reset Boom up/down flow valve Calibrate Boom up/down Thresholds
NOT CALIBRATED until joystick is moved past half defaults set from display. Refer to refer to repair section.
stroke. Display module section.
BOOM UP/DOWN FLOW VALVE Up/down functions inoperative. Boom up/down flow valve coil circuit Refer to charts 13 and 14 to
FAULT open or shorted to ground or the coil troubleshoot.
itself is bad.
BOOM UP VALVE FAULT Up function inoperative. Boom up valve coil circuit open or Refer to chart 13 to troubleshoot.
shorted to ground or the coil itself is
bad.
BOOM DOWN VALVE FAULT Down function inoperative. Boom down valve coil circuit open or Refer to chart 14 to troubleshoot.
bad.
BOOM ANGLE SWITCHES FAULT Extend and up functions inoperative Boom angle operational switches out Refer to chart 12 to troubleshoot.
and boom down function operative of sequence.
only when boom is fully retracted.
EXTEND/RETRACT JOYSTICK Extend/retract functions inoperative Extend/retract joystick not calibrated. Calibrate extend/retract joystick refer
NOT CALIBRATED from platform. to repair section.
EXTEND/RETRACT JOYSTICK Extend/retract functions inoperative Open circuit between platform control Refer to charts 16 and 17 to
SHORTED TO 0V from platform. card and extend/retract joystick. troubleshoot.
EXTEND/RETRACT JOYSTICK Extend/retract functions inoperative Shorted circuit between platform Refer to charts 16 and 17 to
SHORTED TO 5V from platform. control card and extend/retract troubleshoot.
joystick.
EXTEND/RETRACT JOYSTICK Extend/retract functions inoperative Damaged circuit between platform Refer to charts 16 and 17 to
VALUE TOO HIGH from platform. control card and extend/retract troubleshoot.
joystick or Joystick may need to be
replaced.
Continued on next page
FAULT CODE CHART

EXTEND/RETRACT JOYSTICK Extend/retract functions inoperative Damaged circuit between platform Refer to charts 16 and 17 to
VALUE TOO LOW from platform. control card and extend/retract troubleshoot
replaced.
EXTEND/RETRACT BUTTONS Extend/retract functions inoperative Shorted boom extend/retract Consult Genie Industries Service
FAULT from turntable. membrane on turntable membrane Department. The turntable
panel. membrane panel may need to be
replaced.
BOOM EXT/RET SPEED NOT Extend/retract function speeds to fast Extend/retract speed calibration set Calibrate Boom extend/retract speed
CALIBRATED or to slow. from display or Reset Boom ext/ret refer to repair section.
flow valve defaults set from display.
Refer to Display module section.
BOOM EXT/RET FLOW VALVE No movement on extend/retract Reset Boom extend/retract flow valve Calibrate Boom extend/retract
NOT CALIBRATED functions until joystick is moved past defaults set from display. Refer to Thresholds refer to repair section.
half stroke. Display module section.
BOOM EXT/RET FLOW VALVE Extend/retract functions inoperative. Boom extend/retract flow valve coil Refer to charts 16 and 17 to
FAULT circuit open or shorted to ground or troubleshoot.
the coil itself is bad.
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.
bad.
LOCK OUT VALVE P1 FAULT Retract function inoperative when Boom retract lockout valve coil circuit Refer to chart 16 to troubleshoot
boom length is <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 Refer to chart 17 to troubleshoot.
boom length = or >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 from 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 from platform. card and turntable rotate joystick. troubleshoot.
TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Shorted circuit between platform Refer to charts 22 and 23 to
SHORTED TO 5V from platform. control card and turntable rotate troubleshoot.
joystick.
TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Damaged circuit between platform Refer to charts 22 and 23 to
VALUE TOO HIGH from platform. control card and turntable rotate troubleshoot.
replaced.
TURNTABLE ROTATE JOYSTICK Turntable rotate functions inoperative Damaged circuit between platform Refer to charts 22 and 23 to
VALUE TOO LOW from platform. control card and turntable rotate troubleshoot.
replaced.
TURNTABLE ROTATE BUTTONS Turntable rotate functions inoperative Shorted turntable rotate membrane Consult Genie Industries Service
FAULT from turntable. on turntable membrane panel. Department. The turntable
membrane panel may need to be
replaced.
FAULT CODE CHART

TURNTABLE ROTATE SPEED NOT Turntable rotate function speeds to Turntable rotate speed calibration set Calibrate Turntable rotate speed refer
CALIBRATED fast or to slow. from display or Reset turntable rotate to repair section.
flow valve defaults set from display.
Refer to Display module section.
TURNTABLE ROTATE FLOW No movement on Turntable rotate Reset turntable rotate flow valve Calibrate turntable rotate Thresholds
VALVE NOT CALIBRATED functions until joystick is moved past defaults set from display. Refer to refer to repair section.
half stroke. Display module section.
TURNTABLE ROTATE FLOW Turntable rotate functions Turntable rotate flow valve coil circuit Refer to charts 22 and 23 to
VALVE FAULT inoperative. open or shorted to ground or the coil troubleshoot.
itself is bad.
TURNTABLE ROTATE CW VALVE Turntable rotate CW function Turntable rotate CW valve coil circuit Refer to chart 22 to troubleshoot.
FAULT inoperative. open or shorted to ground or the coil
itself is bad.
TURNTABLE ROTATE CCW Turntable rotate CCW function Turntable rotate CCW valve coil Refer to chart 23 to troubleshoot.
VALVE FAULT inoperative. circuit open or shorted to ground or
the coil itself is bad.
MULTI FUNCTION VALVE FAULT Multiple functions inoperative. Boom Multi function valve coil circuit open Refer to chart 32 to troubleshoot.
up/dwn,ext/ret, and turntable rotate or shorted to ground or coil may be
auxiliary functions inoperative. bad
STEERING JOYSTICK NOT Steering functions inoperative. Steering joystick not calibrated.
Calibrate steering joystick refer to
CALIBRATED repair section.
STEERING JOYSTICK SHORTED Steering functions inoperative from Open circuit between platform control Refer to charts 35,36,37, and 38 to
TO 0V 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.
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.
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 Refer to chart 35 to troubleshoot.
SENSOR VALUE TOO HIGH inoperative. blue side steering sensor and DCON
box or steering sensor may need to
be replaced.
BLUE END BLUE SIDE STEER Blue end blue side steering functions Damaged circuit between blue end Refer to chart 35 to troubleshoot.
SENSOR VALUE TOO LOW inoperative. blue side steering sensor and DCON
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.
FAULT CODE CHART

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 functions 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 functions inoperative. yellow side steering sensor and
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 functions 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 functions 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 functions inoperative. blue side steering sensor and DCON
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 functions inoperative. blue side steering sensor and DCON
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 0V 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.
YELLOW 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
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
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 end yellow side CCW functions valve coils circuits open or shorted to
inoperative ground or the coils are bad.
DRIVE JOYSTICK NOT Drive functions inoperative. Drive joystick not calibrated. Calibrate drive joystick refer to repair
CALIBRATED section.
DRIVE JOYSTICK SHORTED TO 0V Drive functions inoperative. Open circuit between platform control Refer to charts 39 and 40 to
card and drive joystick. troubleshoot.
DRIVE JOYSTICK SHORTED TO 5V Drive functions inoperative. Shorted circuit between platform Refer to charts 39 and 40 to
control card and drive joystick. troubleshoot.
FAULT CODE CHART

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.
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 Reset propel valve defaults set from Calibrate propel thresholds refer to
reverse functions until joystick is display. Refer to Display module repair section.
moved past half stroke. section.
DRIVE VALVE FAULT Drive forward and drive reverse Drive forward or drive reverse valve Refer to charts 39 and 40 to
functions inoperative. coils circuits open or shorted to troubleshoot.
BRAKE VALVE FAULT Drive forward or drive reverse Brake valve circuit open or shorted to Refer to charts 39 and 40 to
functions inoperative. ground or coil is bad. troubleshoot.
MOTOR COIL FAULT High drive inoperative. Motor coil circuit open or shorted to Refer to chart 42 to troubleshoot.
ground or the coil is bad.
AUX PROPEL VALVE FAULT Auxiliary drive forward or reverse Auxiliary propel valve coils circuits Refer to chart 44 To troubleshoot.
inoperative (Only seen if Aux. Drive open or shorted to ground or the coils
option is enabled from display. Refer are bad.
to display module section.).
PLATFORM LEVEL TOGGLE Manual platform level inoperative Shorted platform level toggle switch Refer to charts 25 and 26 to
SWITCHES FAULT from platform or turntable controls. on 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 functions inoperative. sensor and platform control box.
PLATFORM LEVEL SENSOR Platform level and boom up/down Shorted circuit between platform level Refer to chart 24 to troubleshoot.
DEGREES SHORTED TO 5V functions 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 functions 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 functions 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.
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. on the platform control box or shorted troubleshoot.
platform rotate CW or CCW
membrane switch on the turntable
membrane panel.
PLATFORM ROTATE VALVE Platform rotate CW or CCW Platform rotate cw or ccw coils Refer to charts 28 and 29 to
FAULT inoperative. circuits open or shorted to ground or troubleshoot.
the coils are bad.
JIB UP/DOWN TOGGLE Jib functions inoperative. Shorted jib toggle switch on the Refer to charts 30 and 31 to
SWITCHES FAULT platform control box or shorted jib up troubleshoot.
or down membrane switch on the
turntable membrane panel.
FAULT CODE CHART

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.
SHORTED TO 5V open.
VALUE TOO HIGH damaged or sensor may need to be
replaced.
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.
SHORTED TO 5V open.
VALUE TOO HIGH damaged or sensor may need to be
replaced.
VALUE TOO LOW damaged or sensor may need to be
replaced.
TURNTABLE LEVEL SENSOR X- Unit out of level LED, icon and alarm Open circuit in turntable level sensor Repair open in circuit. Refer to
DIRECTION SHORTED TO 0V active. X-direction wiring. electrical schematic to troubleshoot.
TURNTABLE LEVEL SENSOR X- Unit out of level LED, icon and alarm Short in turntable level sensor X- Repair short in circuit. Refer to
DIRECTION SHORTED TO 5V active. direction circuit wiring. electrical schematic to troubleshoot.
TURNTABLE LEVEL SENSOR X- Unit out of level LED, icon and alarm Damaged circuit in turntable level Repair damage in circuit wiring. Refer
DIRECTION VALUE TOO HIGH active. sensor X-direction wiring or turntable to electrical schematic to
level sensor may need to be troubleshoot or consult Genie
replaced. Industries Service Department to
determine if turntable level sensor
needs to be replaced.
TURNTABLE LEVEL SENSOR X- Unit out of level LED, icon and alarm Damaged circuit in turntable level Repair damage in circuit wiring. Refer
DIRECTION VALUE TOO LOW active. sensor X-direction wiring or turntable to electrical schematic to
TURNTABLE LEVEL SENSOR Y- Unit out of level LED, icon and alarm Open circuit in turntable level sensor Repair open in circuit. Refer to
DIRECTION SHORTED TO 0V active. Y-direction wiring. electrical schematic to troubleshoot.
FAULT CODE CHART

TURNTABLE LEVEL SENSOR Y- Unit out of level LED, icon and alarm Short in turntable level sensor Y- Repair short in circuit. Refer to
DIRECTION SHORTED TO 5V active. direction circuit wiring. electrical schematic to troubleshoot.
TURNTABLE LEVEL SENSOR Y- Unit out of level LED, icon and alarm Damaged circuit in turntable level Repair damage in circuit wiring. Refer
DIRECTION VALUE TOO HIGH active. sensor Y-direction wiring or turntable to electrical schematic to
TURNTABLE LEVEL SENSOR Y- Unit out of level LED, icon and alarm Damaged circuit in turntable level Repair damage in circuit wiring. Refer
DIRECTION VALUE TOO LOW active. sensor Y-direction wiring or turntable to electrical schematic to
DCON CAN NO RESPONSE All drive chassis functions Open or shorted wires in CAN bus Repair damage in circuit wiring. Refer
inoperative. circuits between DCON and TCON to electrical schematic to
control boxs. troubleshoot or consult Genie
Industries Service Department.
CAN BUS NO RESPONSE No functions from platform control Open or shorted wires in CAN bus Repair damage in circuit wiring. Refer
box and all platform functions circuits between PCON and TCON to electrical schematic to
inoperative when using turntable control boxs. troubleshoot or consult Genie
controls. Industries Service Department.
SAFETY SWITCH P3 FAULT All functions inoperative. Open circuit in tether Emergency stop Repair damage in circuit wiring. Refer
wiring. to electrical schematic to
troubleshoot or consult Genie
SAFETY SWITCH P6R1 FAULT Boom extend and boom down Bad K4 relay inside turntable control Replace K4 relay or consult Genie
functions inoperative. This fault box. Industries Service Department.
creates Safety switch P9A,P10,P11,
and P18 fault.
SAFETY SWITCH P6R2 FAULT Engine cranks but wont start. Bad K3 relay inside turntable control Replace K3 relay or consult Genie
box. Industries Service Department.
SAFETY SWITCH P7 FAULT No boom functions. Fault creates Bad K5 relay inside turntable control Replace K5 or K1 relays or consult
safety switch P7R,P22,P14,P12 and box or bad K1 relay inside platform Genie Industries Service Department.
P22R faults. control box.
SAFETY SWITCH P7R FAULT No boom functions. Fault creates Bad K2 relay inside turntable control Replace relays or consult Genie
safety switch P22,P22R,P14, and box or bad K2 relay inside platform Industries Service Department.
P12 faults. control box.
SAFETY SWITCH P9A FAULT Boom extend and boom down Open in Boom envelope safety Refer to chart 18 or 19 to
functions inoperative. This fault circuits or operational limit switches troubleshoot.
creates Safety switch P10 and P18 LSB3EO,LSB13AO,LSB4EO, or
faults. LSB14AO have failed.
SAFETY SWITCH P9B FAULT Engine cranks but wont start. Open in Boom envelope safety Refer to chart 18 or 19 to
circuits or operational limit switches troubleshoot.
LSB3EO,LSB13AO,LSB4EO, or
LSB14AO have failed.
SAFETY SWITCH P10 FAULT Boom extend inoperative. Boom extension cables out of Refer to chart 20 or 21 to
adjustment or LSB6S limit switch is troubleshoot.
bad or there is an open in the safety
circuit wiring.
SAFETY SWITCH P11 FAULT Boom up inoperative. Open in axle safety switch circuit or Refer to chart 18 or 19 and chart 20
limit switch LSB7DS,LSAX1ES, or or 21 to troubleshoot.
LSAX2ES have failed or operational
limit switch LSB1DO has failed.
FAULT CODE CHART

SAFETY SWITCH P12 FAULT Axle retract inoperative. Open in stowed safety circuit or limit Refer to chart 18 or 19 and chart 20
switch LSB7DS or LSB3RS have or 21 to troubleshoot.
failed or operational limit switches
LSB1DO or LSB3RO have failed.
SAFETY SWITCH P14 FAULT Axle retract inoperative. Open in stowed safety circuit or limit Refer to chart 18 or 19 and chart 20
switch LSB7DS has failed or limit or 21 to troubleshoot.
switch LSB1DO has failed.
SAFETY SWITCH P18 FAULT Boom extend inoperative. Open in axle safety switch circuit or Refer to chart 18 or 19 and chart 20
limit switch LSB3RS,LSAX1ES, or or 21 to troubleshoot.
LSAX2ES have failed or operational
limit switch LSB3RO has failed.
SAFETY SWITCH P22 FAULT Platform level inoperative. Fault Platform out of level >10degrees out Refer to chart 27 to troubleshoot.
creates a safety switch P22R fault. 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.
SAFETY SWITCH P22R FAULT Platform level and Boom up/down Platform out of level >10degrees out Refer to chart 27 to troubleshoot.
inoperative. 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.
DCON SAFETY SWITCH P7R Steering and axle functions Open in Red S56PRV wire circuit that Repair damage in circuit wiring. Refer
FAULT inoperative. runs from the turntable control box to
to electrical schematic to
the DCON control box. troubleshoot or consult Genie
PROX. KILL SW. FAULT All functions inoperative unless spare Proximity Kill Bumper under platform Activate spare membrane and
membrane on platform control box is has run into an obstruction or is out of carefully move away from obstruction
activated. adjustment. or readjust proximity kill limit switch.
PLTFRM OVERLOAD SEN. FAULT All functions inoperative red LED Load in platform is above rated load Unload excessive weight out of
above spare membrane flashing. or load sensor is out of adjustment. 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.
retract inoperative. obstruction with boom extended or
boom down overload switch is out of
adjustment or there is an open in
boom down overload circuit.
PRESS PLATFORM ESTOP Code displayed whenever engine is Just finished a speed calibration for Turn key switch to platform control
running and controller is waiting for boom up/dwn, ext.ret, or turntable position and depress platform
engine to be shut off to save rotate or Joysticks were calibrated Emergency stop.
calibrations or any parameter with engine running or a function
changes made with the display to parameter was changed with the
memory. display while the engine was running.
Chart 1
Display Not 5VKTZNKMXU[TJIUTZXUR )NKIQZNGZZNKXOHHUT /LZNKXOHHUTIGHRKOY
Active HU^GTJINKIQZNGZZNK
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HGJ
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Be sure the key switch JGSGMKJGTJIUTTKIZUX RUIQKJV[YNVR[MOTZU
is in the appropriate OYL[RR_OTYKXZKJGTJ IUTTKIZUX[TZOROZOYL[RR_
position.
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2+*TUZ MUUJ GIZO\KXKVRGIKJOYVRG_

Be sure that both GIZO\K
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buttons are pulled out to

the ON position.
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breakers are not IUTTKIZUXOTYOJKZNK
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tripped. :)54 IUTZXURHU^:)54
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are fully charged and )NKIQ\URZGMKUTZNK 8KVGOXUVKTOT:4]OXK
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CHART 1
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CHART 3
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Chart 4
Engine Starts =OZNZNKQK_Y]OZIN
TU
)UTY[RZZNK-KTOK
and Runs for 3 Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Seconds and +SKXMKTI_9ZUVH[ZZUTY
V[RRKJU[ZZUZNK 54
Dies VUYOZOUTINKIQLUX
JOGMTUYZOIIUJKYUTZNK
JOYVRG_YIXKKTGZZNK
Be sure to check the MXU[TJIUTZXURY
engine oil level and fill 'XKIUJKYVXKYKTZ%
as needed.
_KY
Be sure to check fuel

level and fill as needed. /Y+4-/4+5/2
68+99;8+<'2;+ _KY
8KVRGIKUORVXKYY[XK
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:5525=VXKYKTZUT ZNKKTMOTKSGT[GRLUX
Be sure to check ZNKJOYVRG_YIXKKT% ZXU[HRKYNUUZOTMRU]UOR
coolant level and fill as VXKYY[XK
needed. TU
Be sure fuel system is

properly bled.
/Y+4-/4+5/2 _KY 8KVRGIKZNKUORVXKYY[XK
68+99;8+9+4958 YKTYUX
<'2;+:55./-.UX
Be sure the batteries +4-/4+5/2
are fully charged and 68+99;8+9+4958
properly connected. <'2;+:5525=
VXKYKTZUTZNKJOYVRG_
YIXKKT%
TU
/Y+4-/4+5/2 )NKIQLUXGTUVKTOTZNK HGJ 8KVGOXUXXKVRGIKZNK
68+99;8+9+4958 _KY =:(1)698]OXK =:(1)698]OXK
9.58::5<VXKYKTZ LXUSVOTULZNK0
UTZNKJOYVRG_YIXKKT% IUTTKIZUXGZZNKMXU[TJ
IUTZXURYZUZNKKTMOTKUOR
VXKYY[XKYKTYUXUT
KTMOTK
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TU
8KVRGIKZNKUORVXKYY[XK
YKTYUX
/Y+4-/4+5/2 )NKIQLUXGYNUXZOTZNK HGJ 8KVGOXUXXKVRGIKZNK
68+99;8+9+4958 _KY =.(1)698]OXK =.(1)698]OXK
9.58::5<VXKYKTZ LXUSVOTULZNK0
UTZNKJOYVRG_YIXKKT% IUTTKIZUXGZZNKMXU[TJ
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TU
KTMOTK
MUUJ
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8KVRGIKUORVXKYY[XK
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CHART 4
/Y+4-/4+ _KY /YZNKKTMOTKHRUIQ _KY )NKIQXGJOGZUXLOTYLUX

)UTZOT[KJLXUSZNK
:+36+8':;8+ KÎKYYO\KR_NUZ% IRUMMOTM58XKLKXZUZNK
VXK\OU[YVGMK
<'2;+:55./-. KTMOTKSGT[GRLUX
VXKYKTZUTZNKJOYVRG_ ZXU[HRKYNUUZOTMGT
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=.8*):98]OXK =.8*):98]OXK
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TU
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/Y+4-/4+ _KY 8KVRGIKZNK
:+36+8':;8+ ZKSVKXGZ[XKYKTYUX
9+4958<'2;+:55
./-.UX+4-/4+
:+36+8':;8+
9+4958<'2;+:55
25=VXKYKTZUTZNK
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/Y+4-/4+ )NKIQLUXGTUVKTOT HGJ 8KVGOXUXXKVRGIKZNK
:+36+8':;8+ =.8*):98]OXK =.8*):98]OXK

_KY
9+49589.58::5 LXUSVOTULZNK0
<VXKYKTZUTZNK IUTTKIZUXGZZNKMXU[TJ
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:+36+8':;8+ =.8*):98]OXK =.8*):98]OXK

_KY
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CHART 4
/Y+4-/4+96++*45 )NKIQ\URZGMKUTZNK )NKIQLUXGTUVKTOTZNK

)UTZOT[KJLXUSZNK _KY <
8+96549+VXKYKTZUT (GZVUYZUTZNK 8*6(':]OXKZNGZ
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GTJXKVGOXUXXKVRGIKZNK
8*6(':]OXK58
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< /TJ[YZXOKY9KX\OIK
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=NORKIXGTQOTMZNK 8KVGOXUXXKVRGIKZNK
KTMOTKINKIQZNK 8*)',]OXK58
<
\URZGMKGZZNKGRZKXTGZUX IUTY[RZZNK-KTOK
UTZNK8*)',]OXK /TJ[YZXOKY9KX\OIK
IOXI[OZLXUSVOTULZNK *KVGXZSKTZ
0IUTTKIZUXGZZNK
MXU[TJIUTZXURYZUZNK
GRZKXTGZUX
<
TU
=NORKZNKKTMOTKOY 8KVGOXUXXKVRGIKZNK
RKYY
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ZNGT<
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)863]OXKUTZNK -KTOK/TJ[YZXOKY9KX\OIK
GRZKXTGZUXLXUSVOTUL *KVGXZSKTZ
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MXKGZKXZNGT
<
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
/Y+4-/4+96++* )NKIQNOMN863YKZZOTM
_KY
<'2;+:55./-. GTJGJP[YZZNXUZZRK
VXKYKTZUTZNKJOYVRG_ ROTQGMK9KK
YIXKKT% 3GOTZKTGTIK9KIZOUT
TU
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 5
Engine =OZNZNKQK_Y]OZIN )NKIQNOMNOJRK
High Idle Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
GJP[YZSKTZYKK
3GOTZKTGTIK9KIZOUT
_KY
Inoperative +SKXMKTI_9ZUVH[ZZUTY
V[RRKJU[ZZUZNK 54
58XKLKXZUZNKKTMOTK
SGT[GRLUX
VUYOZOUTYZGXZZNKKTMOTK ZXU[HRKYNUUZOTMZNKL[KR
Be sure mechanical GTJYKRKIZZNKNOMN863 OTPKIZOUTY_YZKS
linkage is not binding. SUJK*UKYZNKYVKKJ
YURKTUOJV[RROT%

are fully charged and TU
properly connected.
)NKIQZNK\URZGMKULZNK )NKIQZNK\URZGMKGZ < 8KVGOXUXXKVRGIKZNK
<
(18*)863]OXKGZ VOTULZNK0IUTTKIZUX 8*(1)863]OXK
ZNKYVKKJYURKTUOJ GZZNKMXU[TJIUTZXURY
<
2UUYKTZNK1XKRG_ 8KVRGIKZNKMXU[TJ
OTYOJKZNKMXU[TJIUTZXUR < IUTZXURHU^58IUTY[RZ
HU^P[YZKTU[MNZU ZNK-KTOK/TJ[YZXOKY
K^VUYKZNKYVGJK 9KX\OIK*KVGXZSKTZ
ZKXSOTGRYULZNKXKRG_
GTJINKIQZNK\URZGMKGZ
ZKXSOTGRULZNKXKRG_
<
)NKIQIUTZOT[OZ_LXUS 8KVRGIKZNKMXU[TJ
VOTUXVOTULZNK0 TU IUTZXURHU^58IUTY[RZ
IUTTKIZUXZUZKXSOTGR ZNK-KTOK/TJ[YZXOKY
ULZNK1XKRG_/YZNKXK 9KX\OIK*KVGXZSKTZ
IUTZOT[OZ_%
< _KY
)NKIQZNK\URZGMKGZ )NKIQZNK\URZGMKGZ
<
ZKXSOTGRULZNK1 ZKXSOTGRULZNK1
XKRG_ XKRG_
<
<
8KVRGIKZNK1XKRG_
.GYZNK'IOXI[OZ 8KVRGIKZNKMXU[TJ
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HXKGQKXHKKTZXOVVKJ% IUTZXURHU^58IUTY[RZ
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
_KY
)NKIQLUXGYNUXZOTZNK
(18* )863]OXK
IOXI[OZLXUSVOTULZNK
0IUTTKIZUXUTMXU[TJ
)UTZOT[KJUT
IUTZXURHU^ZUYVKKJ
ZNKTK^ZVGMK
YURKTUOJ
CHART 5
)NKIQLUXGTUVKTOTZNK HGJ 8KVGOXUXXKVRGIKZNK

)UTZOT[KJLXUSZNK
(84<2<8+:]OXK (84<2<8+:]OXK
VXK\OU[YVGMK
IOXI[OZLXUSVOTULZNK
0IUTTKIZUXGZZNK
MXU[TJIUTZXURHU^ZU
ZNKYVKKJYURKTUOJ
MUUJ
*UKYZNKYVKKJ TU )NKIQZNKROTQGMKLUX HGJ 8KVGOXUXXKVRGIKZNK
YURKTUOJSU\KOTGTJ HOTJOTM ROTQGMK
U[Z]OZNU[ZHOTJOTM%
MUUJ
_KY
8KVRGIKZNKYURKTUOJ
8KVRGIKYVKKJ
YURKTUOJ58IUTY[RZZNK
*KVGXZSKTZ
Chart 6
Engine Low Idle =OZNZNKQK_Y]OZIN )NKIQLUXGYNUXZZU
Inoperative Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
HGZZKX_VUYOZO\KOTZNK
(18*)863]OXK
+SKXMKTI_9ZUVH[ZZUTY LXUSVOTULZNK0
Be sure that mechanical V[RRKJU[ZZUZNK 54

_KY
linkage from 2-speed VUYOZOUTYZGXZZNK IUTZXURYZUZNKYVKKJ
KTMOTKGTJYKRKIZRU] YURKTUOJ58XKVRGIKZNK
solenoid to fuel injection 863SUJK 1XKRG_OTYOJKZNK
system is not binding or *UKYZNKYVKKJ MXU[TJIUTZXURHU^
is defective. YURKTUOJV[RROT%
Be sure the batteries TU

properly connected. *UKYZNKYVKKJ TU )NKIQZNKROTQGMKUX
YURKTUOJSU\KOTGTJ XKVRGIKZNKYURKTUOJ
U[Z]OZNU[ZHOTJOTM%
_KY
)NKIQGJP[YZSKTZULZNK 'JP[YZZNKROTQGMKUX
HGJ
ROTQGMKGTJRU]OJRK GJP[YZZNKRU]OJRK9KK
GJP[YZSKTZ9KK 3GOTZKTGTIK9KIZOUT
3GOTZKTGTIK9KIZOUT
MUUJ
8KLKXZUZNKKTMOTK
SGT[GRLUX
ZXU[HRKYNUUZOTMZNKL[KR
OTPKIZOUTY_YZKS58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 7
All Functions )NKIQZNKV[SVY[IZOUT IRUYKJ *UZNKV[SVYLKKR _KY /LKTMOTKNGYHKKTX[T
Inoperative, ROTKYN[ZULL\GR\KY/T
ZNKUVKTVUYOZOUTZNK
KÎKYYO\KR_NUZ% ]OZN\GR\KYIRUYKJOZ
SG_NG\KJGSGMKJUTK
Engine Starts \GR\KNGTJRKYYNU[RJHK
VGXGRRKR]OZNNUYK
TU
UXGRRULZNKV[SVY
)UTY[RZZNK-KTOK
and Runs 5VKT\GR\KYGTJYZGXZ

/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
ZNKKTMOTK)NKIQGRR
Be sure the hydraulic SGINOTKL[TIZOUTYLUX
suction line shutoff UVKT IUXXKIZUVKXGZOUT
valves for the pumps

are in the OPEN position.
Be sure the hydraulic

/TYZGRRGZU69/ :XU[HRKYNUUZKGIN
VYOUX
tank is filled to the HGXVXKYY[XK
SUXK
L[TIZOUTOTJO\OJ[GRR_58
MG[MKZUZNKZKYZVUXZUT IUTY[RZZNK-KTOK
correct level. ZNKL[TIZOUTSGTOLURJ /TJ[YZXOKY9KX\OIK
9ZGXZZNKKTMOTKLXUS *KVGXZSKTZ
Be sure the batteries are ZNKMXU[TJIUTZXURY
fully charged and 'IZO\GZKZNKL[TIZOUT
properly connected.
KTGHRKNOMN863H[ZZUT
GTJZNKHUUSXKZXGIZ
H[ZZUTGTJINKIQZNK
N_JXG[ROIVXKYY[XK
RKYYZNGT
VYO
*OYIUTTKIZZNKL[KR :XU[HRKYNUUZ
YVROTK
YURKTUOJ]OXOTM OTUVKXGZO\KHUUS
Z[XTY
IUTTKIZUX8KSU\KZNK L[TIZOUTYGTJ
L[TIZOUTV[SVYLXUSZNK OTUVKXGZO\KJXO\K
SGOTV[SVH[ZRKG\KGRR L[TIZOUTYYKVGXGZKR_
NUYKYIUTTKIZKJ6XKYY
ZNKKTMOTKYZGXZH[ZZUT
GTJIXGTQZNKKTMOTK
U\KX]NORKUHYKX\OTM
YVROTKJXO\KZNGZZNKMKGX
V[SVYVR[MOTZU
YVROTKJUKY
TUZZ[XT
:NKKTMOTKZUV[SVLRK^
VRGZKIU[VROTMOYLG[RZ_
58ZNKSGOTV[SVOY
LG[RZ_)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 8
Boom Up/Down, /TYZGRRGZU69/

VYOUX
:XU[HRKYNUUZKGIN
Extend/Retract, HGXVXKYY[XK
MG[MKZUZNKZKYZVUXZUT
SUXK
L[TIZOUTOTJO\OJ[GRR_58
IUTY[RZZNK-KTOK
Turntable Rotate ZNKL[TIZOUTSGTOLURJ
9ZGXZZNKKTMOTKLXUS
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
and Platform ZNKMXU[TJIUTZXURY
'IZO\GZKZNKL[TIZOUT
Functions KTGHRKNOMN863H[ZZUT
GTJZNKHUUSXKZXGIZ
Inoperative, H[ZZUTGTJINKIQZNK
Drive, Steer and

N_JXG[ROIVXKYY[XK
Axle Extend/
RKYYZNGT
VYO
Retract 'JP[YZZNKL[TIZOUT .URJZNKL[TIZOUT
Functions
SGTOLURJY_YZKSXKROKL VYOUX KTGHRKNOMN863H[ZZUT
\GR\KOZKS(/UX,/GRR SUXK GTJVXKYYZNKHUUS
Operational ZNK]G_OTIRUIQ]OYK
IU[TZOTMZNKT[SHKXUL
XKZXGIZH[ZZUTGTJGJP[YZ
ZNKXKROKL\GR\KVXKYY[XK
Z[XTY'IZO\GZKZNK ZUVYOHGX
Be sure the hydraulic L[TIZOUTKTGHRKNOMN
suction line shutoff valve 863H[ZZUTGTJZNK
HUUSXKZXGIZH[ZZUTGTJ
for the lift/steer pump is in INKIQZNKN_JXG[ROI
the OPEN position. VXKYY[XK
Be sure the hydraulic tank RKYYZNGT
VYO
is filled to the correct
level. )NKIQZNKL[TIZOUT
HGJ
8KVRGIKZNKMVS
V[SV9KK8KVGOX 2SOTL[TIZOUT
Be sure the batteries are 9KIZOUT V[SV
fully charged and properly

MUUJ
connected.
8KVRGIKZNKXKROKL\GR\K
OZKS(/UX,/58XKVGOX
UXXKVRGIKZNK
JOLLKXKTZOGRYKTYOTM\GR\K
OZKS(6UX,658
XKVGOXUXXKVRGIKZNK
RUGJYKTYKVXOUXOZ_LRU]
XKM[RGZUX\GR\K
OZKS(+UX,+58ZNK
SGTOLURJNGYGTOTZKXTGR
LG[RZ)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 9
All Platform, /TYZGRRGZU69/

VYOUX
:XU[HRKYNUUZVRGZLUXS
Steering and HGXVXKYY[XK
MG[MKZUZNKZKYZVUXZUT
SUXK
L[TIZOUTYOTJO\OJ[GRR_58
IUTY[RZZNK-KTOK
Axle Functions ZNKVRGZLUXSSGTOLURJ
9ZGXZZNKKTMOTKGTJ
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Inoperative, GIZO\GZKZNKL[TIZOUT
KTGHRKNOMN863H[ZZUT
All Other GTJZNKPOHHUUSJU]T
H[ZZUTGTJINKIQZNK
Functions N_JXG[ROIVXKYY[XK
Operational RKYYZNGT
VYO
Be sure the hydraulic

'JP[YZZNKVRGZLUXS 'IZO\GZKZNKL[TIZOUT
suction line shutoff SGTOLURJY_YZKSXKROKL KTGHRKNOMN863H[ZZUT
valve for the lift/steer \GR\KGZZNKJOYZXOH[ZOUT VYOUX GTJZNKPOHHUUSJU]T
pump is in the OPEN SGTOLURJOZKS')GRR SUXK H[ZZUTGTJGJP[YZZNK
ZNK]G_OTIRUIQ]OYK XKROKLVXKYY[XKZU
position. IU[TZOTMZNKT[SHKXUL VYOHGX)NKIQ
Z[XTY'IZO\GZKZNK YZKKXOTMGTJG^RK
Be sure the hydraulic L[TIZOUTKTGHRKNOMN L[TIZOUTY
tank is filled to the 863H[ZZUTGTJZNKPOH
HUUSJU]TH[ZZUTGTJ
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Chart 10
Ground =OZNZNKMXU[TJIUTZXURY 8KVGOXUVKTOT61]OXK
Controls +SKXMKTI_9ZUVH[ZZUT
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< LXUSZNK+SKXMKTI_
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Controls VOTQ]OXKINKIQKJ
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Normally
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batteries are fully GZZKXSOTGRULQK_
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Platform *UKYKTMOTKYZGXZLXUS _KY 9ZGXZZNKKTMOTKLXUS :KYZUXXKVRGIKZNKLUUZ
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through the cable
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batteries are fully Y]OZINIUTZGIZ('
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Chart 12
Boom Angle =OZNZNKHUUSL[RR_ *OYIUTTKIZGTJZKYZ
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Chart 13
Boom Up =OZNZNKQK_Y]OZIN 'IZO\GZKZNKHUUS[V
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)UTZOT[KJUTVGMK
Function Z[XTKJZUMXU[TJ TU H[ZZUT/YZNKXKGT
Inoperative
IUTZXURYGTJHUZN G[JOHRKHKKV]NKT
+SKXMKTI_9ZUVH[ZZUTY H[ZZUTOYVXKYYKJ%
V[RRKJU[ZZUZNK 54
Be sure all other VUYOZOUTGIZO\GZKZNK
TU
L[TIZOUTKTGHRKNOMN
functions operate 863H[ZZUTGTJZNK
normally. HUUS[VH[ZZUT )UTY[RZZNK-KTOK
'XKZNKXKGT_JOGMTUYZOI /TJ[YZXOKY9KX\OIK
Be sure the axles are IUJKYVXKYKTZUTZNK *KVGXZSKTZ:NKMXU[TJ
JOYVRG_YIXKKTGZZNK IUTZXURSKSHXGTKJKIGR
fully extended. MXU[TJIUTZXURY% SG_TKKJZUHK
XKVRGIKJ
Be sure the platform is
level to gravity within _KY
7 degrees.
_KY
9',+:?9=/:).6
/Y 8KLKXZU)NGXZ
Be sure the batteries are ,';2:GTJ9',+:?
fully charged and 9=/:).68,';2:
properly connected.
VXKYKTZUTZNKJOYVRG_
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TU
(553;6*=4
/Y 8KIGROHXGZKZNKHUUS
05?9:/)145: _KY [VJU]TPU_YZOIQ9KK
)'2/(8':+* VXKYKTZUT 8KVGOX9KIZOUT58
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[VJU]TPU_YZOIQ
TU
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05?9:/)19.58:+*:5 ]OXKYOTYOJKZNKVRGZLUXS
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CHART 13
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CHART 13
(553;6<'2<+
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CHART 13
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)UTZOT[KJLXUS
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OZKS(,UXOZKS,, I_ROTJKXIU[TZKXHGRGTIK
]OZNZNKHUUSK^ZKTJ \GR\KY58ZNKHUUS
TU
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Chart 14
Boom Down =OZNZNKQK_Y]OZIN 'IZO\GZKZNKHUUSJU]T
_KY
)UTZOT[KJUTVGMK
Inoperative
V[RRKJU[ZZUZNK 54
Be sure all other VUYOZOUTGIZO\GZK
TU
ZNKL[TIZOUTKTGHRKNOMN
normally. HUUSJU]TH[ZZUT'XK )UTY[RZZNK-KTOK
ZNKXKGT_JOGMTUYZOI /TJ[YZXOKY9KX\OIK
Be sure the axles are IUJKYVXKYKTZUTZNK *KVGXZSKTZ:NKMXU[TJ
JOYVRG_YIXKKTGZZNK IUTZXURSKSHXGTKJKIGR
fully extended. MXU[TJIUTZXURY% SG_TKKJZUHK
XKVRGIKJ
Be sure the platform is
_KY
level to gravity within
7 degrees. 9',+:?9=/:).6
/Y
_KY
8KLKXZU)NGXZ
,';2:GTJ9',+:?
Be sure the batteries are 9=/:).68,';2:
fully charged and VXKYKTZUTZNKJOYVRG_
properly connected.
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TU
(553;6*=4
/Y 8KIGROHXGZKHUUS
05?9:/)145: _KY [VJU]TPU_YZOIQ9KK
)'2/(8':+* VXKYKTZUT 8KVGOX9KIZOUT58
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[VJU]TPU_YZOIQ
TU
(553;6*=4
/Y )NKIQLUXJGSGMKJ
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*=405?9:/)19.58:+* HUUS[VJU]TPU_YZOIQ
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;6*=405?9:/)1<'2;+ IOXI[OZHUGXJIUTTKIZUX
:55./-.58(553;6 658XKVRGIKZNK
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CHART 14
_KY
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)UTZOT[KJLXUSZNK
,';2:VXKYKTZUTZNK
VXK\OU[YVGMK
JOYVRG_%
TU
(553'4-2+
9=/:).+9 ,';2: 'TMRK9]OZIN,G[RZ
TU
(5532+4-:.
9=/:).+9 ,';2: 2KTMZN9]OZIN,G[RZ
TU
/Y(553;6*=4,25= )GROHXGZKHUUS[VJU]T
_KY
<'2<+45:)'2/(8':+* PU_YZOIQZNXKYNURJ9KK
TU
/Y(553;6*=4,25= )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

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LXUSVOTULZNK0
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IUTZXUR\GR\KOZKS(,UX
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TU
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CHART 14
(553*5=4
/Y /YZNKXKGTUHYZX[IZOUT 8KSU\KUHYZX[IZOUTUX
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CHART 14
/Y(553;6<'2<+ )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

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CHART 14

)UTZOT[KJLXUS
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HUUSLXUSXGOYOTM%
TU
L[TIZOUT
'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKHUUS[V
UVKXGZKY
KTGHRKNOMN863H[ZZUT JU]TJOXKIZOUTGR\GR\K
GTJZNKHUUSJU]T OZKS(*UXOZKS,*
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JOXKIZOUTGR\GR\KH_
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MG[MKGZZNKW[OIQ HUUSLXUSSU\OTM58
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Chart 15
Boom Length =OZNZNKHUUSL[RR_
TU
)UTZOT[KJUTVGMK
Switch Fault XKZXGIZKJGTJHUUS
GTMRKRKYYZNGT
Be sure all other (553

JKMXKKYOY
2+4-:.9=/:).+9 ,';2:
functions operate VXKYKTZUTZNKJOYVRG_%
normally.
_KY
Be sure the boom length
limit switches are *OYIUTTKIZGTJZKYZ 8KVRGIKGTJGJP[YZ
HGJ
properly connected to 29(+59KK8KVGOX 29(+59KK8KVGOX
the correct wiring 9KIZOUT 9KIZOUT
harness leads.
MUUJ
Be sure the batteries are

fully charged and =OZN29(+5 *OYIUTTKIZZNK[VVKX0 8KVGOXUXXKVRGIKZNK
JOYIUTTKIZKJINKIQLUX NGXTKYYLXUSZNKRU]KX (2(1)6(+]OXK

properly connected. \URZGMKUTZNK(2(1 0NGXTKYY)NKIQLUX LXUSVOTULZNKVOT
\URZGMK
)6(+]OXKGZVOTUL _KY \URZGMKUTZNK(2(1 JK[ZYINIUTTKIZUXGZZNK
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CHART 15
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CHART 15
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CHART 15
8GOYKHUUSZUMXKGZKX *OYIUTTKIZGTJZKYZ 8KVRGIKGTJGJP[YZ

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Chart 16
Boom Extend =OZNZNKQK_Y]OZIN 6XKYYZNKHUUSK^ZKTJ
_KY
)UTZOT[KJZUVGMK
Inoperative
V[RRKJU[ZZUZNK54
Be sure all other VUYOZOUTGIZO\GZKZNK
TU
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functions operate KTGHRKH[ZZUTGTJZNK
normally. HUUSK^ZKTJH[ZZUT )UTY[RZZNK-KTOK
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Be sure the axles are IUJKYVXKYKTZUTZNK *KVGXZSKTZ:NK
JOYVRG_YIXKKT% Z[XTZGHRKSKSHXGTK
fully extended. SG_TKKJZUHK
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Be sure the boom is
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within the operation
envelope zone.
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are fully charged and )'2/(8':+* VXKYKTZUT YKK8KVGOX9KIZOUT58
properly connected.
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CHART 16
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CHART 16
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CHART 16
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CHART 16
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CHART 16
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CHART 16
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CHART 16
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Chart 17
Boom Retract =OZNZNKQK_Y]OZIN 'IZO\GZKZNKHUUS
_KY
)UTZOT[KJUTVGMK
Function Z[XTKJZUMXU[TJ TU XKZXGIZH[ZZUT/YZNKXK
Inoperative
IUTZXURYGTJHUZN GTG[JOHRKHKKV]NKT
+SKXMKTI_9ZUVH[ZZUTY ZNKH[ZZUTOYVXKYYKJ%
V[RRKJU[ZZUZNK 54
Make sure all other VUYOZOUTGIZO\GZKZNK
TU
L[TIZOUTKTGHRKNOMN
normally. HUUSXKZXGIZH[ZZUT'XK 8KVRGIKZNKMXU[TJ
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Be sure the axles are VXKYKTZUTZNKJOYVRG_ JKIGR9KK8KVGOX
YIXKKTGZZNKMXU[TJ 9KIZOUT58IUTY[RZZNK
fully extended. IUTZXURY% -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
are fully charged and _KY
properly connected.
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CHART 17
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CHART 17
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ULZNK0IUTTKIZUX
VOTULZNK*/4
IUTTKIZUXGZZNKHUUS
IUOROZKS(4
MUUJ
ZU
UNSY
ZNKHUUSXKZXGIZ /TJ[YZXOKY9KX\OIK
YKW[KTIK\GR\KIUOR *KVGXZSKTZ
OZKS(4
UXOTLOTOZK
UNSY
8KVRGIKZNKHUUS
IUOR
CHART 17
)UTZOT[KJLXUS
VGMK
MG[MKZUZNKW[OIQ HUUSLXUSSU\OTM58

JOYIUTTKIZIU[VROTMUT XKVRGIKZNKHUUSXKZXGIZ
69/UX
ZNKL[TIZOUTSGTOLURJ YKW[KTIK\GR\K
SUXK
9ZGXZZNKKTMOTKGTJ OZKS(458XKVGOX
GIZO\GZKZNKL[TIZOUT I_ROTJKXUXI_ROTJKX
KTGHRKNOMN863H[ZZUT IU[TZKXHGRGTIK\GR\K
GTJZNKHUUSXKZXGIZ 58IUTY[RZZNK-KTOK
H[ZZUTGTJINKIQZNK /TJ[YZXOKY9KX\OIK
VXKYY[XK *KVGXZSKTZ
RKYYZNGT
69/
+ÎNGTMKHUUSK^ZKTJ _KY 8KVRGIKZNKLG[RZ_LRU]
XKZXGIZLRU]IUTZXUR\GR\K IUTZXUR\GR\K
OZKS((UXOZKS,(
]OZNZNKHUUS[VJU]T
LRU]IUTZXUR\GR\KOZKS
(,UXOZKS,,GTJ
INKIQZNKHUUSXKZXGIZ
L[TIZOUT*UKYZNK
L[TIZOUTUVKXGZK%
TU
'JP[YZZNKHUUSXKROKL
\GR\KOZKS(/UXOZKS,/
9KK8KVGOX9KIZOUT
58XKVGOXI_ROTJKXUX
\GR\K58L[TIZOUT
SGTOLURJIU[RJNG\KGT
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Chart 18
Boom Envelope :NKMXU[TJIUTZXURHU^
_KY
)UTZOT[KJUTVGMK
Operational JOYVRG_XKGJY9',+:?
9=/:).6',';2:GTJ
Switch Failure, 9',+:?9=/:). 6(
,';2:UX9',+:?
S-100 and 9=/:).6(,';2:
S-105 Models
*OJZNKKTMOTKYN[ZULL
]NORKZNKHUUS]GY
K^ZKTJOTM%
A boom envelope safety

fault is the result of the TU
boom exceeding the _KY

*OJZNKKTMOTKYN[ZULL )UTZOT[KJUTVGMK
operational limits and ]NORKZNKHUUS]GY
activating the safety HKOTMRU]KXKJ%
switches OR when the ;TGHRKZUJKZKXSOTKLXUS
safety switches are ZNKUVKXGZUX]NKTZNK
tripped within the YGLKZ_Y]OZIN]GYZXOVVKJ
operational range. ;YOTMG[ÔROGX_VU]KX 9GLKZ_Y]OZIN29(+9 )UTZOT[KJUTVGMK
XKZXGIZZNKHUUSZURKYY NGYZXOVVKJ
Press the (+) and (-) ZNGTLKKZGTJ YULZ]GXK\KXYOUT
keys together to access

RU]KXZNKHUUSZUG +TMOTKYZUVYGTJ
NUXOÙTZGRVUYOZOUT LG[RZSKYYGMKYIXURRY
the status screen. The 9ZGXZZNKKTMOTK'IIKYY GIXUYYZNKYIXKKT
status screen can ZNKYZGZ[YYIXKKTGTJ

KTMOTK
\KXYOUTGTJ
YIXURRJU]T[TZORZNK MXKGZKX +TMOTKYZUVY

display the following HUUSRKTMZNYIXKKT GTJZNKXKZXGIZHUUS
information: GVVKGXY+^ZKTJZNK 2+*2)*LRGYNGRUTM
- Hydraulic pressure HUUS]NORKUHYKX\OTM ]OZNZNKG[ÔROGX_VU]KX
ZNKJOYVRG_YIXKKT H[ZZUTGZZNKVRGZLUXS
- Boom Length *UKYZNKKTMOTKYZUV IUTZXURYGTJZNKHGZZKX_
- Boom Angle 58JUKYZNKHUUSYZUV OIUTGZZNKMXU[TJ
- Axle status GZLKKZGTJOYZNK IUTZXURY
XGOYKHUUSGXXU]
LRGYNOTM%
Boom lengths are given
in feet. The first number HUUS
is the length for a S-100,

the second number is 9ZGXZZNKKTMOTKGTJ 9GLKZ_Y]OZIN29('9 )UTZOT[KJUTVGMK
for a S-105. For

XGOYKZNKHUUSZU NGYZXOVVKJ
MXKGZKXZNGTJKMXKKY YULZ]GXK\KXYOUT
example, 75.5/80.5 feet. GTJK^ZKTJZNKHUUSZU +TMOTKYZUVYGTJ
SUXKZNGTLKKZ LG[RZSKYYGMKYIXURRY
Greater than or equal to 'IZO\GZKZNKL[TIZOUT GIXUYYZNKYIXKKT

_KY
is indicated by >= on the KTGHRKNOMN863H[ZZUT
GTJZNKHUUSJU]T
YULZ]GXK\KXYOUT
GTJMXKGZKX +TMOTK
display. H[ZZUTGTJRU]KXZNK YZUVYGTJZNKXKZXGIZ
HUUS*UKYZNKKTMOTK HUUS2+*2)*LRGYN
A digital protractor YZUV]OZNZNKHUUSGZ GRUTM]OZNZNKG[ÔROGX_
will be needed to JKMXKKY% VU]KXH[ZZUTGZZNK
VRGZLUXSIUTZXURYGTJ
properly troubleshoot ZNKHGZZKX_OIUTGZZNK
the machine. TU
MXU[TJIUTZXURY

are fully charged and (KMOTZXU[HRKYNUUZOTM
LXUSZNKHKMOTTOTMUL
properly connected. ZNKINGXZ58IUTY[RZZNK
*KVGXZSKTZ
CHART 18
'IIKYYZNKYZGZ[Y -UZUROLZL[TIZOUTXGSV YULZ]GXK\KXYOUT

)UTZOT[KJLXUS
YIXKKTGTJYIXURRJU]T ZOSK:[XTZNKQK_ 8KYKZZNKXGSV
VGMK
[TZORZNK (5532+4-:. Y]OZINZUZNK5,, TU ZOSKZUSY
$
YIXKKTGVVKGXYUTZNK VUYOZOUT6XKYYGTJNURJ YULZ]GXK\KXYOUT
JOYVRG_
ZNKH[ZZUTGTJZ[XT 8KYKZZNKXGSV
=NGZHUUSRKTMZNOY ZNKQK_Y]OZINZUMXU[TJ ZOSKZUSY
YNU]TUTZNKJOYVRG_% IUTZXURY

6XKYYGTJ
YIXURRJU]T[TZORHUUS
+>:+4*8+:8'):8'36
*+)+2 GVVKGXYUTZNK
JOYVRG_YIXKKT
YULZ]GXK\KXYOUT
/YZNKXGSVZOSK
YNU]TSY%
YULZ]GXK\KXYOUT
/YZNKXGSVZOSK
YNU]TSY%
_KY
YULZ]GXK\KXYOUT TU 8KYKZZNKHUUSYVKKJ
-UZUZNKHUUS ZU
L[TIZOUTYYVKKJY
YIXKKT:[XTZNKQK_
Y]OZINZUZNK5,,
VUYOZOUT6XKYYGTJNURJ

ZNKH[ZZUTGTJZ[XT
ZNKQK_Y]OZINZUMXU[TJ
IUTZXURY6XKYYZNK
H[ZZUTYGTJ
$ YIXURRJU]T[TZOR (553
+>:+4*96++* OYYNU]T
UTZNKJOYVRG_YIXKKT
/YZNKYVKKJOY
VXKIKTZ%
YULZ]GXK\KXYOUT
GTJRGZKX 6XUIKKJZU
ZNKTK^ZYZKV
_KY
:KYZ29('5LUX 8KINKIQZNKUVKXGZOUT
MUUJ
VXUVKXUVKXGZOUT9KK ULZNKHUUS8KZXGIZZNK
8KVGOX9KIZOUT HUUSLKKZZNKTK^ZKTJ
ZNKHUUS/LZNKHUUS
LGORYZNOYZKYZHKMOT
ZXU[HRKYNUUZOTMLXUSZNK
HKMOTTOTMULZNKINGXZ
58IUTY[RZZNK-KTOK
HGJ /TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
ZNKTK^ZVGMK VGMK
CHART 18
*OYIUTTKIZ29(+5 8KSU\KZNKUXGTMK
)UTZOT[KJLXUSZNK TU
'XKZNKZKXSOTGRY YKIUTJGX_RUIQGTJXK
VXK\OU[YVGMK
VXUVKXR_OTYKXZKJOTZU OTYKXZZNKZKXSOTGR
ZNKJK[ZYINIUTTKIZUX%
_KY
:KYZ29(+5LUXVXUVKX 8KVRGIKGTJGJP[YZ
HGJ
UVKXGZOUT9KK8KVGOX 29(+59KK8KVGOX
9KIZOUT 9KIZOUT
MUUJ
YNUXZOT)6(+GTJ )6(+GTJUX)29
)29]OXKIOXI[OZY HGJ ]OXKIOXI[OZY58XKSU\K
:XGIKZNKIOXI[OZYHGIQ ZNKUXGTMKYKIUTJGX_
ZUZNKMXU[TJIUTZXUR RUIQGTJXKOTYKXZZNK
HU^)NKIQZNK]OXOTMGZ ZKXSOTGR
ZNKIUTTKIZUXHKZ]KKT
ZNK[VVKXGTJRU]KXROSZ
Y]OZINNGXTKYY3GQK
Y[XKZNGZZKXSOTGRUT
0OYVXUVKXR_OTYKXZKJ
'XKZNK]OXKYMUUJ%
MUUJ
)NKIQZUSGQKY[XKZNGZ 2UUYKTZNKXKJ
VOTULZNK0 YKIUTJGX_RUIQGTJXK
HGJ
IUTTKIZUXGZZNKMXU[TJ OTYKXZZNKZKXSOTGR
IUTZXURYOYVXUVKXR_ /TYZGRRZNKYKIUTJGX_
OTYKXZKJ RUIQOTZUYKI[XKZNK
ZKXSOTGROTVRGIK
MUUJ
)NKIQZUSGQKY[XKZNGZ 2UUYKTZNKXKJ
VOTUTZNK0 YKIUTJGX_RUIQGTJXK
HGJ
IUTTKIZUXGZZNKMXU[TJ OTYKXZZNKZKXSOTGR
IUTZXURHUÔYVXUVKXR_ /TYZGRRZNKYKIUTJGX_
OTYKXZKJ RUIQOTZUYKI[XKZNK
ZKXSOTGROTVRGIK
MUUJ
8KVRGIKZNKMXU[TJ
IUTZXURHU^58IUTY[RZ
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
CHART 18
6XKYYQK_Y -UZUROLZL[TIZOUTXGSV YULZ]GXK\KXYOUT

)UTZOT[KJLXUS
ZUMKZNKXZUGIIKYYZNK ZOSK:[XTZNKQK_ 8KYKZZNKXGSV
VGMK
YZGZ[YYIXKKT9IXURR $# Y]OZINZUZNK 5,, TU ZOSKZUSY
JU]T[TZOR(553'4-2+ JKMXKKY VUYOZOUT6XKYYGTJNURJ YULZ]GXK\KXYOUT
OYVXKYKTZUTZNKJOYVRG_
ZNKH[ZZUTGTJZ[XT 8KYKZZNKXGSV
YIXKKT ZNKQK_Y]OZINZUMXU[TJ ZOSKZUSY
=NGZHUUSGTMRKOY IUTZXURY
YNU]TUTZNKJOYVRG_%
6XKYYZNKT
(553
YIXURR[TZOR
+>:+4* 8+:8'):8'36
*+)+2 OYVXKYKTZUTZNK
JOYVRG_
YULZ]GXK\KXYOUT
/YZNKXGSVZOSK
YNU]TSY%
YULZ]GXK\KXYOUT
/YZNKXGSVZOSK
YNU]TSY%
_KY
:[XTZNKQK_Y]OZINZU TU 8KYKZZNKHUUSYVKKJ
ZNKULLVUYOZOUT6XKYY ZU

GTJNURJZNKH[ZZUT
GTJZ[XTZNKQK_Y]OZIN
ZUMXU[TJIUTZXURY
6XKYYGTJ
(553
YIXURRJU]T[TZOR
;6*5=496++* (+25=
,++:OYVXKYKTZUT
ZNKJOYVRG_*UKYZNK
JOYVRG_YNU]%
$#
JKMXKKY _KY
'ZZGINGJOMOZGR 2UUYKTZNK29('5
VXUZXGIZUXZUZNKZUVUL TU SU[TZOTMLGYZKTKXYGTJ
ZNKHUUSZ[HK8GOYK IUTZOT[OZ_ GJP[YZZNKY]OZINYUZNGZ
ZNKHUUS[TZORZNKHUUS OZIRUYKY]NKTZNKHUUS
GTMRKOYGZJKMXKKY GTMRKXKGINKY
*OYIUTTKIZ29('5 JKMXKKY
JK[ZYINIUTTKIZUXGTJ
INKIQLUXIUTZOT[OZ_
HKZ]KKTZKXSOTGRY
GTJ
IUTZOT[OZ_
)UTTKIZ29('5 2UUYKTZNK29('9
2U]KXZNKHUUS[TZORZNK SU[TZOTMLGYZKTKXYGTJ
HUUSGTMRKOY GJP[YZZNKY]OZINYUZNGZ
IUTZOT[OZ_
JKMXKKY*OYIUTTKIZ ZNKIUTZGIZYULZNK
29('9JK[ZYIN Y]OZINUVKT]NKTZNK
IUTTKIZUXGTJINKIQLUX HUUSGTMRKXKGINKY
TUIUTZOT[OZ_HKZ]KKT JKMXKKY
VOTYGTJGTJ
HKZ]KKTVOTYGTJ
)UTZOT[KJUT TUIUTZOT[OZ_
ZNKTK^ZVGMK
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
CHART 18
*OYIUTTKIZ29('5 8KSU\KZNKUXGTMK
)UTZOT[KJLXUSZNK
JK[ZYINIUTTKIZUX'XK TU YKIUTJGX_RUIQGTJ
VXK\OU[YVGMK
ZNKZKXSOTGRYOTYKXZKJ XKOTYKXZZNKZKXSOTGRY
VXUVKXR_% /TYZGRRZNKUXGTMK
YKIUTJGX_RUIQ
_KY
:KYZ29('59KK HGJ 8KVRGIKGTJGJP[YZ
8KVGOX9KIZOUT 29('59KK8KVGOX
9KIZOUT
MUUJ
HGJ
YNUXZOT)'9GTJ )'9GTJ)29]OXK
)29]OXKIOXI[OZY IOXI[OZY
:XGIKZNKIOXI[OZYHGIQ
ZUZNKMXU[TJIUTZXUR
HU^
MUUJ
IUTTKIZUXGZZNKMXU[TJ YKIUTJGX_RUIQGTJXK
HGJ
IUTZXURHU^ZUSGQKY[XK OTYKXZZNKZKXSOTGR
ZNGZZNKZKXSOTGROY /TYZGRRZNKYKIUTJGX_
OTYKXZKJVXUVKXR_ RUIQOTZUYKI[XKZNK
ZKXSOTGROTVRGIK
MUUJ
HGJ
IUTZXURHU^ZUSGQKY[XK OTYKXZZNKZKXSOTGR
ZNGZZNKZKXSOTGROY /TYZGRRZNKYKIUTJGX_
OTYKXZKJVXUVKXR_ RUIQOTZUYKI[XKZNK
ZKXSOTGROTVRGIK
MUUJ
8KVRGIKZNKMXU[TJ
IUTZXURHU^58IUTY[RZ
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Chart 19
Boom Envelope :NKMXU[TJIUTZXURHU^ _KY /YZNKHUUSRKTMZNKW[GR TU /YZNKHUUSRKTMZNKW[GR
Operational JOYVRG_XKGJY9',+:?
9=/:).6',';2:GTJ
ZULKKZ% ZUUXLKKZ%
Switch Failure, 9',+:?9=/:). 6(
,';2:UX9',+:?
_KY _KY
S-120 and 9=/:).6(,';2:

*OJZNKKTMOTKYN[ZULL )UTZOT[KJUTVGMK )UTZOT[KJUTVGMK
S-125 Models ]NORKZNKHUUS]GY
K^ZKTJOTM%
A boom envelope safety

fault is the result of the TU
boom exceeding the

*OJZNKKTMOTKYN[ZULL 'ZZGINGJOMOZGR
operational limits and ]NORKZNKHUUS]GY
_KY
VXUZXGIZUXZUZNKZUVUL
JKMXKKY
)UTZOT[KJUTVGMK
activating the safety HKOTMRU]KXKJ% ZNKHUUS8KGJZNK
switches OR when the HUUSGTMRK
safety switches are ;TGHRKZU
tripped within the JKZKXSOTK
LXUSZNK
JKMXKKY
operational range. UVKXGZUX

)UTZOT[KJUTVGMK
]NKTZNK
Press the (+) and (-) YGLKZ_Y]OZIN
keys together to access ]GYZXOVVKJ
the status screen. The

;YOTMG[ÔROGX_VU]KX 9GLKZ_Y]OZIN29(+9 )UTZOT[KJUTVGMK
status screen can XKZXGIZZNKHUUSZURKYY NGYZXOVVKJ
display the following ZNGTLKKZGTJ YULZ]GXK\KXYOUT
information: RU]KXZNKHUUSZUG +TMOTKYZUVYGTJ
NUXOÙTZGRVUYOZOUT LG[RZSKYYGMKYIXURRY
- Hydraulic pressure 9ZGXZZNKKTMOTK'IIKYY GIXUYYZNKYIXKKT
- Boom Length ZNKYZGZ[YYIXKKTGTJ KTMOTK \KXYOUTGTJ
- Boom Angle YIXURRJU]T[TZORZNK
HUUSRKTMZNYIXKKT
MXKGZKX +TMOTKYZUVY
GTJZNKXKZXGIZHUUS
- Axle status GVVKGXY+^ZKTJZNK 2+*2)*LRGYNGRUTM
HUUS]NORKUHYKX\OTM ]OZNZNKG[ÔROGX_VU]KX
Boom lengths are given ZNKJOYVRG_YIXKKT H[ZZUTGZZNKVRGZLUXS
in feet. The first number *UKYZNKKTMOTKYZUV
58JUKYZNKHUUSYZUV
IUTZXURYGTJZNKHGZZKX_
OIUTGZZNKMXU[TJ
is the length for a S-120, GZLKKZGTJOYZNK IUTZXURY
the second number is XGOYKHUUSGXXU]
for a S-125. For LRGYNOTM%
example, 75.5/80.5 feet.
Greater than or equal to

is indicated by >= on the
display.
HUUS
A digital protractor
will be needed to
properly troubleshoot
the machine.

are fully charged and )UTZOT[KJUT
ZNKTK^ZVGMK
properly connected.
CHART 19
'ZZGINGJOMOZGR 9GLKZ_Y]OZIN29(89 )UTZOT[KJUTVGMK

)UTZOT[KJLXUSZNK
VXUZXGIZUXZUZNKZUVUL NGYZXOVVKJ
VXK\OU[YVGMK
ZNKHUUSU[ZKXSUYZ YULZ]GXK\KXYOUT
HUUSZ[HKYKIZOUT +TMOTKYZUVYGTJ
8GOYKZNKHUUSZU LG[RZSKYYGMKYIXURRY
MXKGZKXZNGTJKMXKKY GIXUYYZNKYIXKKT
H[ZRKYYZNGT YULZ]GXK\KXYOUT
_KY
JKMXKKY GTJMXKGZKX +TMOTK
9IXURRJU]TZNKYZGZ[Y YZUVYGTJZNKXKZXGIZ
YIXKKT[TZORZNKHUUS HUUS2+*2)*LRGYN
RKTMZNYIXKKTGVVKGXY GRUTM]OZNZNKG[ÔROGX_
+^ZKTJZNKHUUS]NORK VU]KXH[ZZUTGZZNK
UHYKX\OTMZNKJOYVRG_ VRGZLUXSIUTZXURYGTJ
YIXKKT ZNKHGZZKX_OIUTGZZNK
*UKYZNKKTMOTKYZUVGZ MXU[TJIUTZXURY
LKKZ%
TU
9IXURRJU]TZNKYZGZ[Y 9GLKZ_Y]OZIN29('9
(553'4-2+
YIXKKT[TZOR NGYZXOVVKJ )UTZOT[KJUTVGMK
GVVKGXYUTZNKJOYVRG_ YULZ]GXK\KXYOUT
YIXKKT8GOYKZNKHUUS +TMOTKYZUVYGTJ
ZUMXKGZKXZNGT LG[RZSKYYGMKYIXURRY
JKMXKKYGTJK^ZKTJZNK GIXUYYZNKYIXKKT
HUUSVGYZLKKZ _KY YULZ]GXK\KXYOUT
6XKYYZNKHUUSJU]T GTJMXKGZKX +TMOTK
H[ZZUTGTJRU]KXZNK YZUVYGTJZNKXKZXGIZ
HUUS*UKYZNKKTMOTK HUUS2+*2)*LRGYN
YZUV]NKTZNKHUUSOY GRUTM]OZNZNKG[ÔROGX_
GZJKMXKKYGTJOYZNK VU]KXH[ZZUTGZZNK
HUUSXKZXGIZROMNZTUZ VRGZLUXSIUTZXURYGTJ
LRGYNOTM% ZNKHGZZKX_OIUTGZZNK
MXU[TJIUTZXURY
TU
6XKYYZNKHUUSJU]T 9GLKZ_Y]OZIN29('9 )UTZOT[KJUTVGMK
H[ZZUTGTJRU]KXZNK NGYZXOVVKJ
_KY
HUUS*UKYZNKKTMOTK YULZ]GXK\KXYOUT
YZUV]OZNZNKHUUSGZ +TMOTKYZUVYGTJ
JKMXKKY% LG[RZSKYYGMKYIXURRY
GIXUYYZNKYIXKKT
YULZ]GXK\KXYOUT
GTJMXKGZKX +TMOTK
YZUVYGTJZNKXKZXGIZ
HUUS2+*2)*LRGYN
GRUTM]OZNZNKG[ÔROGX_
VU]KXH[ZZUTGZZNK
TU
VRGZLUXSIUTZXURYGTJ
ZNKHGZZKX_OIUTGZZNK
MXU[TJIUTZXURY
(KMOTZXU[HRKYNUUZOTM
LXUSZNKHKMOTTOTMUL
*KVGXZSKTZ
CHART 19
'IIKYYZNKYZGZ[Y -UZUROLZL[TIZOUTXGSV YULZ]GXK\KXYOUT

)UTZOT[KJLXUS
YIXKKTGTJYIXURRJU]T ZOSK:[XTZNKQK_ 8KYKZZNKXGSV
VGMK
[TZORZNK (5532+4-:. Y]OZINZUZNK5,, TU ZOSKZUSY
$
YIXKKTGVVKGXYUTZNK VUYOZOUT6XKYYGTJNURJ YULZ]GXK\KXYOUT
JOYVRG_=NGZHUUS
ZNKH[ZZUTGTJZ[XT UXMXKGZKX 8KYKZZNK
RKTMZNOYYNU]TUTZNK ZNKQK_Y]OZINZUMXU[TJ XGSVZOSKZUSY
JOYVRG_% IUTZXURY

6XKYYGTJ
YIXURRJU]T[TZORHUUS
+>:+4*8+:8'):8'36
*+)+2 GVVKGXYUTZNK
JOYVRG_YIXKKT/YZNK
XGSVZOSKYNU]T
SY%
_KY
YULZ]GXK\KXYOUT TU 8KYKZZNKHUUSYVKKJ
-UZUZNKHUUS ZU
L[TIZOUTYYVKKJY
YIXKKT:[XTZNKQK_
Y]OZINZUZNK5,,
VUYOZOUT6XKYYGTJNURJ

ZNKH[ZZUTGTJZ[XT
ZNKQK_Y]OZINZUMXU[TJ
IUTZXURY6XKYYZNK
H[ZZUTYGTJ
YIXURRJU]T[TZOR (553
+>:+4*96++* OYYNU]T
UTZNKJOYVRG_YIXKKT/Y
ZNKYVKKJ%
YULZ]GXK\KXYOUT
$
GTJMXKGZKX 6XUIKKJ
ZUZNKTK^ZYZKV
_KY
ZNKTK^ZVGMK VGMK
CHART 19
TUZ
*OYIUTTKIZ29(+5 2UUYKTH[ZJUTUZ
)UTZOT[KJLXUSZNK VXUVKXR_
)NKIQZNGZZNKZKXSOTGRY XKSU\KZNKXKJ
VXK\OU[YVGMK OTYKXZKJ
GXKVXUVKXR_OTYKXZKJ YKIUTJGX_RUIQGTJXK
OTYKXZZNKZKXSOTGR
/TYZGRRZNKYKIUTJGX_
RUIQOTZUYKI[XKZNK
VXUVKXR_ ZKXSOTGROTVRGIK
OTYKXZKJ
UVKXGZOUT9KK8KVGOX HGJ 29(+59KK8KVGOX
9KIZOUT 9KIZOUT
MUUJ
YNUXZOTZNK)6(+ )6(+GTJUX)29
GTJ)29]OXKIOXI[OZY ]OXKIOXI[OZY58RUUYKT
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CHART 21
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Function VUYOZOUTVXKYYZNKLUUZ
Inoperative
_KY
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functions operate ZNKXGT_LG[RZIUJKY MG[MKGZZNKW[OIQ VXUVUXZOUTGR\GR\KOZKS
normally. VXKYKTZUTZNKJOYVRG_GZ JOYIUTTKIZIU[VROTMUT (-UXOZKS,-58
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CHART 22
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Chart 23
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Clockwise VUYOZOUTVXKYYZNKLUUZ
G[JOHRKHKKV%
Function L[TIZOUTKTGHRKNOMN
863H[ZZUTGTJZNK
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functions operate ZNKMXU[TJIUTZXURY%
normally. TU
Be sure the axles are

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fully extended. HGXVXKYY[XK Z[XTZGHRKXUZGZK
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properly connected. KTMOTK'ZZNKMXU[TJ
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CHART 23
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TU
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)'2/(8':+* VXKYKTZUT 8KVGOX9KIZOUT
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TU
)UTZOT[KJUT
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CHART 23
/Y:;84:'(2+ 85:':+ )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIK

)UTZOT[KJLXUSZNK
,25=<'2<+,';2: _KY YNUXZOTZNK=.8* =.8*):8,]OXK
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YIXKKT% ULZNK0IUTTKIZUXGZ
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VOTULZNK*OT
IUTTKIZUXGZZNK
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OZKS(-UXOZKS,-
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TU
\GR\KIUOROZKS(-UX
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UXOTLOTOZKUNSY
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)UTZOT[KJUT
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CHART 23
(553*5=4
)UTZOT[KJLXUSZNK
5<+825'*,';2: _KY XKYZXOIZOUTYQKKVOTMZNK SKINGTOIGRXKYZXOIZOUT
VXK\OU[YVGMK
TU
XKYZXOIZOUTYQKKVOTMZNK SKINGTOIGRXKYZXOIZOUT
RUGJSUSKTZL[TIZOUT
LXUSUVKXGZOTM%
TU
HGJ
MUUJ
9KK8KVGOX9KIZOUT
MUUJ

TU
)29]OXKLXUSVOT
ULZNK0IUTTKIZUX
29(25
MUUJ
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ULZNK0IUTTKIZUX
29(25
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 23
/Y:;84:'(2+ 85:':+ )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

)UTZOT[KJLXUSZNK
))=<'2<+ ,';2: _KY YNUXZOTZNK=.(1 =.(1):88]OXK
VXK\OU[YVGMK
VXKYKTZUTZNKJOYVRG_ ):88]OXKLXUSVOT
YIXKKT% ULZNK0IUTTKIZUX
VOTULZNK*OT
IUTTKIZUXGZZNK
IRUIQ]OYK\GR\KIUOR
OZKS(-UXOZKS,-
MUUJ
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUX
VOTULZNK*OT
IUTTKIZUXGZZNK
IRUIQ]OYK\GR\K\GR\K
IUOROZKS(-UXOZKS
TU
,-
MUUJ
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IUOROZKS()UXOZKS
,)
UXOTLOTOZKUNSY
\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 24
Platform Level =OZNZNKQK_Y]OZIN :[XTZNKQK_Y]OZINZU _KY 8KVRGIKZNKZUMMRK
Function Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN TU
VRGZLUXSIUTZXURYGTJ
ZKYZZNKVRGZLUXSRK\KR
Y]OZIN
54
V[RRKJU[ZZUZNK
ZUMMRKY]OZINLUXVXUVKX
UVKXGZOUT9KK8KVGOX
VUYOZOUTVXKYYJU]TZNK 9KIZOUT
Be sure all other LUUZY]OZINGTJGIZO\GZK /YZNKY]OZINLG[RZ_%
functions operate ZNKL[TIZOUTKTGHRKNOMN
normally. 863H[ZZUTGTJZNK
VRGZLUXSRK\KR[VH[ZZUT
TU
'XKZNKXKGT_JOGMTUYZOI
Be sure the platform IUJKYVXKYKTZUTZNK )NKIQLUXGTUVKTUX 8KVGOXUXXKVRGIKZNK
HGJ
out of level LED and JOYVRG_GZZNKMXU[TJ YNUXZOTZNKOTZKXTGR OTZKXTGRVRGZLUXS]OXK
ICON are not flashing IUTZXURY% VRGZLUXSIUTZXURHU^]OXK
NGXTKYYHKZ]KKTZNK
NGXTKYY
at the ground control 99GTJ9
box. IUTTKIZUXYGZZNKZUMMRK
Y]OZINGTJVOTYGTJ
Be sure the batteries ULZNK6IUTTKIZUX
GZZNKIOXI[OZHUGXJ
properly connected. MUUJ
HGXVXKYY[XK VRGZLUXSRK\KR\GR\K
MG[MKGZZNKW[OIQ OZKS).UXOZKS-.
JOYIUTTKIZIU[VROTMUT 58XKVGOXUXXKVRGIKZNK
ZNKVRGZLUXSL[TIZOUT RKYYZNGT IU[TZKXHGRGTIK\GR\KY
SGTOLURJGTJYZGXZZNK VYO 58XKVGOXUXXKVRGIKZNK
KTMOTK'ZZNKMXU[TJ I_ROTJKX58ZNKVRGZLUXS
IUTZXURYGIZO\GZKZNK L[TIZOUTSGTOLURJIU[RJ
L[TIZOUTKTGHRKNOMN NG\KGTOTZKXTGRLG[RZ
863H[ZZUTGTJZNK )UTY[RZZNK-KTOK
VRGZLUXSRK\KR[VH[ZZUT /TJ[YZXOKY9KX\OIK
GTJINKIQZNKVXKYY[XK *KVGXZSKTZ
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69/
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8KVGOXUXXKVRGIKZNK
VRGZLUXSRK\KR\GR\KY58
XKVGOXUXXKVRGIKZNK
\GR\K58XKVGOXUX
XKVRGIKZNKI_ROTJKX58
ZNKVRGZLUXSL[TIZOUT
SGTOLURJIU[RJNG\KGT
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9KX\OIK*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 24
/Y62':,5832+<+2 )NKIQLUXGTUVKTUX 8KVRGIKZNKVRGZLUXSZORZ

)UTZOT[KJLXUSZNK
9+4958*+-8++9 YNUXZOTZNK]OXKIOXI[OZ MUUJ YKTYUX58IUTY[RZZNK
VXK\OU[YVGMK
9.58:+*:5<52:9 HKZ]KKTVOTYGTJ -KTOK/TJ[YZXOKY9KX\OIK
5862':,5832+<+2 ULZNK0IUTTKIZUX *KVGXZSKTZ

_KY
9+4958*+-8++9 GZZNKVRGZLUXSIUTZXUR
9.58:+*:5<52:9 HU^GTJVOTYGTJ
5862':,5832+<+2 ULZNKJK[ZYINIUTTKIZUX
9+4958*+-8++9 <'2;+ GZZNKVRGZLUXSZORZ
:55./-.58 YKTYUX
62':,5832+<+2
9+4958*+-8++9 <'2;+
HGJ
:5525=VXKYKTZUTZNK
JOYVRG_YIXKKT%
8KVGOXZNK]OXKIOXI[OZ
TU
9',+:?9=/:).6
/Y 8KLKXZUZNKGVVXUVXOGZK
,';2:589',+:? VRGZLUXSRK\KR
TU
9=/:).68,';2: OTUVKXGZO\KINGXZZU
VXKYKTZUTZNKJOYVRG_ IUTZOT[K
YIXKKT% ZXU[HRKYNUUZOTM
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8KLKXZU)NGXZ
Chart 25
Platform Level =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKMXU[TJ
Up Function Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
TU
KTGHRKNOMN863H[ZZUT
GTJZNKVRGZLUXSRK\KR[V
TU
IUTZXURYSKSHXGTK
JKIGRJKIGR58IUTY[RZ
V[RRKJU[ZZUZNK54
H[ZZUT/YZNKXKGT
G[JOHRKHKKV%
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
VUYOZOUTGIZO\GZKZNK
Be sure all other L[TIZOUTKTGHRKNOMN
_KY
normally. VRGZLUXSRK\KR[VH[ZZUT
'XKZNKXKGT_LG[RZ 'ZZNKVRGZLUXSIUTZXURY HGJ 8KVRGIKZNKZUMMRK
IUJKYVXKYKTZUTZNK ZKYZZNKVRGZLUXSRK\KR Y]OZIN

Be sure the platform JOYVRG_YIXKKT% ZUMMRKY]OZINLUXVXUVKX
out of level LED and UVKXGZOUT9KK8KVGOX
ICON are not flashingat 9KIZOUT
the ground control box.

MUUJ

are fully charged and )NKIQLUXGTUVKTUX
HGJ
8KVGOXUXXKVRGIKZNK
YNUXZOTZNKOTZKXTGR OTZKXTGRVRGZLUXS]OXK
properly connected. VRGZLUXSIUTZXURHU^]OXK NGXTKYY
NGXTKYYHKZ]KKTZNK
99GTJ9
IUTTKIZUXYGZZNKZUMMRK
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GTJULZNK6
IUTTKIZUXGZZNKIOXI[OZ
HUGXJ
MUUJ
HGXVXKYY[XK RK\KR[VVXUVUXZOUTGR
MG[MKGZZNKW[OIQ \GR\KOZKS).UXOZKS
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JOYIUTTKIZIU[VROTMUT -.58XKVGOXUX
ZNKVRGZLUXSL[TIZOUT RKYYZNGT XKVRGIKZNKI_ROTJKX
SGTOLURJGTJYZGXZZNK 69/ IU[TZKXHGRGTIK\GR\KY
KTMOTK'ZZNKMXU[TJ 58XKVGOXUXXKVRGIKZNK
IUTZXURYGIZO\GZKZNK I_ROTJKX58ZNKVRGZLUXS
L[TIZOUTKTGHRKNOMN L[TIZOUTSGTOLURJIU[RJ
863H[ZZUTGTJZNK NG\KGTOTZKXTGRLG[RZ
VRGZLUXSRK\KR[VH[ZZUT )UTY[RZZNK-KTOK
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*KVGXZSKTZ
69/
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XKYZXOIZOUTYQKKVOTMZNK TU I_ROTJKXIU[TZKXHGRGTIK
VRGZLUXSRK\KR[V \GR\KY58XKVGOXUX
L[TIZOUTLXUSUVKXGZOTM% XKVRGIKZNKI_ROTJKX58
IUTY[RZZNK-KTOK
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8KSU\KUXXKVGOXZNK
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 25
/Y62':,5832+<+2 :KYZZNKVRGZLUXSRK\KR _KY 8KVRGIKZNKZUMMRK

)UTZOT[KJLXUSZNK
:5--2+9=/:). 9,';2: _KY ZUMMRKY]OZINGZZNK Y]OZIN
VXK\OU[YVGMK
VXKYKTZUTZNKJOYVRG_ VRGZLUXSIUTZXURYLUX
YIXKKT% VXUVKXUVKXGZOUT9KK
8KVGOX9KIZOUT/YZNK
Y]OZINLG[RZ_%
HGJ
)NKIQLUXGTUVKTUX 8KVGOXUXXKVRGIK
HGJ
VRGZLUXSIUTZXURHU^]OXK NGXTKYY
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MUUJ
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YNUXZOTZNKVRGZLUXS IUTZXURHU^SKSHXGTK
HGJ
RK\KRSKSHXGTKJKIGRGZ JKIGR58IUTY[RZZNK
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HKZ]KKTVOTULZNK0 *KVGXZSKTZ
SKSHXGTKJKIGR
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MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 25
/Y(553;65<+825'* 'XKZNKXKSKINGTOIGR _KY 8KSU\KUXXKVGOXZNK

,';2:VXKYKTZUTZNK XKYZXOIZOUTYQKKVOTMZNK SKINGTOIGRXKYZXOIZOUTY
VXK\OU[YVGMK
JOYVRG_YIXKKT% HUUSJU]TL[TIZOUT
LXUSUVKXGZOTM%
TU
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ULZNK0IUTTKIZUX
29(25
MUUJ
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29(25
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)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
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)UTZOT[KJUT
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CHART 25
62':,5832+<+2;6
<'2<+,';2:VXKYKTZUT YNUXZOTZNK58)62; 58)62;]OXK
VXK\OU[YVGMK
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IUTTKIZUXGZZNK
VRGZLUXSIUTZXURHU^ZU
VOTULZNK*OT
IUTTKIZUXGZZNK
VRGZLUXSRK\KR\GR\KIUOR
OZKS).UXOZKS-.
MUUJ
YNUXZOTZNK(8<2<8+: (8<2<8+:]OXK
]OXKLXUSVOTULZNK0
IUTTKIZUXGZZNK
VOTULZNK*OT
IUTTKIZUXGZZNK
TU OZKS).UXOZKS-.
MUUJ
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UNSY
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IUOROZKS).UXOZKS *KVGXZSKTZ
-.
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 26
Platform Level =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKMXU[TJ
Down Function Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
TU
KTGHRKNOMN863H[ZZUT
GTJZNKVRGZLUXSRK\KR
TU
IUTZXURYSKSHXGTK
JKIGR58IUTY[RZZNK
V[RRKJU[ZZUZNK54
JU]TH[ZZUT/YZNKXKGT
G[JOHRKHKKV%
*KVGXZSKTZ
VUYOZOUTGIZO\GZKZNK
Be sure all other L[TIZOUTKTGHRKNOMN
_KY
normally. VRGZLUXSRK\KRJU]T
H[ZZUT ,XUSZNKVRGZLUXS HGJ 8KVRGIKZNKZUMMRK
'XKZNKXKGT_LG[RZ IUTZXURYZKYZZNK Y]OZIN

Be sure the platform out IUJKYVXKYKTZUTZNK VRGZLUXSRK\KRZUMMRK
of level LED and ICON JOYVRG_YIXKKT% Y]OZINLUXVXUVKX
are not flashing at the UVKXGZOUT9KK8KVGOX
9KIZOUT
ground control box.
Be sure the batteries are MUUJ
fully charged and

properly connected. YNUXZOTZNKOTZKXTGR
HGJ
OTZKXTGRVRGZLUXS]OXK
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTY
GTJULZNK6
HUGXJ
MUUJ
HGXVXKYY[XK RK\KRJU]TLRU]\GR\K
_KY MG[MKGZZNKW[OIQ OZKS).UXOZKS-.
ZNKVRGZLUXSL[TIZOUT RKYYZNGT I_ROTJKXIU[TZKXHGRGTIK
SGTOLURJGTJYZGXZZNK 69/ \GR\KY58XKVGOXUX
KTMOTK'ZZNKMXU[TJ XKVRGIKZNKI_ROTJKX58
IUTZXURYGIZO\GZKZNK ZNKVRGZLUXSL[TIZOUT
L[TIZOUTKTGHRKNOMN SGTOLURJIU[RJNG\KGT
863H[ZZUTGTJGIZO\GZK OTZKXTGRLG[RZ)UTY[RZ
ZNKVRGZLUXSRK\KRJU]T ZNK-KTOK/TJ[YZXOKY
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VXKYY[XK
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L[TIZOUTLXUSUVKXGZOTM% XKVRGIKZNKI_ROTJKX58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
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*KVGXZSKTZ
)UTZOT[KJUT 8KSU\KUXXKVGOXZNK
ZNKTK^ZVGMK SKINGTOIGRXKYZXOIZOUTY
CHART 26
/Y62':,5832+<+2 :KYZZNKVRGZLUXSRK\KR _KY 8KVRGIKZNKZUMMRK

)UTZOT[KJLXUSZNK
:5--2+9=/:).+9 _KY ZUMMRKY]OZINGZZNK Y]OZIN
VXK\OU[YVGMK
,';2:VXKYKTZUTZNK VRGZLUXSIUTZXURYLUX
JOYVRG_YIXKKT% VXUVKXUVKXGZOUT9KK
8KVGOX9KIZOUT
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TU
HGJ
NGXTKYYHKZ]KKTZNK
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MUUJ
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HUGXJGTJVOTULZNK
TU
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)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
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CHART 26
(553*5=4
)UTZOT[KJLXUSZNK
5<+825'*,';2: _KY XKYZXOIZOUTYQKKVOTMZNK SKINGTOIGRXKYZXOIZOUTY
VXK\OU[YVGMK
TU
)NKIQ29(25LUX 8KVRGIKGTJGJP[YZ
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MUUJ
MUUJ
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ULZNK0IUTTKIZUX
29(525
MUUJ
TU
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUX
29(525
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 26
/Y62':,5832+<+2 )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

)UTZOT[KJLXUSZNK
*5=4<'2<+,';2: _KY YNUXZOTZNK58(1 58(1)62*]OXK
VXK\OU[YVGMK
VXKYKTZUTZNKJOYVRG_ )62*]OXKLXUSVOT
YIXKKT% ULZNK0IUTTKIZUXGZ
ZNKVRGZLUXSIUTZXURHU^
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IUTTKIZUXGZZNK
OZKS).UXOZKS-.
MUUJ
]OXKLXUSVOTULZNK0
IUTTKIZUXUTZNK
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IUTTKIZUXGZZNK
OZKS).UXOZKS-.
TU
MUUJ
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IUOR *KVGXZSKTZ
OZKS).UXOZKS-.
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 27
Platform Level =OZNZNKQK_Y]OZIN :[XTZNK9KX\OIK(_VGYY
TU
8KZ[XTZNK9KX\OIK
Safety Fault Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
QK_Y]OZINZUZNKYKX\OIK
H_VGYYSUJK'IZO\GZK
(_VGYYQK_Y]OZINZUZNK
X[TSUJK9KK)NGXZ
+SKXMKTI_9ZUVH[ZZUTY ZNKL[TIZOUTKTGHRKNOMN
"SAFETY SWITCH V[RRKJU[ZZUZNK54

VUYOZOUTV[YNUTKULZNK
_KY 863H[ZZUTGTJZNK
VRGZLUXSRK\KRH[ZZUTOT
P22 FAULT" 2)*YIXKKTH[ZZUTY[TZOR ZNKIUXXKIZO\KJOXKIZOUT
62':,5832+<+2
"SAFETY SWITCH
)GTZNKVRGZLUXSHK
9+4958*+-8++9OY RK\KRKJHGIQZU]OZNOT
P22R FAULT"
VXKYKTZUTZNKJOYVRG_ JKMXKKYULRK\KR%
/YZNKGTMRKJOYVRG_KJ
JKMXKKYUXSUXK%
_KY
Be sure all other
functions operate 8KZ[XTZNK9KX\OIK 9ZGXZZXU[HRKYNUUZOTM
normally. (_VGYYQK_Y]OZINZUZNK
_KY
LXUSZNKHKMOTTOTMUL
9',+:?
X[TSUJK/Y ZNOYINGXZ
Be sure the batteries 9=/:).6,';2:

are fully charged and VXKYKTZUTZNKJOYVRG_
YIXKKT%
properly connected.
TU
9',+:?9=/:).68
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TU
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TU
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)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 27
9',+:?9=/:).6
,';2:VXKYKTZUTZNK YNUXZOTZNK8*66:9 8*66:9]OXK
VXK\OU[YVGMK
JOYVRG_YIXKKT% ]OXKLXUSVOTULZNK
0IUTTKIZUXGZZNK
VRGZLUXSIUTZXURYZUVOT
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YKTYUX
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YNUXZOTZNK8*(1 8*(1)6:9]OXK
)6:9]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKVRGZLUXSIUTZXURY
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IUTTKIZUXGZZNK
VRGZLUXSRK\KRYKTYUX
UQ
YNUXZOTZNK(86:98+: (86:98+:]OXK
]OXKLXUSVOTULZNK
0IUTTKIZUXGZZNK
TU GZZNKVRGZLUXSRK\KR
YKTYUX
UQ
9',+:?9=/:).68
/Y 8KVRGIKZNK1XKRG_
_KY
,';2:VXKYKTZUTZNK OTYOJKZNKVRGZLUXS
JOYVRG_YIXKKT% IUTZXURHU^58IUTY[RZ
ZNK-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
TU
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 27
9',+:?9=/:).68
/Y )NKIQLUXGTUVKTUX 8VGOXUXXKVRGIKZNK8*
,';2:VXKYKTZUTZNK YNUXZOTZNK8*668< 668<]OXK58
VXK\OU[YVGMK
JOYVRG_YIXKKT% ]OXKLXUSVOTULZNK0 HGJ XKVRGIKZNKSGOTIGHRK
IUTTKIZUXGZZNK 58IUTY[RZZNK-KTOK
VRGZLUXSIUTZXURYZUVOT /TJ[YZXOKY9KX\OIK
ULZNK0IUTTKIZUXGZ *KVGXZSKTZ
ZNKMXU[TJIUTZXURY
MUUJ
8KVRGIKZNK1XKRG_
TU
OTYOJKZNKMXU[TJIUTZXUR
HU^58IUTY[RZZNK
*KVGXZSKTZ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 28
Platform Rotate =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKMXU[TJ
Clockwise Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
TU
KTGHRKGTJZNKVRGZLUXS
XUZGZKIRUIQ]OYKH[ZZUT
TU
58IUTY[RZZNK-KTOK
Function +SKXMKTI_9ZUVH[ZZUTY
54
V[RRKJU[ZZUZNK
/YZNKXKGTG[JOHRK
HKKV%
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Inoperative VUYOZOUTGIZO\GZKZNK
L[TIZOUTKTGHRKH[ZZUT
_KY
GTJZNKVRGZLUXSXUZGZK
Be sure all other IRUIQ]OYKH[ZZUT
functions operate 'XKZNKXKGT_JOGMTUYZOI 'ZZNKVRGZLUXSIUTZXURY _KY 8KVRGIKZNKZUMMRK
normally. IUJKYVXKYKTZUTZNK ZKYZZNKVRGZLUXSXUZGZK Y]OZIN
JOYVRG_GZZNKMXU[TJ ZUMMRKY]OZINLUXVXUVKX
IUTZXURY% UVKXGZOUT9KK8KVGOX
Be sure the axles are 9KIZOUT
fully extended. /YZNKY]OZINLG[RZ_%
Be sure the batteries TU

properly connected. )NKIQLUXGTUVKTUX
HGJ
8KVGOXUXXKVRGIKZNK
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTYGTJ
ULZNK6IUTTKIZUX
GZZNKIOXI[OZHUGXJ
MUUJ
HGXVXKYY[XK VRGZLUXSXUZGZK\GR\K
MG[MKGZZNKW[OIQ OZKS)*UXOZKS-*
_KY JOYIUTTKIZIU[VROTMUT 58XKVGOXUXXKVRGIKZNK
ZNKVRGZLUXSL[TIZOUT RKYYZNGT XUZGZUXIU[TZKXHGRGTIK
SGTOLURJGTJYZGXZZNK VYO \GR\KY58XKVGOXUX
KTMOTK'ZZNKMXU[TJ XKVRGIKZNKVRGZLUXS
IUTZXURYGIZO\GZKZNK XUZGZUX58ZNKVRGZLUXS
L[TIZOUTKTGHRKNOMN L[TIZOUTSGTOLURJIU[RJ
863H[ZZUTGTJZNK NG\KGTOTZKXTGRLG[RZ
VRGZLUXSXUZGZK )UTY[RZZNK-KTOK
IRUIQ]OYKH[ZZUTGTJ /TJ[YZXOKY9KX\OIK
INKIQZNKVXKYY[XK *KVGXZSKTZ
69/
UXSUXK
XKYZXOIZOUTYQKKVOTMZNK XUZGZUXIU[TZKXHGRGTIK
TU
VRGZLUXSXUZGZK \GR\KY58XKVGOXUX
IRUIQ]OYKL[TIZOUTLXUS XKVRGIKZNKXUZGZUX58
UVKXGZOTM% IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
_KY
)UTZOT[KJUT
ZNKTK^ZVGMK 8KSU\KUXXKVGOXZNK
CHART 28
/Y62':,58385:':+ :KYZZNKVRGZLUXSXUZGZK _KY 8KVRGIKZNKZUMMRK

)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
8KVGOX9KIZOUT
/YZNKY]OZINLG[RZ_%
TU
HGJ
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTYGTJ
ULZNK6IUTTKIZUX
GZZNKIOXI[OZHUGXJ
MUUJ
HGJ
XUZGZKIRUIQ]OYK JKIGR58IUTY[RZZNK
SKSHXGTKJKIGRGZZNK -KTOK/TJ[YZXOKY9KX\OIK
MXU[TJIUTZXURYHKZ]KKT *KVGXZSKTZ
VOTULZNK0
SKSHXGTKJKIGR
TU
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
HGJ
XUZGZKIU[TZKXIRUIQ]OYK JKIGR58IUTY[RZZNK
SKSHXGTKJKIGRGZZNK -KTOK/TJ[YZXOKY9KX\OIK
VOTULZNK0
SKSHXGTKJKIGR
HUGXJGTJVOTULZNK
0SKSHXGTK
HUGXJ
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 28
/Y62':,58385:':+ )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

<'2<+,';2:VXKYKTZUT YNUXZOTZNK-8(1 -8(1)688]OXK
VXK\OU[YVGMK
ZNKJOYVRG_YIXKKT% )688]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
ZNKVRGZLUXSIUTZXURYHU^
ZUVOTULZNK*OT
IUTTKIZUXGZZNK
VRGZLUXSXUZGZK\GR\KIUOR
OZKS)*UXOZKS-*
MUUJ
]OXKLXUSVOTULZNK0
IUTZXURY:)54ZUVOT
ULZNK*OTIUTTKIZUXGZ
ZNKVRGZLUXSXUZGZK\GR\K
IUOROZKS)*UXOZKS
-*
TU
MUUJ
ZU
UNSY
IUOROZKS)*UXOZKS *KVGXZSKTZ
-*
UXOTLOTOZK
UNSY
8KVRGIKZNK\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 29
Platform Rotate =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKMXU[TJ
Counter Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
TU
KTGHRKH[ZZUTGTJZNK
VRGZLUXSXUZGZKIU[TZKX
TU
58IUTY[RZZNK-KTOK
Clockwise +SKXMKTI_9ZUVH[ZZUTY
54
V[RRKJU[ZZUZNK
IRUIQ]OYKH[ZZUT/Y
ZNKXKGTG[JOHRKHKKV%
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Function VUYOZOUTGIZO\GZKZNK
L[TIZOUTKTGHRKNOMN
Inoperative
_KY
863H[ZZUTGTJZNK
VRGZLUXSXUZGZKIU[TZKX
Be sure all other

IRUIQ]OYKH[ZZUT 'ZZNKVRGZLUXSIUTZXURY _KY 8KVRGIKZNKZUMMRK
'XKZNKXKGT_JOGMTUYZOI ZKYZZNKVRGZLUXSXUZGZK Y]OZIN
functions operate IUJKYVXKYKTZUTZNK ZUMMRKY]OZINLUXVXUVKX
normally. JOYVRG_GZZNKMXU[TJ UVKXGZOUT9KK8KVGOX
IUTZXURY% 9KIZOUT
Be sure the axles are /YZNKY]OZINLG[RZ_%
fully extended.
TU

are fully charged and )NKIQLUXGTUVKTUX
YNUXZOTZNKOTZKXTGR
HGJ
8KVGOXUXXKVRGIKZNK
OTZKXTGRVRGZLUXS]OXK
properly connected. VRGZLUXSIUTZXURHU^]OXK NGXTKYY
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTYGTJ
ULZNK6IUTTKIZUX
GZZNKIOXI[OZHUGXJ
MUUJ
HGXVXKYY[XK VRGZLUXSXUZGZK\GR\K
MG[MKGZZNKW[OIQ OZKS)*UXOZKS-*
_KY
ZNKVRGZLUXSL[TIZOUT RKYYZNGT XUZGZUXIU[TZKXHGRGTIK
SGTOLURJGTJYZGXZZNK VYO \GR\KY58XKVGOXUX
KTMOTK'ZZNKMXU[TJ XKVRGIKZNKXUZGZUX58
IUTZXURYGIZO\GZKZNK ZNKVRGZLUXSL[TIZOUT
L[TIZOUTKTGHRKNOMN SGTOLURJIU[RJNG\KGT
863H[ZZUTGTJZNK OTZKXTGRLG[RZ)UTY[RZ
VRGZLUXSXUZGZKIU[TZKX ZNK-KTOK/TJ[YZXOKY
IRUIQ]OYKH[ZZUTGTJ 9KX\OIK*KVGXZSKTZ
INKIQZNKVXKYY[XK
69/
UXSUXK
XKYZXOIZOUTYQKKVOTMZNK XUZGZUXIU[TZKXHGRGTIK
TU
VRGZLUXSXUZGZKIU[TZKX \GR\KY58XKVGOXUX
IRUIQ]OYKL[TIZOUTLXUS XKVRGIKZNKXUZGZUX58
UVKXGZOTM% IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
_KY
CHART 29
/Y62':,58385:':+ :KYZZNKVRGZLUXSXUZGZK _KY 8KVRGIKZNKZUMMRK

)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
8KVGOX9KIZOUT
/YZNKY]OZINLG[RZ_%
TU
HGJ
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTYGTJ
ULZNK6IUTTKIZUX
GZZNKIOXI[OZHUGXJ
MUUJ
HGJ
XUZGZKIU[TZKXIRUIQ]OYK JKIGR58IUTY[RZZNK
SKSHXGTKH[ZZUTGZZNK -KTOK/TJ[YZXOKY9KX\OIK
VOTULZNK0
SKSHXGTKJKIJGR
TU
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
HGJ
XUZGZKIU[TZKXIRUIQ]OYK 58IUTY[RZZNK-KTOK
SKSHXGTKH[ZZUTGZZNK /TJ[YZXOKY9KX\OIK
VOTULZNK0
SKSHXGTKJKIGR
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 29
/Y62':,58385:':+ )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

<'2<+,';2:VXKYKTZUT YNUXZOTZNK-8)682 -8)682]OXK
VXK\OU[YVGMK
ZNKJOYVRG_YIXKKT% ]OXKLXUSVOTULZNK0
IUTTKIZUXGZZNK
VRGZLUXSIUTZXURYHU^ZU
VOTULZNK*OT
IUTTKIZUXGZZNK
VRGZLUXSXUZGZK\GR\KIUOR
OZKS)*UXOZKS-*
MUUJ
]OXKLXUSVOTULZNK0
IUTTKIZUXGZZNK
ULZNK*OTIUTTKIZUXGZ
ZNKVRGZLUXSXUZGZK\GR\K
IUOROZKS)*UX
TU OZKS-*
MUUJ
ZU
UNSY
IUOROZKS)*UXOZKS *KVGXZSKTZ
-*
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 30
Jib Up =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKMXU[TJ
IUTZXURYGTJHUZN
TU KTGHRKGTJZNKPOHHUUS
[VH[ZZUT/YZNKXKGT
TU IUTZXURSKSHXGTKJKIGR
58IUTY[RZZNK-KTOK
54
V[RRKJU[ZZUZNK
G[JOHRKHKKV% /TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
VUYOZOUTGIZO\GZKZNK
Be sure all other functions L[TIZOUTKTGHRKNOMN _KY
operate normally. 863H[ZZUTGTJZNKPOH
[VH[ZZUT
Be sure the axles are fully 'XKZNKXKGT_JOGMTUYZOI :KYZZNKPOHHUUS _KY 8KVRGIKZNKZUMMRK
IUJKYVXKYKTZUTZNK [VJU]TZUMMRKY]OZINGZ Y]OZIN

extended. JOYVRG_GZZNKMXU[TJ ZNKVRGZLUXSIUTZXURYLUX
IUTZXURY% VXUVKXUVKXGZOUT9KK
Be sure the batteries are 8KVGOX9KIZOUT
fully charged and properly /YZNKY]OZINLG[RZ_%
connected.
TU
HGJ
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTY
GTJULZNK6
HUGXJ
MUUJ
/TYZGRRGZU69/ 8KVGOXUXXKVRGIKZNKPOH
HGXVXKYY[XK [V\GR\KOZKS)258
_KY MG[MKGZZNKW[OIQ XKVGOXUXXKVRGIKZNK
JOYIUTTKIZIU[VROTMUT I_ROTJKXIU[TZKXHGRGTIK
RKYYZNGT
ZNKVRGZLUXSL[TIZOUT \GR\KY58XKVGOXUX
VYO
SGTOLURJGTJYZGXZZNK XKVRGIKZNKI_ROTJKX58
KTMOTK'ZZNKMXU[TJ ZNKVRGZLUXSL[TIZOUT
IUTZXURYVXKYYGTJNURJ SGTOLURJIU[RJNG\KGT
ZNKL[TIZOUTKTGHRK OTZKXTGRLG[RZ)UTY[RZ
H[ZZUTGTJGIZO\GZKZNK ZNK-KTOK/TJ[YZXOKY
POHHUUS[VH[ZZUTGTJ 9KX\OIK*KVGXZSKTZ
INKIQZNKVXKYY[XK
69/
UXSUXK
POHHUUS[VL[TIZOUT \GR\KY58XKVGOXUX
LXUSUVKXGZOTM% XKVRGIKZNKI_ROTJKX58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
_KY
*KVGXZSKTZ
8KSU\KUXXKVGOXZNK
)UTZOT[KJUT SKINGTOIGRXKYZXOIZOUTY
ZNKTK^ZVGMK
CHART 30
0/(;6*=4:5--2+
/Y :KYZZNKPOHHUUS _KY 8KVRGIKZNKZUMMRK
)UTZOT[KJLXUSZNK
9=/:).+9,';2: _KY [VJU]TZUMMRKY]OZINGZ Y]OZIN
VXK\OU[YVGMK
VXKYKTZUTZNKJOYVRG_ ZNKVRGZLUXSIUTZXURYLUX
8KVGOX9KIZOUT
/YZNKY]OZINLG[RZ_%
TU
HGJ
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTY
GTJULZNK6
HUGXJ
MUUJ
YNUXZOTZNKPOHHUUS[V IUTZXURHU^SKSHXGTK
HGJ
SKSHXGTKH[ZZUTGZZNK JKIGR58IUTY[RZZNK
MXU[TJIUTZXURYHKZ]KKT -KTOK/TJ[YZXOKY9KX\OIK
SKSHXGTKJKIGR
TU
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
YNUXZOTZNKPOHHUUS IUTZXURHU^SKSHXGTK
HGJ
JU]TSKSHXGTKH[ZZUT JKIGR58IUTY[RZZNK
SKSHXGTKJKIGR
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 30
/Y 0/(<'2<+,';2: )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

VXKYKTZUTZNKJOYVRG_ YNUXZOTZNK-8)0; -8)0;]OXK
VXK\OU[YVGMK
YIXKKT% ]OXKLXUSVOTULZNK0
IUTTKIZUXGZZNK
VRGZLUXSIUTZXURYHU^ZU
VOTULZNK*OT
IUTTKIZUXGZZNKPOH
HUUS[V\GR\KIUOROZKS
)2
MUUJ
]OXKLXUSVOTULZNK0
IUTZXURYZUVOTULZNK
*OTIUTTKIZUXGZZNKPOH
HUUS[V\GR\KIUOROZKS
)2
TU
MUUJ
ZU
UNSY
POHHUUS[V\GR\KIUOR /TJ[YZXOKY9KX\OIK
OZKS)2 *KVGXZSKTZ
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 31
Jib Down =OZNZNKQK_Y]OZIN 'IZO\GZKZNKL[TIZOUT 8KVRGIKZNKMXU[TJ
IUTZXURYGTJHUZN
TU
KTGHRKGTJZNKPOHHUUS
JU]TSKSHXGTKH[ZZUT
TU
58IUTY[RZZNK-KTOK
54
V[RRKJU[ZZUZNK
/YZNKXKGTG[JOHRK
HKKV%
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
VUYOZOUTGIZO\GZKZNK
Be sure all other functions L[TIZOUTKTGHRKNOMN
_KY
operate normally. 863H[ZZUTGTJZNKPOH
HUUSJU]TH[ZZUT
Be sure the axles are fully 'XKZNKXKGT_JOGMTUYZOI :KYZZNKPOHHUUS _KY 8KVRGIKZNKZUMMRK
IUJKYVXKYKTZUTZNK [VJU]TZUMMRKY]OZINGZ Y]OZIN

extended. JOYVRG_GZZNKMXU[TJ ZNKVRGZLUXSIUTZXURYLUX
IUTZXURY% VXUVKXUVKXGZOUT9KK
Be sure the batteries are 8KVGOX9KIZOUT
fully charged and properly /YZNKY]OZINLG[RZ_%
connected.
TU
HGJ
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTY
GTJULZNK6
HUGXJ
MUUJ
/TYZGRRGZU69/ 8KVGOXUXXKVRGIKZNKPOH
HGXVXKYY[XK HUUSJU]T\GR\KOZKS
_KY MG[MKGZZNKW[OIQ )258XKVGOXUXXKVRGIK
JOYIUTTKIZIU[VROTMUT ZNKI_ROTJKX
ZNKVRGZLUXSL[TIZOUT RKYYZNGT IU[TZKXHGRGTIK\GR\KY
SGTOLURJGTJYZGXZZNK VYO 58XKVGOXUXXKVRGIKZNK
KTMOTK'ZZNKMXU[TJ I_ROTJKX58ZNKVRGZLUXS
IUTZXURYGIZO\GZKZNK L[TIZOUTSGTOLURJIU[RJ
L[TIZOUTKTGHRKNOMN NG\KGTOTZKXTGRLG[RZ
863H[ZZUTGTJZNKPOH )UTY[RZZNK-KTOK
HUUSJU]TSKSHXGTK /TJ[YZXOKY9KX\OIK
H[ZZUTGTJINKIQZNK *KVGXZSKTZ
VXKYY[XK
69/UX
SUXK
POHHUUSJU]TL[TIZOUT \GR\KY58XKVGOXUX
LXUSUVKXGZOTM% XKVRGIKZNKI_ROTJKX58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
_KY
*KVGXZSKTZ
CHART 31
0/(;6*5=4:5--2+
/Y :KYZZNKPOHHUUS[V _KY 8KVRGIKZNKZUMMRK
)UTZOT[KJLXUSZNK
9=/:).+9,';2: _KY JU]TZUMMRKY]OZINGZ Y]OZIN
VXK\OU[YVGMK
VXKYKTZUTZNKJOYVRG_ ZNKVRGZLUXSIUTZXURYLUX
8KVGOX9KIZOUT
/YZNKY]OZINLG[RZ_%
TU
HGJ
NGXTKYYHKZ]KKTZNK
99GTJ9
Y]OZINGTJVOTY
GTJULZNK6
HUGXJ
MUUJ
YNUXZOTZNKPOHHUUS[V IUTZXURHU^SKSHXGTK
HGJ
SKSHXGTKH[ZZUTGZZNK JKIGR58IUTY[RZZNK
MXU[TJIUTZXURYHKZ]KKT -KTOK/TJ[YZXOKY9KX\OIK
SKSHXGTKJKIGR
TU
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
YNUXZOTZNKPOHHUUS IUTZXURHU^SKSHXGTK
HGJ
JU]TSKSHXGTKH[ZZUT JKIGR58IUTY[RZZNK
SKSHXGTKJKIGR
HUGXJGTJVOTULZNK
0SKSHXGTKJKIGR
HUGXJ
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 31
/Y 0/(<'2<+,';2: )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

VXKYKTZUTZNKJOYVRG_ YNUXZOTZNK-8(1 -8(1)0*]OXK
VXK\OU[YVGMK
YIXKKT% )0*]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
ZNKVRGZLUXSIUTZXURHU^
ZUVOTULZNK*OT
IUTTKIZUXGZZNKPOH
HUUSJU]T\GR\KIUOR
OZKS)2
MUUJ
]OXKLXUSVOTULZNK0
IUTTKIZUXGZZNK
VOTULZNK*OT
IUTTKIZUXGZZNKPOH
HUUSJU]T\GR\KIUOR
TU
OZKS)2
MUUJ
ZU
UNSY
POHHUUSJU]T\GR\KIUOR /TJ[YZXOKY9KX\OIK
OZKS)2 *KVGXZSKTZ
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
/LGT_UZNKXIUJKYGXK
UTZNKJOYVRG_YIXKKT
XKLKXZUZNKLG[RZIUJK
INGXZLUXSUXK
OTLUXSGZOUT
Chart 32
Auxiliariy =OZNZNKQK_Y]OZIN _KY )UTZOT[KJZU
Functions Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
VGMK
V[RRKJU[ZZUZNK 54
VUYOZOUTGIZO\GZK
Be sure all other L[TIZOUTKTGHRKH[ZZUT
functions operate GTJGHUUSL[TIZOUT
normally.
H[ZZUTKMHUUS
K^ZKTJXKZXGIZUXHUUS
[VJU]T*UKYZNK
Be sure the batteries SUZUXUVKXGZK%

properly connected.
TU
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CHART 32
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Chart 33
Axle Extend =OZNZNKQK_Y]OZIN 6XKYYJU]TZNKLUUZ _KY )UTZOT[KJZU
Function Z[XTKJZUVRGZLUXS
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CHART 33
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CHART 33
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Chart 34
Axle Retract =OZNZNKQK_Y]OZIN 6XKYYJU]TZNKLUUZ
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normally. IUTZXURY%
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are fully charged and 8KSU\KUXXKVGOXZNK
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CHART 34
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CHART 34
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)NKIQLUXGTUVKTUX 8KVRGIKZNKKRKIZXOI
YNUXZOTZNK(8]OXK HGJ Y]O\KR58IUTY[RZZNK
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VOTJK[ZYINIUTTKIZUX *KVGXZSKTZ
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IUTTKIZUXUTZNKJXO\K
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MUUJ
)UTZOT[KJUT
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CHART 34

)UTZOT[KJLXUSZNK
YNUXZOTZNK-8 -8)'>8:]OXK
VXK\OU[YVGMK
)'>8:]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
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ULZNKVOTJK[ZYIN
IUTTKIZUXGZZNKKRKIZXOI
Y]O\KR
MUUJ
9(9:5]OXKLXUSVOT
ULZNKJK[ZYIN
IUTTKIZUXZU29(89ZU
VOTULZNKVOT
JK[ZYINIUTTKIZUXGZZNK
MXU[TJIUTZXURYZUZNK
[VVKX0NGXTKYYZUZNK
RU]KX0NGXTKYY
MUUJ
9(9:5]OXKLXUSVOT
ULZNKVOTJK[ZYIN
IUTTKIZUXUTZNK
Z[XTZGHRKZNGZIUTTKIZY
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ZUVOTPULZNK0
IUTZXURY
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 35
Blue End =OZNZNKQK_Y]OZIN 9ZUVZNKKTMOTK/TYZGRR )NKIQLUXSKINGTOIGR
Blue Side Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
GZU69/
HGXVXKYY[XKMG[MKGZ
YZKKXL[TIZOUTLXUS
Steering +SKXMKTI_YZUVH[ZZUTY
V[RRKJU[ZZUZNK 54
ZNKW[OIQJOYIUTTKIZ
IU[VRKXUTZNKYZKKXG^RK
UVKXGZOTM58XKVGOXUX
XKVRGIKZNKYZKKX
Function
TU TU
VUYOZOUTYZGXZZNKKTMOTK SGTOLURJ9ZGXZZNK I_ROTJKX58XKVGOXUX
GTJV[YNZNKYZKKX KTMOTKGTJGIZO\GZKZNK XKVRGIKZNKVORUZ
Inoperative SUJKYKRKIZH[ZZUTLUX
YW[GXKKTJHR[KKTJ
YZKKXL[TIZOUTOTHUZN
JOXKIZOUTY
UVKXGZKJINKIQ\GR\KY
OZKSY+1GTJ+**
Be sure all other

YZKKX6XKYYJU]TZNK /YZNKVXKYY[XKRKYYZNGT 58IUTY[RZZNK-KTOK
LUUZY]OZINGTJGIZO\GZK VYOHGX% /TJ[YZXOKY9KX\OIK
functions operate ZNKYZKKXL[TIZOUTOTHUZN *KVGXZSKTZ
normally. JOXKIZOUTY
_KY
Be sure the batteries IUJKYVXKYKTZUTZNK
JOYVRG_GZZNKMXU[TJ
are fully charged and IUTZXURY%
9ZUVZNKKTMOTK
_KY 8KVRGIKZNKLG[RZ_YZKKX
+ÎNGTMKZNKYW[GXK
properly connected. KTJ_KRRU]YOJKYZKKX
\GR\K
\GR\KOZKS+']OZNZNK
YW[GXKKTJHR[KYOJK
YZKKX\GR\KOZKS+(
9ZGXZZNKKTMOTKGTJ
GIZO\GZKZNKYZKKX
L[TIZOUT*UKYZNK
YW[GXKKTJHR[KYOJK
YZKKXOTML[TIZOUTOTHUZN
JOXKIZOUTY%
TU
_KY
8KVGOXUXXKVRGIKZNK
YZKKXI_ROTJKX58XKVGOX
UXXKVRGIKZNKVORUZ
UVKXGZKJINKIQ\GR\KY
OZKSY+1GTJ+**
58ZNKXKSG_HKGLG[RZ
OTZNKSGTOLURJ58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
/Y9:++8/4- 05?9:/)1 8KIGROHXGZKZNKYZKKX
45:)'2/(8':+* _KY PU_YZOIQYKK8KVGOX
VXKYKTZUTZNKJOYVRG_ 9KIZOUT58XKVRGIKZNK
YIXKKT% YZKKXPU_YZOIQ
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 35
/Y9:++8/4-05?9:/)1 )NKIQLUXJGSGMKJ
)UTZOT[KJLXUSZNK
9.58:+*:5<52:9UX ]OXKYOTOTZKXTGRVRGZLUXS
VXK\OU[YVGMK
9:++8/4-05?9:/)1 IUTZXURY]OXKNGXTKYY
9.58:+*:5<52:9UX HKZ]KKTYZKKXPU_YZOIQ
_KY
9:++8/4-05?9:/)1 IUTTKIZUX6GTJGTJ
<'2;+:55./-.UX IOXI[OZHUGXJIUTTKIZUX
9:++8/4-05?9:/)1 658IUTY[RZZNK
<'2;+:5525=VXKYKTZ -KTOK/TJ[YZXOKY9KX\OIK
UTZNKJOYVRG_YIXKKT% *KVGXZSKTZ
TU
(2;++4*(2;+9/*+
/Y )NKIQYW[GXKKTJHR[K 8KVRGIKZNKYZKKX
HGJ
9:++89+49589.58:+* KTJHR[KYOJKYZKKX YKTYUX9KK8KVGOX
:5<52:9UX(2;+ _KY YKTYUXLUXVXUVKX 9KIZOUT
+4*(2;+9/*+9:++8 OTYZGRRGZOUTGTJ
9+4958 9.58:+*:5 UVKXGZOUTYKK8KVGOX
<52:9UX(2;++4* 9KIZOUT
(2;+9/*+9:++89+4958
<'2;+:55./-.UX MUUJ
(2;++4* (2;+9/*+
9:++89+4958<'2;+
:5525=VXKYKTZUTZNK
YNUXZOTZNK58 58)2,9]OXK
JOYVRG_YIXKKT%
)2,9]OXKLXUSVOT
(ULZNKYW[GXKKTJHR[K
YOJKYZKKXYKTYUX
IUTTKIZUXZUVOTUL
ZNK0IUTTKIZUXUTZNK
*)54
MUUJ
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TU ZNK0IUTTKIZUXUTZNK
*)54
MUUJ
YNUXZOTZNK(168: (168:]OXK
]OXKLXUSVOT)ULZNK
YW[GXKKTJHR[KYOJK
YZKKXYKTYUXIUTTKIZUX
ZUVOTULZNK0
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INGYYOYIUTZXURRKX
*)54
MUUJ
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)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
CHART 35
/Y(2;++4* (2;+9/*+ /LGT_UZNKXIUJKYGXK

)UTZOT[KJLXUSZNK
9:++8<'2<+,';2: VXKYKTZUTZNKJOYVRG_
VXK\OU[YVGMK TU
VXKYKTZUTZNKJOYVRG_ YIXKKTXKLKXZUZNKLG[RZ
YIXKKT% IUJKINGXZLUXSUXK
OTLUXSGZOUT
_KY
YNUXZOTZNK(2<2,9 (2<2,9]OXK
]OXKLXUSVOTULZNK
INGYYOYIUTZXURRKX
*)54ZUVOTULZNK
*OTIUTTKIZUXGZZNK
YW[GXKKTJHR[KYOJK
YZKKX\GR\KIUOR
OZKS+(UXOZKS.7
MUUJ
YNUXZOTZNK(2(1 (2(1<2,9]OXK
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ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
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ULZNK*OTIUTTKIZUXGZ
ZNKYW[GXKKTJHR[K
YOJKYZKKX\GR\KIUOR
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MUUJ
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ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
IUTZXURRKX*)54ZUVOT
ULZNK*OTIUTTKIZUXGZ
ZNKYW[GXKKTJHR[K
YOJKYZKKX\GR\KIUOR
OZKS+(
MUUJ
)NKIQZNKXKYOYZGTIKUL ZU )UTY[RZZNK-KTOK
ZNKYW[GXKKTJHR[K UNSY /TJ[YZXOKY9KX\OIK
YOJKYZKKX\GR\KIUOR *KVGXZSKTZ
OZKS+(
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
Chart 36
Blue End =OZNZNKQK_Y]OZIN 9ZUVZNKKTMOTK/TYZGRR )NKIQLUXSKINGTOIGR
Yellow Side Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
GZU69/
HGXVXKYY[XKMG[MKGZ
YZKKXL[TIZOUTLXUS
V[RRKJU[ZZUZNK 54 TU
ZNKW[OIQJOYIUTTKIZ
IU[VRKXUTZNKYZKKXG^RK
TU SU\OTM58XKVGOXUX
XKVRGIKZNKYZKKX
Function VUYOZOUTYZGXZZNKKTMOTK
GTJV[YNZNKYZKKX
SGTOLURJ9ZGXZZNK
KTMOTKGTJGIZO\GZKZNK
I_ROTJKX58XKVGOXUX
XKVRGIKZNKVORUZ
YW[GXKKTJHR[KKTJ
YZKKXL[TIZOUTYOTHUZN
JOXKIZOUTY
UVKXGZKJINKIQ\GR\KY
OZKSY+3GTJ+((58
Be sure all other

YZKKX6XKYYJU]TZNK /YZNKVXKYY[XKRKYYZNGT IUTY[RZZNK-KTOK
LUUZY]OZINGTJGIZO\GZK VYOHGX% /TJ[YZXOKY9KX\OIK
functions operate ZNKYZKKXL[TIZOUTOTHUZN *KVGXZSKTZ
_KY
JOYVRG_GZZNKMXU[TJ
+ÎNGTMKZNKYW[GXK _KY 8KVRGIKZNKLG[RZ_YZKKX
KTJ_KRRU]YOJKYZKKX \GR\K
properly connected. \GR\KOZKS+']OZNZNK
YW[GXKKTJHR[KYOJK
YZKKX\GR\KOZKS+(
9ZGXZZNKKTMOTKGTJ
GIZO\GZKZNKYZKKX
L[TIZOUT*UKYZNK
IOXIRKKTJ_KRRU]YOJK
YZKKXOTML[TIZOUTOTHUZN
JOXKIZOUTY%
TU
_KY
8KVGOXUXXKVRGIKZNK
UXXKVRGIKZNKVORUZ
UVKXGZKJINKIQ\GR\KY
OZKSY+3GTJ+((
58IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 36
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
_KY
9:++8/4-05?9:/)1 658IUTY[RZZNK
TU
/Y(2;++4*?+225= )NKIQYW[GXKKTJHR[K 8KVRGIKZNKYZKKX

HGJ
9/*+9:++8 9+4958 KTJ_KRRU]YOJKYZKKX YKTYUX9KK8KVGOX
9.58:+*:5<52:9UX _KY YKTYUXLUXVXUVKX 9KIZOUT
(2;++4* ?+225=9/*+ OTYZGRRGZOUTGTJ
9:++89+49589.58:+* UVKXGZOUTYKK8KVGOX
:5<52:9UX(2;+ 9KIZOUT
+4*?+225=9/*+9:++8
9+4958 <'2;+ :55./-. MUUJ
UX(2;+ +4* ?+225=
9/*+9:++8 9+4958
<'2;+:5525=VXKYKTZ
YNUXZOTZNK58 58)8,9]OXK
UTZNKJOYVRG_YIXKKT%
)8,9]OXKLXUSVOT
(ULZNKYW[GXKKTJ
_KRRU]YOJKYZKKXYKTYUX
IUTTKIZUXZUVOTUL
ZNK0IUTTKIZUXUTZNK
*)54
MUUJ
6'4-]OXKLXUSVOT
'ULZNKYW[GXKKTJ
IUTTKIZUXZUVOTUL
*)54
MUUJ
]OXKLXUSVOT)ULZNK
YW[GXKKTJ_KRRU]YOJK
ZUVOTULZNK0
IUTTKIZUXUTZNKJXO\K
INGYYOYIUTZXURRKX
*)54
MUUJ
)UTZOT[KJUT
ZNKTK^ZVGMK
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
CHART 36
/Y(2;++4* ?+225= /LGT_UZNKXIUJKYGXK

)UTZOT[KJLXUSZNK
9/*+9:++8<'2<+ VXKYKTZUTZNKJOYVRG_
VXK\OU[YVGMK
,';2:VXKYKTZUTZNK TU
JOYVRG_YIXKKT% IUJKINGXZLUXSUXK
OTLUXSGZOUT
_KY
YNUXZOTZNK(2<8,9 (2<8,9]OXK
]OXKLXUSVOTULZNK
ULZNK*OTIUTTKIZUXGZ
ZNKYW[GXKKTJ_KRRU]
YOJKYZKKX\GR\KIUOR
OZKS+'
MUUJ
YNUXZOTZNK(2(1 (2(1<8,9]OXK
<8,9]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
*OTIUTTKIZUXGZZNK
YW[GXKKTJ_KRRU]YOJK
YZKKX\GR\KIUOR
OZKS+'
MUUJ
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
*OTIUTTKIZUXGZZNK
YW[GXKKTJ_KRRU]YOJK
YZKKX\GR\KIUOR
OZKS+'
MUUJ
ZNKYW[GXKKTJ_KRRU] UNSY /TJ[YZXOKY9KX\OIK
OZKS+'
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
Chart 37
Yellow End =OZNZNKQK_Y]OZIN 9ZUVZNKKTMOTK/TYZGRR )NKIQLUXSKINGTOIGR
Blue Side Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
GZU69/
HGXVXKYY[XKMG[MKGZ
YZKKXL[TIZOUTLXUS
V[RRKJU[ZZUZNK 54
ZNKW[OIQJOYIUTTKIZ
IU[VROTMUTZNK
SU\OTM58XKVGOXUX
XKVRGIKZNKYZKKX
Function
TU TU
VUYOZOUTYZGXZZNKKTMOTK YZKKXG^RKSGTOLURJ I_ROTJKX58XKVGOXUX
GTJV[YNZNKYZKKX 9ZGXZZNKKTMOTKGTJ XKVRGIKZNKVORUZ
IOXIRKKTJ_KRRU]KTJ
GIZO\GZKZNKYZKKX
L[TIZOUTYOTHUZN
UVKXGZKJINKIQ\GR\KY
OZKS+-GTJ+..58
Be sure all other

YZKKX6XKYYJU]TZNK JOXKIZOUTY IUTY[RZZNK-KTOK
LUUZY]OZINGTJGIZO\GZK /YZNKVXKYY[XKRKYYZNGT /TJ[YZXOKY9KX\OIK
functions operate ZNKYZKKXL[TIZOUTOTHUZN VYOHGX% *KVGXZSKTZ
_KY
JOYVRG_GZZNKMXU[TJ
+ÎNGTMKZNKIOXIRKKTJ _KY 8KVRGIKZNKLG[RZ_YZKKX
properly connected. _KRRU]YOJKYZKKX\GR\K \GR\K
OZKS+)]OZNZNKIOXIRK
KTJHR[KYOJKYZKKX
\GR\KOZKS+*9ZGXZ
ZNKKTMOTKGTJGIZO\GZK
ZNKYZKKXL[TIZOUT*UKY
ZNKIOXIRKKTJ_KRRU]
YOJKYZKKXOTML[TIZOUTOT
HUZNJOXKIZOUTY%
TU
_KY
8KVGOXUXXKVRGIKZNK
UXXKVRGIKZNKVORUZ
UVKXGZKJINKIQ\GR\KY
OZKSY+-GTJ+..
58ZNKXKSG_HKGLG[RZ
OTZNKSGTOLURJ58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 37
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
_KY
9:++8/4-05?9:/)1 658IUTY[RZZNK
TU
/Y?+225=+4*(2;+ )NKIQIOXIRKKTJ_KRRU] 8KVRGIKZNKYZKKX

HGJ
9/*+9:++8 9+4958 _KY KTJHR[KYOJKYZKKX YKTYUX9KK8KVGOX
9.58:+*:5<52:9UX YKTYUXLUXVXUVKX 9KIZOUT
?+225=+4* (2;+ 9/*+ OTYZGRRGZOUTGTJ
9:++89+49589.58:+* UVKXGZOUTYKK8KVGOX
:5<52:9UX?+225= 9KIZOUT
+4*(2;+9/*+9:++8
9+4958 <'2;+ :55./-. MUUJ
UX?+225=+4*(2;+
9/*+9:++8 9+4958
<'2;+:5525=VXKYKTZ
YNUXZOTZNK58 58)289]OXK
UTZNKJOYVRG_YIXKKT%
)289]OXKLXUSVOT
(ULZNKIOXIRKKTJHR[K
YOJKYZKKXYKTYUX
IUTTKIZUXZUVOTUL
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*)54
MUUJ
6'4-]OXKLXUSVOT
'ULZNKIOXIRKKTJHR[K
YOJKYZKKXYKTYUX
IUTTKIZUXZUVOTUL
*)54
MUUJ
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IOXIRKKTJHR[KYOJK
ZUVOTULZNK0
IUTTKIZUXUTZNKJXO\K
INGYYOYIUTZXURRKX
*)54
MUUJ
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ZNKTK^ZVGMK
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
CHART 37
/Y?+225=+4*(2;+ /LGT_UZNKXIUJKYGXK
)UTZOT[KJLXUSZNK
9/*+9:++8<'2<+,';2: TU VXKYKTZUTZNKJOYVRG_
VXK\OU[YVGMK
OTLUXSGZOUT
_KY
YNUXZOTZNK(2<289 (2<289]OXK
]OXKLXUSVOTULZNK
ULZNK*OTIUTTKIZUXGZ
ZNKIOXIRKKTJHR[KYOJK
YZKKX\GR\KIUOR
OZKS+*
MUUJ
YNUXZOTZNK(2(1 (2(1<289]OXK
<289]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
IUTZXURRKX*)54ZUVOT
ULZNK*OTIUTTKIZUXGZ
ZNKIOXIRKKTJHR[KYOJK
YZKKX\GR\KIUOROZKS
+*
MUUJ
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
*OTIUTTKIZUXGZZNK
IOXIRKKTJHR[KYOJK
YZKKX\GR\KIUOR
OZKS+*
MUUJ
ZNKIOXIRKKTJHR[KYOJK UNSY /TJ[YZXOKY9KX\OIK
YZKKX\GR\KIUOR *KVGXZSKTZ
OZKS+*
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
Chart 38
Yellow End =OZNZNKQK_Y]OZIN 9ZUVZNKKTMOTK/TYZGRR )NKIQLUXSKINGTOIGR
Yellow Side Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
GZU69/
HGXVXKYY[XKMG[MKGZ
YZKKXL[TIZOUTLXUS
V[RRKJU[ZZUZNK 54
ZNKW[OIQJOYIUTTKIZ
IU[VRKXUTZNK
SU\OTM58XKVGOXUX
XKVRGIKZNKYZKKX
Function
TU TU
VUYOZOUTYZGXZZNKKTMOTK YZKKXG^RKSGTOLURJ I_ROTJKX58XKVGOXUX
LXUSZNKVRGZLUXS 9ZGXZZNKKTMOTKGTJ XKVRGIKZNKVORUZ
Inoperative IUTZXURYGTJV[YNZNK
YZKKXSUJKYKRKIZH[ZZUT
GIZO\GZKZNKYZKKX
L[TIZOUTOTHUZN
UVKXGZKJINKIQ\GR\KY
OZKS+.UX+,,58
Be sure all other

LUXIOXIRKKTJ_KRRU] JOXKIZOUTY IUTY[RZZNK-KTOK
KTJYZKKX6XKYYJU]T /YZNKVXKYY[XKRKYYZNGT /TJ[YZXOKY9KX\OIK
functions operate ZNKLUUZY]OZINGTJ VYOHGX% *KVGXZSKTZ
normally. GIZO\GZKZNKYZKKX
L[TIZOUTOTHUZN
_KY
Be sure the batteries JOXKIZOUTY'XKZNKXKGT_
JOGMTUYZOIIUJKY
are fully charged and VXKYKTZUTZNKJOYVRG_GZ
9ZUVZNKKTMOTK _KY 8KVRGIKZNKLG[RZ_YZKKX
properly connected. ZNKMXU[TJIUTZXURY%
+ÎNGTMKZNKIOXIRKKTJ \GR\K
_KRRU]YOJKYZKKX\GR\K
OZKS+)]OZNZNKIOXIRK
KTJHR[KYOJKYZKKX
\GR\KOZKS+*9ZGXZ
ZNKKTMOTKGTJGIZO\GZK
ZNKYZKKXL[TIZOUT*UKY
ZNKIOXIRKKTJ_KRRU]
YOJKYZKKXOTML[TIZOUTOT
HUZNJOXKIZOUTY%
TU
_KY
8KVGOXUXXKVRGIKZNK
I_ROTJKXUXVORUZUVKXGZKJ
INKIQ\GR\KYOZKSY+.
UX+,,58IUTY[RZZNK
*KVGXZSKTZ
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 38
9:++8/4-05?9:/)1
/Y )NKIQLUXJGSGMKJ
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
9:++8/4-05?9:/)1 IUTZXURY6)54]OXK
9.58:+*:5<52:9UX NGXTKYYHKZ]KKTYZKKX
_KY
9:++8/4-05?9:/)1 PU_YZOIQIUTTKIZUX6
<'2;+:55./-.UX GTJGTJIOXI[OZHUGXJ
9:++8/4-05?9:/)1 IUTTKIZUX658
<'2;+:5525=VXKYKTZ IUTY[RZZNK-KTOK
UTZNKJOYVRG_YIXKKT% /TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
TU
/Y?+225=+4*?+225= )NKIQIOXIRKKTJ_KRRU] 8KVRGIKZNKYZKKX

HGJ
9/*+9:++8 9+4958 KTJ_KRRU]YOJKYZKKX YKTYUX9KK8KVGOX
9.58:+*:5<52:9UX _KY YKTYUXLUXVXUVKX 9KIZOUT
?+225=+4* ?+225= OTYZGRRGZOUTGTJ
9/*+9:++8 9+4958 UVKXGZOUTYKK8KVGOX
9.58:+*:5<52:9UX 9KIZOUT
?+225=+4* ?+225=
9/*+9:++8 9+4958 MUUJ

<'2;+:55./-.UX
?+225=+4* ?+225=
9/*+9:++8 9+4958
YNUXZOTZNK58 58)889]OXK
<'2;+:5525=VXKYKTZ
)889]OXKLXUSVOT
UTZNKJOYVRG_YIXKKT%
(ULZNKIOXIRKKTJ
IUTTKIZUXZUVOTUL
ZNK0IUTTKIZUXUTZNK
MUUJ
6'4-]OXKLXUSVOT
'ULZNKIOXIRKKTJ
IUTTKIZUXZUVOTUL
ZNK0IUTTKIZUXGZZNK
TU JXO\KINGYYOYIUTZXURRKX
MUUJ
]OXKZNGZX[TYLXUSVOT)
ULZNKIOXIRKKTJ_KRRU]
YOJKYZKKXYKTYUX
IUTTKIZUXZUVOTUL
ZNK0IUTTKIZUXGZZNK
MUUJ
)UTY[RZZNK-KTOK
)UTZOT[KJUT
/TJ[YZXOKY9KX\OIK
ZNKTK^ZVGMK
*KVGXZSKTZ
CHART 38
/Y?+225=+4*?+225= /LGT_UZNKXIUJKYGXK
)UTZOT[KJLXUSZNK
9/*+9:++8<'2<+,';2: TU VXKYKTZUTZNKJOYVRG_
VXK\OU[YVGMK
OTLUXSGZOUT
_KY
YNUXZOTZNK(2<889 (2<889]OXK
]OXKLXUSVOTULZNK0
IUTTKIZUXGZZNKJXO\K
ULZNK*OTIUTTKIZUXGZ
ZNKIOXIRKKTJ_KRRU]
YOJKYZKKX\GR\KIUOR
OZKS+)
MUUJ
YNUXZOTZNK(2(1 (2(1<889]OXK
<889]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
ZNKJXO\KINGYYOY
IUTZXURRKX*)54ZUVOT
ULZNK*OTIUTTKIZUXGZ
ZNKIOXIRKKTJ_KRRU]
YOJKYZKKX\GR\KIUOR
OZKS+)
MUUJ
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
*OTIUTTKIZUXGZZNK
IOXIRKKTJ_KRRU]YOJK
YZKKX\GR\KIUOR
OZKS+)
MUUJ
ZU
UNSY
ZNKIOXIRKKTJ_KRRU] /TJ[YZXOKY9KX\OIK
OZKS+)
UXOTLOTOZKUNSY
8KVRGIKZNK\GR\KIUOR
Chart 39
Drive Forward =OZNZNKQK_Y]OZIN _KY )UTZOT[KJZU
IUTZXURYGTJHUZN
VGMK
V[RRKJU[ZZUZNK 54
VUYOZOUTYZGXZZNK
normally.
ZNKJXO\KLUX]GXJ
L[TIZOUT'XKZNKXKGT_
JOGMTUYZOIIUJKY
Be sure the engine is VXKYKTZUTZNKJOYVRG_GZ
running. MXU[TJIUTZXURY%
Be sure the drive hubs _KY
are not in the free wheel

configuration. *8/<+05?9:/)145:
/Y
_KY
)GROHXGZKZNKJXO\K
)'2/(8':+*UTZNK PU_YZOIQ9KK8KVGOX
Be sure the batteries JOYVRG_YIXKKT% 9KIZOUT

TU
properly connected.
*8/<+05?9:/)1
/Y )NKIQLUXJGSGMKJ
*8/<+05?9:/)1 IUTZXUR]OXKNGXTKYY
9.58:+*:5<52:9UX _KY
HKZ]KKTZNKJXO\K
*8/<+ 05?9:/)1<'2;+ PU_YZOIQIUTTKIZUX6
:5./-.UX*8/<+ GTJGTJIOXI[OZHUGXJ
05?9:/)1<'2;+:525= IUTTKIZUX658ZNK
VXKYKTZUTZNKJOYVRG_ JXO\KPU_YZOIQSG_TKKJ
YIXKKT% ZUHKXKVRGIKJYKK
8KVGOX9KIZOUT58
IUTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 39
/Y *8/<+<'2<+,';2: )NKIQLUXGYNUXZUX HGJ 8KVGOXUXXKVRGIKZNK

VXKYKTZUTZNKJOYVRG_ UVKTOTZNK=. =.<,=*]OXK
VXK\OU[YVGMK
YIXKKT% <,=*]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
ZNKMXU[TJIUTZXURYZU
VOTULZNK*OT
IUTTKIZUXUTZNK
KRKIZXUTOIVXUVUXZOUTGR
IUTZXUR+6)GZZNK
JXO\KV[SV
MUUJ
)NKIQLUXGYNUXZUX HGJ 8KVGOXUXXKVRGIK(8
UVKTOTZNK(8 <2<8+:]OXK
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUX
VOTULZNK*OT
IUTTKIZUXUTZNK
TU IUTZXUR+6)GZZNK
JXO\KV[SV
MUUJ
ZU
UNSY
ZNKKRKIZXUTOI /TJ[YZXOKY9KX\OIK
+6)UTZNKJXO\K
V[SV
UXOTLOTOZK
UNSY
8KVRGIKZNK+6)
/Y (8'1+ <'2<+,';2: /LGT_UZNKXIUJKYGXK

TU
VXKYKTZUTZNKJOYVRG_ VXKYKTZUTZNKJOYVRG_
YIXKKT% YIXKKTXKLKXZUZNKLG[RZ
IUJKINGXZLUXSUXK
OTLUXSGZOUT
_KY
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 39
)NKIQLUXGYNUXZUX HGJ 8KVGOXUXXKVRGIKZNK

)UTZOT[KJLXUSZNK
UVKTOTZNK=.8* =.8*<(81]OXK
VXK\OU[YVGMK
<(81]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
*OTIUTTKIZUXGZZNK
HXGQK\GR\KIUOR
OZKS*5
UQ
UVKTOTZNK(8 (8<2<8+:]OXK
<2<8+:]OXKLXUSVOT
ULZNK0IUTTKIZUXGZ
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*OTIUTTKIZUXGZZNK
HXGQK\GR\KIUOR
OZKS*5
UQ
ZU
UNSY
ZNKHXGQK\GR\KIUOR /TJ[YZXOKY9KX\OIK
OZKS*5 *KVGXZSKTZ
UXOTLOTOZK
UNSY
8KVRGIKZNKIUOR
CHART 39
'ZZNKMXU[TJIUTZXURY 'JP[YZKTMOTKNOMNOJRK
)UTZOT[KJLXUS TU
JOYVRG_YIXURR[TZOR 9KK3GOTZKTGTIK
VGMK
KTMOTKYVKKJOYVXKYKTZ 9KIZOUT
/YZNKKTMOTKNOMNOJRK
YKZZUXVS%
_KY
9ZUVZNKKTMOTK/TYZGRR _KY )UTZOT[KJZU
Z]UZU69/ VGMK
HGXVXKYY[XKMG[MKYUT
ZNKW[OIQJOYIUTTKIZYZU
ZNK'(VUXZYULZNK
JXO\KV[SV9ZGXZZNK
KTMOTK/YZNKVXKYY[XK
VYOHGXUX
SUXK%
TU
9ZUVZNKKTMOTK TU 8KVGOXUXXKVRGIKZNK
*OYIUTTKIZZNKNUYKY JXO\KV[SV
LXUS'(VUXZYUT
JXO\KV[SVGTJVR[MZNK
VUXZY9ZGXZZNKKTMOTK
/YZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
6XKYYJU]TZNKLUUZ TU 8KVGOXUXXKVRGIKZNK
Y]OZINGTJGIZO\GZKZNK JXO\KV[SV
JXO\KLUX]GXJL[TIZOUT/Y
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
)UTZOT[KJUTZNKTK^Z
VGMK
CHART 39
9ZUVZNKKTMOTKGTJ _KY 8KVGOXUXXKVRGIKZNK

)UTZOT[KJLXUSZNK
IUTTKIZZNK'(NUYKY HGJJXO\KSUZUX
VXK\OU[YVGMK
ZUZNKJXO\KV[SV
*OYIUTTKIZZNKIGYK
JXGOTNUYKLXUSUTK
JXO\KSUZUX9ZGXZZNK
XK\KXYKL[TIZOUTLUXUTK
SOT[ZKSKGY[XOTMZNK
\UR[SKULUOR/YZNKUOR
\UR[SKMXKGZKXZNGT
MGRRUTROZKXY%
8KVKGZLUXKGINSUZUX
TU
*OYIUTTKIZGTJVR[MZNK TU 8KVGOXUXXKVRGIK
'(NUYKYGZZNKJXO\K N_JXG[ROIY]O\KR
SGTOLURJ9ZGXZZNK
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
CHART 39
6XKYYJU]TZNKLUUZ )UTY[RZZNK-KTOK
)UTZOT[KJLXUS _KY
Y]OZINGTJGIZO\GZKZNK /TJ[YZXOKY9KX\OIK
VGMK
JXO\KLUX]GXJL[TIZOUT/Y *KVGXZSKTZ
ZNKVXKYY[XKVYO
HGXUXSUXK%
TU
*OYIUTTKIZNUYKYLXUS TU 8KVGOXUXXKVRGIKJXO\K
ZNK'(VUXZYUTZNK V[SV
JXO\KV[SVGTJVR[MZNK
VUXZY9ZGXZZNKKTMOTK
/YZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
6XKYYJU]TZNKLUUZ TU 8KVGOXUXXKVRGIKJXO\K
Y]OZINGTJGIZO\GZKZNK V[SV
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
IUTTKIZZNK'(NUYKY HGJJXO\KSUZUX
ZUZNKJXO\KV[SV
*OYIUTTKIZZNKIGYK
JXGOTLXUSUTKJXO\K
SUZUX9ZGXZZNKKTMOTK
GTJGIZO\GZKZNKJXO\K
LUX]GXJL[TIZOUTLUXUTK
SOT[ZKSKGY[XOTMZNK
\UR[SKULUOR/YZNKUOR
\UR[SKMXKGZKXZNGT
MGRRUTROZKXY%
8KVKGZLUXKGINSUZUX
TU
*OYIUTTKIZGTJVR[M' TU 8KVGOXUXXKVRGIK
(NUYKYGZZNKJXO\K N_JXG[ROIY]O\KR
SGTOLURJ9ZGXZZNK
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 40
Drive Reverse =OZNZNKQK_Y]OZIN TU )UTZOT[KJUT
IUTZXURYGTJHUZN
VGMK
V[RRKJU[ZZUZNK 54
VUYOZOUTYZGXZZNK
normally.
ZNKJXO\KXK\KXYK
L[TIZOUT
Be sure the engine is IUJKYVXKYKTZUTZNK
running. JOYVRG_GZMXU[TJ
IUTZXURY%
Be sure the drive hubs

are not in the free wheel _KY
configuration.
/Y*8/<+05?9:/)145: )GROHXGZKZNKJXO\K
_KY
)'2/(8':+*UTZNK
Be sure the batteries JOYVRG_YIXKKT%
PU_YZOIQ9KK8KVGOX
9KIZOUT
properly connected. TU
*8/<+05?9:/)1
/Y )NKIQLUXJGSGMKJ
9.58:+*:5<52:9UX ]OXKYOTZNKOTZKXTGR
*8/<+05?9:/)1 VRGZLUXSIUTZXURHU^]OXK
9.58:+*:5<52:9UX _KY NGXTKYYHKZ]KKTZNK
*8/<+05?9:/)1<'2;+ JXO\KPU_YZOIQIUTTKIZUX
:5./-.UX*8/<+ 6GTJHUGXJIUTTKIZUX
05?9:/)1<'2;+:525= 658*XO\KPU_YZOIQ
UTZNKJOYVRG_YIXKKT% SG_TKKJZUHK
XKVRGIKJ58IUTY[RZZNK
*KVGXZSKTZ
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 40
/Y *8/<+<'2<+,';2: )NKIQLUXGTUVKTUX HGJ 8KVGOXUXXKVRGIKZNK

VXKYKTZUTZNKJOYVRG_ YNUXZOTZNK=.(1 =:(1<8+<]OXK
VXK\OU[YVGMK
YIXKKT% <8+<]OXKIOXI[OZ
LXUSVOTULZNK0
IUTZXURYZUVOTULZNK
*OTIUTTKIZUXUT
IUTZXUR+6)UTZNK
JXO\KV[SV
MUUJ
<2<8+:]OXKIOXI[OZ
LXUSVOTULZNK0
IUTZXURYZUVOTULZNK
*OTIUTTKIZUXGZZNK
TU
IUTZXUR+6)
MUUJ
ZU
UNSY
ZNKKRKIZXUTOI /TJ[YZXOKY9KX\OIK
+6)
UXOTLOTOZKUNSY
8KVRGIKZNK+6)
/Y (8'1+ <'2<+,';2: TU /LGT_UZNKXIUJKYGXK
VXKYKTZUTZNKJOYVRG_ VXKYKTZUTZNKJOYVRG_
YIXKKT% YIXKKTXKLKXZUZNKLG[RZ
IUJKINGXZLUXSUXK
OTLUXSGZOUT
_KY
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 40

)UTZOT[KJLXUSZNK
UVKTOTZNK=.8* =.8*<(81]OXK
VXK\OU[YVGMK
<(81]OXKLXUSVOT
ULZNK0IUTTKIZUX
GZZNKJXO\KINGYYOY
*OTIUTTKIZUXGZZNK
HXGQK\GR\K
UQ
]OXKIOXI[OZLXUSVOTUL
ZNK0IUTTKIZUXGZZNK
ZUVOTULZNK*OT
IUTTKIZUXGZZNKHXGQK
\GR\KIUOR
UQ
ZU
UNSY
ZNKHXGQK\GR\KIUOR /TJ[YZXOKY9KX\OIK
OZKS*5 *KVGXZSKTZ
UXOTLOTOZK
UNSY
8KVRGIKZNKIUOR
CHART 40
'ZZNKMXU[TJIUTZXURY 8KGJP[YZKTMOTKNOMN
)UTZOT[KJLXUS TU
JOYVRG_YIXURR[TZOR OJRK9KK3GOTZKTGTIK
VGMK
KTMOTKYVKKJOYVXKYKTZ 9KIZOUT
/YZNKKTMOTKNOMNOJRK
YKZZUXVS%
_KY
9ZUVZNKKTMOTK/TYZGRR _KY )UTZOT[KJUT
Z]UZU69/ VGMK
HGXVXKYY[XKMG[MKYUT
ZNKW[OIQJOYIUTTKIZYZU
ZNK'(VUXZYULJXO\K
V[SV9ZGXZZNKKTMOTK
/YZNKVXKYY[XKVYO
HGXUXSUXK%
TU
9ZUVZNKKTMOTK TU 8KVGOXUXXKVRGIKZNK
*OYIUTTKIZZNKNUYKY JXO\KV[SV
LXUS'(VUXZYUT
JXO\KV[SVGTJVR[MZNK
VUXZY9ZGXZZNKKTMOTK
/YZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
JXO\KXK\KXYKL[TIZOUT/Y
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 40

)UTZOT[KJLXUSZNK
XKIUTTKIZ'(NUYKY LG[RZ_JXO\KSUZUXY
VXK\OU[YVGMK
ZUZNKJXO\KV[SV
*OYIUTTKIZZNKSUZUX
IGYKJXGOTLXUSUTK
JXO\KSUZUX9ZGXZZNK
XK\KXYKL[TIZOUTLUXUTK
SOT[ZKSKGY[XOTMZNK
\UR[SKULUOR/YZNKUOR
\UR[SKMXKGZKXZNGT
MGRRUTROZKXY%
8KVKGZLUXKGINSUZUX
TU
*OYIUTTKIZGTJVR[M' TU 8KVGOXUXXKVRGIKZNK
(NUYKYGZZNKJXO\K N_JXG[ROIY]O\KR
SGTOLURJ9ZGXZZNK
JXO\KXK\KXYKL[TIZOUT/Y
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
CHART 40
6XKYYJU]TZNKLUUZ )UTY[RZZNK-KTOK
)UTZOT[KJLXUS _KY
Y]OZINGTJGIZO\GZKZNK /TJ[YZXOKY9KX\OIK
VGMK
JXO\KXK\KXYKL[TIZOUT/Y *KVGXZSKTZ
ZNKVXKYY[XKVYO
HGXUXSUXK%
TU
*OYIUTTKIZZNKNUYKY TU 8KVGOXUXXKVRGIKZNK
LXUS'(VUXZYUT JXO\KV[SV
JXO\KV[SVGTJVR[MZNK
VUXZY9ZGXZZNKKTMOTK
/YZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
XKIUTTKIZ'(NUYKY LG[RZ_JXO\KSUZUXY
ZUZNKJXO\KV[SV
*OYIUTTKIZZNKSUZUX
IGYKJXGOTLXUSUTK
JXO\KSUZUX9ZGXZZNK
JXO\KLUX]GXJL[TIZOUT
LUXUTKSOT[ZK
SKGY[XOTMZNK\UR[SKUL
UOR/YZNKUOR\UR[SK
MXKGZKXZNGTMGRRUT
ROZKXY%
8KVKGZLUXKGINSUZUX
TU
*OYIUTTKIZGTJVR[MZNK TU 8KVGOXUXXKVRGIKZNK
'(NUYKYGZZNKJXO\K N_JXG[ROIY]O\KR
SGTOLURJ9ZGXZZNK
ZNKVXKYY[XKVYO
HGXUXSUXK%
_KY
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 41
Drive Enable =OZNZNKQK_Y]OZIN
_KY
)NKIQ29:5LUXVXUVKX
HGJ
8KVRGIKGTJGJP[YZ
Fault Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
UVKXGZOUTGTJ
OTYZGRRGZOUT9KK8KVGOX
29:59KK8KVGOX
9KIZOUT
+SKXMKTI_YZUVH[ZZUTY 9KIZOUT
Be sure all other V[RRKJU[ZZUZNK 54
functions operate VUYOZOUTL[RR_XKZXGIZZNK
MUUJ
normally.
HUUSGTJRU]KXZNK
HUUSHKRU]JKMXKKY
6[YNZNKYZKKXSUJK )NKIQLUXYNUXZUT(2 HGJ 8KVGOXUXXKVRGIKZNK

Be sure the batteries YKRKIZH[ZZUTLUXYW[GXK )*8+4]OXKLXUSVOT (2)*8+4]OXK
are fully charged and KTJHR[KKTJYZKKXGTJ ULZNKJK[ZYIN
properly connected.
XUZGZKZNKHUUS[TZOROZOY IUTTKIZUXZU29:5ZU
HKZ]KKTZNKIOXIRKKTJ VOTUTZNK0
_KRRU]KTJZOXKY IUTTKIZUXGZZNKMXU[TJ
'ZZNKVRGZLUXSIUTZXURY IUTZXURY
JUKYZNKJXO\KKTGHRK
2+*Z[XTUT%
MUUJ
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
TU *KVGXZSKTZ
8UZGZKZNKHUUS[TZOROZ 6[YNZNKJXO\KKTGHRK )UTY[RZZNK-KTOK

_KY
OYU[ZYOJKZNKIOXIRKKTJ _KY H[ZZUT*U_U[NKGXGT /TJ[YZXOKY9KX\OIK
_KRRU]KTJZOXKY'ZZNK G[JOHRKHKKV]NKT *KVGXZSKTZ
VRGZLUXSIUTZXURYJUKY H[ZZUTOYGIZO\GZKJ%
ZNKJXO\KKTGHRK2+*
Z[XTUT%
TU
)UTY[RZZNK-KTOK
/TJ[YZXOKY9KX\OIK
TU *KVGXZSKTZ
)NKIQ29:5LUXVXUVKX 8KVRGIKGTJGJP[YZ
HGJ
UVKXGZOUTGTJ 29:59KK8KVGOX
OTYZGRRGZOUT9KK8KVGOX 9KIZOUT
9KIZOUT
MUUJ
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 41

)UTZOT[KJLXUSZNK
(2)*8+4]OXKLXUS (2)*8+4]OXK
VXK\OU[YVGMK
VOTULZNKJK[ZYIN
IUTTKIZUXGZ29:5ZU
VOTULZNK0
IUTZXURY
UQ
YNUXZOTZNK58(1 58(1)29]OXK
)29]OXKLXUSVOT
GZ29:5ZUVOTUL
ZNK0IUTTKIZUXGZZNK
MXU[TJIUTZXURY
UQ
)UTZGIZZNK-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Chart 42
Drive Mode =OZNZNKQK_Y]OZIN )UTY[RZZNK-KTOK
Select Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
TU
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ6RGZLUXS
V[RRKJU[ZZUZNK 54
SKSHXGTKJKIGRSG_
TKKJZUHKXKVRGIKJ
VUYOZOUTGIZO\GZKJXO\K
Be sure the boom is SUJKYKRKIZH[ZZUT/Y
in the stowed ZNKXKGTG[JOHRKHKKV%
position.
_KY
Be sure all other

functions operate 'IZO\GZKZNKJXO\KSUJK _KY )UTZOT[KJZU
normally. YKRKIZH[ZZUT*UKYZNK
NOMNJXO\KSUJK2+*
VGMK
Z[XTUT%
are fully charged and TU
properly connected.
_KY
)NKIQZNKJOYVRG_ (5532+4-:.
/Y 8KLKXZU)NGXZ
YIXKKTGZZNKMXU[TJ _KY 9=/:).+9 ,';2:

IUTZXURY'XKZNKXK VXKYKTZUTZNKJOYVRG_
IUJKYVXKYKTZ% YIXKKT%
TU
_KY
(553'4-2+
/Y 8KLKXZU)NGXZ
9=/:).+9 ,';2:
VXKYKTZUTZNKJOYVRG_
YIXKKT%
TU
/LGT_UZNKXIUJKYGXK
VXKYKTZUTZNKJOYVRG_
IUJKINGXZLUXSUXK
OTLUXSGZOUT
TU
)UTZOT[KJUT
ZNKTK^ZVGMK
CHART 42
:[XTZNKQK_Y]OZINZU ;YOTMZNKJOYVRG_ )UTY[RZZNK-KTOK

)UTZOT[KJLXUSZNK TU
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Chart 43
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First Edition First Printing Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

electrically charged circuits could
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions printed in the Genie or spray.
S-100 and Genie S-105 Operator's Manual or General Repair Process
Genie S-120 and Genie S-125 Operator's
Manual.
Malfunction Identify Troubleshoot
Be sure that all necessary tools and test discovered symptoms
equipment are available and ready for use.
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Section 6 Schematics First Edition First Printing
Electrical Components
Item Description Genie Manufacturer Manufacturer Qty

Part Number Part Number
B1 ........................... Battery,
12V DC, 105AH ................. 57159 ............ Allied ...................................... Group 27TM ............. 1
B2 ........................... Battery,
12V DC, 190AH ................. 57160 ............ Allied ...................................... Group 4D .................. 1
B3 ........................... Battery separator ............... 61343 ............ Surepower Industries ............. 1314 .......................... 1
CB1 ........................ Circuit breaker, 40A ........... 61188 ............ Klixon ..................................... 7851-37-40-I ............. 1
CB2 ........................ Circuit breaker, 20A ........... 61187 ............ Klixon ..................................... 7851-37-20-I ............. 1
CR6, CR7,
CR10 through
CR17 ...................... Relay, SPDT, 12V DC ....... 34052 ............ Potter-Brumfield ..................... VF4-15F11-CO5 ..... 10
F1 ........................... Fuse, 20A, Maxi

(Deutz models) .................. 75433 ............ Bussman ................................ MAX 20 ..................... 1
F2 ........................... Fuse, 70A, Maxi ................. 61116 ............ Bussman ................................ MAX 70 ..................... 1
FB .......................... Flashing beacon ................ 20189 ............ ECCO Electronic Controls ..... 6400A-GEN .............. 2
FS1 ........................ Foot switch ........................ 13482 ............ Linemaster Switch Corp. ........ 632-S ........................ 1
H1, H2 .................... Alarm - Audio ..................... 62379 ............ Sauer Danfoss ....................... K27631 ..................... 2
H3 .......................... Horn,
12V DC, 112 dB ................. 54506 ............ Wolo Industries ...................... 300LJ-12 ................... 1
JC1, JC3 ................ Joystick controller,

Dual axis ............................ 62390 ............ Sauer Danfoss ....................... K26519(1090332) ..... 2
JC2 ......................... Joystick controller,

Single axis ......................... 62391 ............ Sauer Danfoss ....................... K26520(1090333) ..... 1
KS1, KS2 ............... Contact, N.O. ..................... 45081 ............ Telemecanique ...................... ZB2-BE101 ............... 5
Contact, N.C. ..................... 29732 ............ Telemecanique ...................... ZB2-BE102 ............... 6
ELECTRICAL COMPONENTS
Item Description Genie Manufacturer Manufacturer Qty

Part Number Part Number
Proximity switch ..... Proximity switch ................. 60987 ............ Power Components ................ FP-2000 .................. 10
Relay ...................... Relay, SPDT, 12V DC

(Deutz models) .................. 60521 ............ Potter-Brumfield ..................... VF4-65F11-S01 ........ 4
(Cummins and
Perkins models) ................. 60521 ............ Potter-Brumfield ..................... VF4-65F11-S01 ........ 3
Relay ...................... Relay, SPDT, 12V DC

(Deutz models) .................. 61225 ............ Potter-Brumfield ..................... VF7-41F11-C05 ........ 2
(Cummins and
Perkins models) ................. 61225 ............ Potter-Brumfield ..................... VF7-41F11-C05 ........ 1
SS1 through
SS4 ........................ Steer sensor ...................... 50159 ............ Power Components ................ HP-NRPS ................. 4
TS1, TS2,
TS3 ........................ Toggle switch, DPDT,
3 position momentary ........ 16397 ............ Microswitch Control Inc. ......... 2NT1-7 ...................... 3
Wire Circuit Legend
Circuit numbering Circuit suffix

1 Circuit numbers consist of three parts: the Definition suffix
circuit prefix, circuit number and circuit suffix. AC Generator GEN
The circuit prefix indicates the type of circuit. Angle ANG
The circuit number describes the function of the Auxiliary Boom Valve ABV
circuit. The circuit suffix provides an Auxiliary Forward Valve AFV
abbreviation for the number or may be used to Auxiliary Platform Valve APV
further define the function of this portion of the Auxiliary Reverse Valve AREV
circuit. It also may be used to indicate the final Auxiliary Reverse Valve AREV
end of the circuit, i.e., LS or limit sw. Auxiliary Steer/Drive Valve ASV
Axle Extend Valve AXEX
2 The circuit number may be used more than
Axle Oscillate AXOS
once in a circuit.
Axle Retract Valve AXRT
Battery BAT
For Example:
Boom Extended BEX
C 74 PRLO This is the circuit for the lockout Boom Stowed BST
valve #1. C stands for control, 74 is the number of Brake BRK
the circuit for the primary #1 lock out valve. PRLO Bypass Valves BV
stands for Primary Lockout. CAN High Signal CAN+
CAN Low Signal CAN-
S 62 BSTO This is the circuit that communicates CAN Shield SHLD
to the onboard computers of the machine that the Chain Break CNBK
boom is fully stowed. S stands for safety, 62 is the Data High DTA+
number of the circuit for boom stowed and BSTO Data Low DTA-
stands for Boom Stowed. Drive Chassis Controller DCON
Drive Enable DRE
P 48 LP P stands for power. 48 is the circuit
Electrical Displacement Control EDC
number for work lamps and LP stands for Lamp.
Engine Speed Select ESPD
R 48 LP R stands for relay. In this case it is the Engine Status Lamp ESL
wire that feeds the relay coil for the work lamp. All Filter Restricted FLR
other numbers remain the same. Filter Switch FLTR
Float Switch FS
V 61 AXRT V stands for valve power. 61 stands Foot switch Signal FTS
for axle retracted circuit and AXRT is the Forward FWD
mnemonic for Axle Retracted. Fuel Select (gas/LP) FUEL
WIRE CIRCUIT LEGEND
Fuel Solenoid FSOL Primary Boom Up/Down Flow Control PBF

Ground Control TCON Primary Lockout #1 P1L
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) STC
Platform Rotate Right (CW) PRR Steering 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
WIRE CIRCUIT LEGEND
Wire Coloring Color, Circuit #, and Primary function

RD 1 Primary boom up drive
1 All cylinder extension colors are solid and all RD/BK 2 Primary boom down drive
retract functions are striped black. When using RD/WH 3 Primary boom up/down FC
black wire, the stripe shall be white. proportional valve drive
WH 4 Turntable rotate left valve drive
2 All rotations that are LEFT or CW are solid,
WH/BK 5 Turntable rotate right valve drive
RIGHT or CCW are striped and black. When the
WH/RD 6 Turntable rotate FC proportional
wire is black, the stripe is white.
valve drive
3 All proportional valve wiring is striped. BK 7 Primary boom extend
BK/WH 8 Primary boom retract
BK/RD 9 Primary boom Extend/Retract
Wire Color Legend proportional valve drive
BL 10 Secondary boom up valve drive
BL Blue
BL/BK 11 Secondary boom down valve drive
BL/BK Blue/Black
BL/WH 12 Secondary boom up/down FC
BL/RD Blue/Red
proportional valve drive
BL/WH Blue/White
BL/RD 13 Drive enable
BK Black
OR 14 Platform level up valve
BK/RD Black/Red
OR/BK 15 Platform level down valve
BK/WH Black/White
OR/RD 16 Platform up/down FC
BR Brown
proportional valve drive
GRN Green
GR/RD 17 Platform rotate left valve driver
GR/BK Green/Black
GR/BK 18 Platform rotate right valve driver
GR/WH Green/White
GR/WH 19 Jib select valve driver circuit
RD Red
RD 20 12 battery supply
RD/BK Red/Black
WH 21 12 ignition supply
RD/WH Red/White
BK 22 Key switch power to platform
OR Orange
Emergency Stop
OR/BL Orange/Blue
WH 23 Power to platform
OR/BK Orange/Black
WH 24 Power to warning senders
OR/RD Orange/Red
WH/BK 25 Power to oil pressure sender
WHT White
WH/RD 26 Power to temp sender
WH/BK White/Black
RD 27 Auxiliary Power
WH/RD White/Red
RD/BK 28 Platform level alarm
YL Yellow
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
WIRE CIRCUIT LEGEND
BL/BK 37 Steer counterclockwise WH 77 Lower Angle #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 +
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
Limit Switches
Types of Limit Switches Limit Switch Numbering

There are two types of limit switches, which are LSAX1RO Front axle retract proximity
found in various locations throughout the machine: LSAX2RO Rear axle retract proximity
mechanical-type operational or safety switches LSAX1EO Front axle extend proximity
and magnetic proximity switches. As in aircraft, LSAX2EO Rear axle extend proximity
which features redundant safety systems, each LSAX1ES Front axle extend safety
mechanical safety switch is backed up with an LSAX2ES Rear axle extend safety
independently functioning proximity switch. LSB6S Cable tension safety
LSB7DS Boom 11 angle safety
The mechanical-type operational or safety LSB3RS Boom 3 foot (0.9 m) extend safety
switches are used to sense a positive displacement LSB2RS Boom 101 feet (30.8 m) extend
or movement of the limit switch actuator, or arm, as safety
the machine moves through its range of operational LSB9AS Boom 65 angle safety
functions. Included in this group are envelope limit LSB8AS Boom 50 angle safety
switches, which sense the extended length and LSB4ES Boom 76 feet (23.2 m) extend
angle of the boom, position of the axles and safety
rotational position of the turntable. LST1O Drive enable mechanical
For example, when the 53 operational switch is LSB1DO Boom 10 mechanical
activated by achieving a 53 boom angle, the boom LSB2RO Boom >100 feet (30.5 m)
may then be extended beyond 75 feet (22.9 m). retract proximity
Another example is the drive enable limit switch, LSB3RO Boom >3 feet (0.9 m) stowed
which disables the drive function anytime the boom mechanical
is rotated past the rear axles, indicated by the LSB3EO Boom 75 feet (22.9 m)
'square' end of the drive chassis. extend proximity
In some cases, the engine will be stopped if safety LSB4EO Boom 100 feet (30.5 m)
parameters are exceeded. extend proximity
Magnetic proximity switches are used to sense LSB13AO Boom 53 angle proximity
very specific positions of a part of the machine in LSB14AO Boom 68 angle proximity
relation to the remainder of the machine. Proximity LSB19LO Load moment mechanical
switches must be correctly aligned for the machine LSB20LO Reverse load moment proximity
functions to operate. Proximity switches are found ( S-120 and S-125 models only)
at the front and rear axle, the turntable and several
locations on the boom.
LIMIT SWITCHES
S-100 & S-105 Models S-120 & S-125 Models

(S-100 shown) (S-120 shown)
Relay Layout
a Fuel solenoid relay (Deutz models only).

b Oil cooler relay (Deutz models only).
c Engine cold start relay.
d Starter relay.
e Horn relay.
f Flashing beacon relay.
g CR17 relay (K7) - powers C35RPM
circuit (Hi/low solenoid).
h CR16 relay (K8) - powers C34SA
circuit (Engine cold start).
i CR12 relay (K4) - powers primary valves 1 and
2, ignition, glow plug, starter relay, generator,
and the boom retract, multifunction and
platform rotate valve coils.
j CR14 relay (K2) - powers P7R or S56PRV
circuit including the auxiliary valve, boom
extend/retract and turntable rotate valve coils.
k CR10 relay (K6) - powers C21IGN and C107AF
circuits (Fuel on/off solenoid and alternator
field).
l CR15 relay (K1) - powers P22R or C03PBF
circuit (Boom up/down valve coil).
m CR13 relay (K5) - powers P_7 and throttle
relay.
n CR11 relay (K3) - powers P-6R2 or P54ENG
circuits.
Drive Chassis Controller Pin Legend
Platform Controller Pin Legend
Turntable Controller Pin Legend

Drive Chassis (DCON) and Platform Controls (PCON)

Ground Controls (TCON)
Electrical Symbols Legend
Limit Switch Harness Schematic,

S-100 & S-105 Models
N M L K J I H G F E D C B A
Limit Switch Harness Schematic,

S-120 & S-125 Models
Safety Circuit Schematic
Generators
Deutz Models
Hydraulic Symbols Legend
Hydraulic Schematic,
S-100 Models with 2 Wheel Steer
A B C D E F G H I J K L M N
S-120 Models
S-120 Models
S-125 Models
S-125 Models
First Edition First Printing Section 7 Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this
reverse order.
machine.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine. Safety alert symbolused to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Used to indicate the presence of
and operating instructions in the Genie S-100 & an imminently hazardous situation
Genie S-105 Operators Manual and the which, if not avoided, will result in
Genie S-120 & Genie S-125 Operators Manual. death or serious injury.
Be sure that all necessary tools and parts are Used to indicate the presence of a
available and ready for use. potentially hazardous situation
which, if not avoided, could result
Read each procedure completely and adhere in death or serious injury.
to the instructions. Attempting shortcuts may
produce hazardous conditions. With safety alert symbolused to
indicate the presence of a
Unless otherwise specified, perform each potentially hazardous situation
repair procedure with the machine in the which, if not avoided, may cause
following configuration: minor or moderate injury.
Machine parked on a flat, level surface
Without safety alert symbolused
Boom in the stowed position to indicate the presence of a
Turntable rotated with the boom between potentially hazardous situation
the circle-end wheels which, if not avoided, may result in
property damage.
Turntable secured with the turntable
rotation lock pin Greenused to indicate operation
Key switch in the OFF position with the or maintenance information.
key removed Indicates that a specific result is expected after
Wheels chocked performing a series of steps.
All external AC power supply disconnected Indicates that an incorrect result has occurred
from the machine after performing a series of steps.
Part No. 62401 Genie S-100 S-105 S-120 S-125 7-1

Section 7 Repair Procedures First Edition First Printing
Display Module
This table lists the various screens and menu options of the operating software. Some display menus are
for informational purpose only, while others can be changed to alter the machine operating parameters.
The key switch must be in the OFF position before entering the programming mode.
Screen or Menu Procedure Description

Operator Default Hour meter
Engine speed
Engine oil pressure PSI
Engine oil pressure KPA
Engine temperature F
Engine temperature C
Turntable level sensor X
Turntable level sensor Y
Machine With key switch ON, press the Hydraulic pressure
and at the same time. Boom length
Status Boom angle
Axle status
Unit of With the key switch OFF, press Metric/Imperial measurements

and hold the button and turn Language selection
Measure the key switch to the ON position.
and Release the button and press
.
Language
Drive With the key switch OFF, press Drive output max forward
and hold the button and turn Drive output max reverse
Functions the key switch to the ON position. Elevated drive % (>80 ft, >24.4 m)
Release the button and Elevated drive % (<80 ft, <24.4 m)
press . Stowed drive %
Drive acceleration %
Drive deceleration %
Speed limit on steer angle
Boom With the key switch OFF, press Boom up/down speed % (fully retracted)
and hold the button and turn Boom up/down speed %
Function the key switch to the ON position. (<80 ft, <24.4 m)
Speeds Release the button and
Boom up/down speed %
press .
(>80 ft, >24.4 m)
Boom up/down speed %
(>100 ft, >30.5 m)
Turntable rotate speed %
(<80 ft, <24.4 m)
(>80 ft, >24.4 m)
Jib boom up/down ramp deceleration
7-2 Genie S-100 S-105 S-120 S-125 Part No. 62401

DISPLAY MODULE
Screen or Menu Procedure Description

Lift With the key switch OFF, press Boom up/down ramp acceleration
and hold the button and turn Boom up/down ramp deceleration
Function the key switch to the ON position. Boom extend/retract ramp deceleration
Ramp Release the button and Turntable rotate ramp acceleration
press . Turntable rotate ramp deceleration
Settings Jib boom up/down ramp deceleration
Valve With the key switch OFF, press Reset drive valve defaults
and hold the button and turn Reset boom up/down valve defaults
Calibration the key switch to the ON position. Reset boom extend/retract valve defaults
Release the button and Reset turntable rotate valve defaults
press . Reset platform level valve defaults
Allow boom up/down speed calibration
Allow boom extend/retract speed
calibration
Allow turntable rotate speed calibration
Reset drive joystick defaults
Reset boom up/down joystick defaults
Reset boom extend/retract joystick
defaults
Reset turntable rotate joystick defaults
Reset steer joystick defaults
Options With the key switch OFF, press Limit boom height to 100 ft (30.5 m):
and hold the button and turn < 100, NO LT
the key switch to the ON position.
Limit boom height to 80 ft (24.4 m):
Release the button and
< 80, NO LT
press .
AC generator: NO GN, W REG, W/O R
Alarm: NO AL, MO AL, TR AL, DE AL, TD AL
Lift/drive cut outs: NO CO, DCONS, LORDR
Boom extend cut out if boom angle >5
Auxiliary drive enable: YES, NO
Proximity kill switch OR platform overload
sensing: NONE, PROX, PLTFS
Worklight: YES, NO
Flashing beacon: YES, NO
Drive lights: YES, NO
Steer mode change while driving: YES, NO

Platform Controls REV B
The platform controls contains two printed circuit a b

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

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

REV B PLATFORM CONTROLS
1-1 6 Remove the platform control box lid retaining

fasteners. Open the control box lid.
Circuit Boards
7 Locate the ECM circuit board mounted to the
When an ECM circuit board is inside of the platform control box.
replaced, the joystick controllers Electrocution hazard. Contact with
will need to be calibrated. See 1-3, electrically charged circuits could
How to Calibrate a Joystick result in death or serious injury.
Controller. Remove all rings, watches and
other jewelry.
How to Remove the ECM
Circuit Board Component damage hazard.
Electrostatic discharge (ESD) can
1 Push in the Emergency Stop button to the OFF damage printed circuit board
position at both the ground and platform components. Maintain firm contact
controls. with a metal part of the machine
that is grounded at all times when
2 Remove the platform control box mounting
handling printed circuit boards OR
fasteners. Remove the platform control box
use a grounded wrist strap.
from the machine.
8 Remove the ECM circuit board mounting
fasteners.
Cables can be damaged if they
are kinked or pinched. 9 Carefully remove the ECM circuit board from
the platform control box.
3 Locate the cables that connect to the bottom of
the control box. Number each cable and its How to Remove the Membrane
location at the control box.
Circuit Board
4 Disconnect the cables from the bottom of the
platform control box. 1 Push in the Emergency Stop button to the OFF
5 Remove the control cable plug retaining controls.
fasteners from the bottom of the platform
control box. 2 Remove the platform control box lid retaining
fasteners. Open the control box lid.

PLATFORM CONTROLS REV B
3 Locate the membrane circuit board mounted to 1-2

the inside of the platform control box lid.
Membrane Decal
Electrocution hazard. Contact with
How to Replace the Membrane
Remove all rings, watches and Decal
other jewelry.
The membrane decal is a special decal that
Component damage hazard. consists of a decal with an electronic membrane
Electrostatic discharge (ESD) can on the backside. The membrane contains touch
damage printed circuit board sensitive areas that, when pushed, activates the
components. Maintain firm contact machine functions. The membrane buttons
with a metal part of the machine activate machine functions similar to toggle
that is grounded at all times when switches, but do not have any moving parts.
use a grounded wrist strap. 1 Push in the Emergency Stop button to the OFF
4 Carefully disconnect the two ribbon cables from controls.
the membrane circuit board.
2 Remove the platform control box lid retaining
5 Remove the membrane circuit board retaining fasteners. Open the control box lid.
fasteners.
3 Carefully disconnect the two ribbon cables from
6 Carefully remove the membrane circuit board the membrane circuit board.
from the platform control box lid.
Remove all rings, watches and
other jewelry.
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine

4 Close the control box lid. 1-3

5 Remove the decal from the platform control box. Joysticks
6 Carefully remove the membrane decal from the
platform control box while guiding the ribbon How to Calibrate a Joystick
cables out of the control box lid.
The joystick controllers on this machine utilize
7 Remove any decal adhesive from the control digital Hall Effect technology for proportional
box lid with a mild solvent. control. If a joystick controller is disconnected or
replaced, it must be calibrated before that particular
Do not allow any solvent to come
machine function will operate.
in contact with the membrane
circuit board. The joystick must be calibrated
8 Install the new membrane decal (Genie part before the threshold, max-out or
number 50810) while guiding the ribbon cables ramping can be set.
through the control box lid. It is possible to reset multiple
Be sure that all LED locations on joystick defaults before exiting the
the membrane decal align with the programming mode.
LED's on the membrane circuit After each joystick is calibrated,
board. check the display at the ground
9 Install a new platform controls decal (Genie part control box. There should be no
number 65182) over the membrane decal. calibration faults shown on the
display. If calibration faults exist,
10 Open the control box lid and carefuly connect repeat steps 1 through 8 for that
the ribbon cables from the membrane decal to joystick controlled function.
the membrane circuit board.
Contact Genie Industries Service
Department before using the reset
all joystick default option.
engine off.
The calibration procedure for each joystick begins
on the next page.

Drive functions: Steer functions:

If the calibration fault is already If the calibration fault is already
displayed at the ground box begin displayed at the ground box begin
with step 6. with step 6.
1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the 2 Press and hold the enter button on the
ground control panel while turning the key ground control panel while turning the key
switch to platform controls. Hold the enter switch to platform controls. Hold the enter
button for approximately 5 seconds. button for approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until RESET DRIVE JOYSTICK DEFAULTS is menu until RESET STEER JOYSTICK DEFAULTS is
displayed. Press the button to select YES, displayed. Press the button to select YES,
then press the button. then press the button.
5 Exit programming mode. 5 Exit programming mode.
To exit programming mode, use To exit programming mode, use
the scroll button to scroll the scroll button to scroll
through the menu until the through the menu until the
screen displays exit, then press screen displays exit, then press
the plus button once, change the plus button once, change
the NO to YES, and press the the NO to YES, and press the
enter button . enter button .
6 Do not start the engine. 6 Do not start the engine.
7 Locate the drive/steer joystick. 7 Locate the drive/steer joystick.
8 Move the drive/steer joystick full stroke in the 8 Move the drive/steer joystick full stroke in the
forward direction and hold for 5 seconds, then left direction and hold for 5 seconds, then return
return to the center or neutral position. to the center or neutral position.
9 Move the drive/steer joystick full stroke in the 9 Move the drive/steer joystick full stroke in the
reverse direction and hold for 5 seconds, then right direction and hold for 5 seconds, then
return to the center or neutral position. return to the center or neutral position.
Result: The alarm at the ground controls should Result: The alarm at the ground controls should
sound for a successful calibration. sound for a successful calibration.
Result: If the alarm does not sound, repeat the Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1. calibration procedure, beginning with step 1.

Boom extend/retract functions: Boom up/down functions:

If the calibration fault is already If the calibration fault is already
displayed at the ground box begin displayed at the ground box begin
with step 6. with step 6.
1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the 2 Press and hold the enter button on the
ground control panel while turning the key ground control panel while turning the key
switch to platform controls. Hold the enter switch to platform controls. Hold the enter
button for approximately 5 seconds. button for approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until RESET BOOM EXTEND/RETRACT JOYSTICK menu until RESET BOOM UP/DOWN JOYSTICK DEFAULTS
DEFAULTS is displayed. Press the button to is displayed. Press the button to select YES,
select YES, then press the button. then press the button.
5 Exit programming mode. 5 Exit programming mode.
To exit programming mode, use To exit programming mode, use
the scroll button to scroll the scroll button to scroll
through the menu until the through the menu until the
screen displays exit, then press screen displays exit, then press
the plus button once, change the plus button once, change
the NO to YES, and press the the NO to YES, and press the
enter button . enter button .
6 Do not start the engine. 6 Do not start the engine.
7 Locate the boom/turntable rotate joystick. 7 Locate the boom/turntable rotate joystick.
8 Move the boom extend/retract joystick full 8 Move the boom/turntable rotate joystick full
stroke in the extend direction and hold for 5 stroke in the up direction and hold for 5
seconds, then return to the center or neutral seconds, then return to the center or neutral
position. position.
9 Move the boom extend/retract joystick full 9 Move the boom/turntable rotate joystick full
stroke in the retract direction and hold for 5 stroke in the down direction and hold for 5
seconds, then return to the center or neutral seconds, then return to the center or neutral
position. position.
Result: The alarm at the ground controls should Result: The alarm at the ground controls should
sound for a successful calibration. sound for a successful calibration.
Result: If the alarm does not sound, repeat the Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1. calibration procedure, beginning with step 1.

Turntable rotate functions: How to Reset a Proportional

If the calibration fault is already Valve Coil Default
displayed at the ground box begin
with step 6. Software version 2.0 requires the
use of Web GPI to perform this
1 Turn the key switch to the off position. procedure. Refer to 5-5, Software.
2 Press and hold the enter button on the This procedure only needs to be
ground control panel while turning the key performed if a proportional valve
switch to platform controls. Hold the enter has been replaced.
button for approximately 5 seconds.
After the valve coil defaults have
3 Press the minus button twice, then press the been set, each machine function
enter button twice. threshold and default function
4 Use the scroll button to scroll through the speed must be set. See How to
menu until RESET TURNTABLE ROTATE JOYSTICK Set the Function Thresholds and
DEFAULTS is displayed. Press the button to Default Function Speeds.
select YES, then press the button. 1 Turn the key switch to the off position.
5 Exit programming mode. 2 Press and hold the enter button on the
To exit programming mode, use ground control panel while turning the key
the scroll button to scroll switch to platform controls. Hold the enter
through the menu until the button for approximately 5 seconds.
screen displays exit, then press 3 Press the minus button twice, then press the
the plus button once, change enter button twice.
the NO to YES, and press the
enter button . 4 Use the scroll button to scroll through the
menu until the function valve that needs to be
6 Do not start the engine. reset is displayed. Press the button to
7 Locate the boom/turntable rotate joystick. select YES, then press the button to save the
setting.
8 Move the boom/turntable joystick full stroke in
the left direction and hold for 5 seconds, then Choices are: Propel (drive) valve
return to the center or neutral position. reset; Boom up/down valve reset;
Boom extend/retract valve reset;
9 Move the boom/turntable joystick full stroke in or TT rotate valve reset.
the right direction and hold for 5 seconds, then
return to the center or neutral position. 5 Push one of the LCD screen buttons shown
until EXIT is displayed.
Result: The alarm at the ground controls should
sound for a successful calibration. 6 Press the plus button or minus button to
select YES and then press the enter button .
Result: If the alarm does not sound, repeat the
calibration procedure, beginning with step 1.
7 - 10 Genie S-100 S-105 S-120 S-125 Part No. 62401

How to Set the Function 5 While holding the joystick in position, press the
engine start button at the platform controls
Thresholds and Function
to set the joystick controller threshold.
Speeds
6 Slowly move the joystick off center in the
Software version 2.0 requires the opposite direction just until the machine function
use of Web GPI to perform this starts to move, then move the joystick very
procedure. Refer to 5-5, Software. slowly towards the neutral or center position just
before the machine function stops.
Before the threshold and default
Do not let go of the joystick.
function speeds can be set, the
boom function proportional valve 7 While holding the joystick in position, press the
coil defaults must be set first. engine start button at the platform controls
See How to Reset a Proportional to set the joystick controller threshold.
Valve Coil Default.
8 Repeat steps 3 through 7 for each joystick
If a boom function proportional controlled machine function (boom up/down and
valve coil has not been replaced turntable rotate left/right, boom extend/retract,
and just want to reset the function and drive forward/reverse).
speed to original factory settings,
begin with step 10. 9 Once all the joystick controllers have been
calibrated, push in the Emergency Stop button
1 Start the engine from the platform controls. at the platform controls to save the settings in
2 Press down the foot switch. memory.
Note: Be sure the engine rpm is set to foot switch The Emergency Stop button at the
activated high idle. platform controls must be pushed
in to the OFF position following
Function threshold: calibration of the joystick
controllers to save the settings in
3 Select a joystick controlled function that needs
memory.
to have the threshold set.
10 At the ground controls, turn the key switch to
4 Slowly move the joystick off center in either
the off position, wait a moment and then turn
direction just until the machine function starts to
the key switch to platform controls.
move, then move the joystick very slowly
towards the neutral or center position just before 11 Check the display at the ground controls to be
the machine function stops. sure there are no calibration faults.
Do not let go of the joystick.
There should be no calibration
faults shown on the display. If
calibration faults exist, repeat this
procedure.
Part No. 62401 Genie S-100 S-105 S-120 S-125 7 - 11

REV B
Function speeds: 16 At the ground controls, turn the key switch to

the off position, wait a moment and then turn
Be sure the machine is in the the key switch to platform controls.
stowed position and the boom is
rotated between the circle end 17 Check the display at the ground controls to be
tires. sure there are no calibration faults.
Perform this procedure with the There should be no calibration

machine parked on a firm, level faults shown on the display. If
surface which is free of calibration faults exist, repeat this
obstructions. procedure.
12 Start the engine from the platform controls. How to Adjust the Function
13 Select a boom function that needs the function Speeds
speed set.
1 Pull out the red Emergency Stop button to the
14 Boom up/down functions: Starting in the on position at both the ground and platform
stowed position, move the joystick full stroke in controls.
the up direction. When the alarm sounds, move
the joystick in the opposite direction full stroke 2 Press and hold the enter button on the
until the alarm sounds again. Return the joystick ground control panel while turning the key
to center. switch to ground controls. Hold the enter
Boom extend/retract functions: Raise the
boom until the low-speed drive function is 3 Press the plus button twice, then press the
enabled. Move the joystick full stroke in the minus button twice.
extend direction. When the alarm sounds, move 4 Press the scroll button until the function to
the joystick in the opposite direction full stroke be adjusted is displayed.
until the alarm sounds again. Return the joystick
to center. 5 Press the plus button to increase the speed
or press the minus button to decrease the
Turntable rotate functions: Raise the boom speed.
until the low-speed drive function is enabled.
Move the joystick full stroke to the left (cw) until 6 Press the enter button to save the setting in
the drive enable light turns on. Then move the memory.
joystick full stroke to the right (ccw). When the 7 Push one of the LCD screen buttons shown
alarm sounds, move the joystick in the opposite until EXIT is displayed.
direction full stroke until the alarm sounds
again. Return the joystick to center. 8 Press the plus button or minus button to
select YES and then press the enter button .
15 Once all the joystick controllers have been
calibrated, push in the Emergency Stop button 9 Continue to perform this procedure until the
at the platform controls to save the settings in machine function speed meets specification.
memory. Refer to Section 2, Specifications for function
speeds.
The Emergency Stop button at the
platform controls must be pushed
in to the OFF position following
calibration of the joystick
controllers to save the settings in
memory.

REV B
How to Adjust the Function Specifications

Ramp Rate Setting
Ramp rate (factory settings)
The ramp rate setting of a joystick controls the time
Turntable rotate
at which it takes for the joystick to reach maximum
accelerate 2 seconds
output, when moved out of the neutral position. The decelerate 0.25 second
ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain Boom up/down
peak performance from the machine. accelerate 3 seconds
decelerate 0..25 second
boom in the stowed position. Boom extend/retract
1 Pull out the red Emergency Stop button to the decelerate 0.25 second
on position at both the ground and platform
controls. Jib boom up/down
2 Press and hold the enter button on the decelerate 0.25 second
ground control panel while turning the key
Drive
switch to ground controls. Hold the enter
3 Press the plus button twice, then press the
scroll button twice.
4 Press the scroll button until the function to
be adjusted is displayed.
5 Press the plus button to increase the ramp
rate or press the minus button to decrease
the ramp rate.
6 Press the enter button to save the setting in
memory.
7 Push one of the LCD screen buttons shown
until EXIT is displayed.
8 Press the plus button to select YES and then
press the enter button .

PLATFORM CONTROLS
1-4 6 Press down the foot switch. Connect the leads

from an ohmmeter or continuity tester to the
Foot Switch wire combination listed below and check for
continuity.
How to Test the Foot Switch
Test Desired result
key switch in the OFF position. black to white continuity
(C to N.O.) (zero )
1 Disconnect the wire connector from the foot
switch cable at the back of the platform.
2 Remove the foot switch guard mounting
fasteners from the platform.
3 Remove the foot switch mounting fasteners that
attach the foot switch to the foot switch guard.
4 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
5 Do not press down the foot switch. Connect the
leads from an ohmmeter or continuity tester to
the wire combination listed below and check for
continuity.
Test Desired result
black to white no continuity

(C to N.O.) (infinite )

PLATFORM CONTROLS
1-5 Test Desired result

Toggle Switches Left position
Toggle switches used for single function switching terminal 1 to 2, 3, 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches. Dual (infinite :)
function switching requires a double pole double terminal 2 to 3 continuity
throw (DPDT) switch. (zero:)
How to Test a Toggle Switch terminal 2 to 4, 5 & 6 no continuity

(infinite :)
Continuity is the equivalent of 0 to terminal 3 to 4, 5 & 6 no continuity
3 ohms. A simple continuity tester (infinite :)
may not accurately test the switch.
terminal 4 to 5 & 6 no continuity
This procedure covers fundamental switch testing (infinite :)
and does not specifically apply to all varieties of
toggle switches. terminal 5 to 6 continuity
(zero:)
1 Turn the key switch to the OFF position. Tag
and disconnect all wiring from the toggle switch
to be tested. Center position There are no terminal combinations
that will produce continuity
2 Connect the leads of an ohmmeter to the switch (infinite :)
terminals in the following combinations listed
Right position
below to check for continuity.
terminal 1 to 2 continuity
(zero:)
Left Center Right terminal 1 to 3, 4, 5 & 6 no continuity

(infinite :)
terminal 2 to 3, 4, 5 & 6 no continuity
(infinite :)
terminal 3 to 4, 5 & 6 no continuity
(infinite :)
1 3 1 3 1 3 (zero:)
2 2 2
Single pole terminal 4 to 6 no continuity
double throw (infinite :)
(SPDT) 1 2 3 1 2 3 1 2 3
terminal 5 to 6 no continuity
4 5 6 4 5 6 4 5 6
(infinite :)
Double pole
double throw
(DPDT)
1 2 3 1 2 3 1 2 3

Platform Components
2-1 2-2
Platform Platform Leveling Cylinder
How to Remove the Platform The platform leveling cylinder keeps the platform
level through the entire range of boom motion. The
1 Separate the foot switch quick disconnect plug. platform is maintained level to the turntable. The
ECM at the ground controls compares the
2 Support the platform with an appropriate lifting
difference in readings between the platform angle
device.
sensor and the turntable level sensor. The ECM at
3 Locate the cables that connect to the bottom of the ground controls sends a signal to the platform
the control box. Number each cable and its controls to open or close the appropriate platform
location at the platform control box. level proportional valve on the platform manifold to
maintain a level platform. The platform leveling
4 Disconnect the cables from the bottom of the
cylinder is equipped with counterbalance valves to
platform control box.
prevent movement in the event of a hydraulic line
5 Remove the platform control box mounting failure.
fasteners. Remove the platform control box and
set it aside. How to Remove the Platform
6 Remove the air line to platform bracket retaining Leveling Cylinder
fasteners (if equipped). When removing a hose assembly
7 Remove the weld cables from the platform or fitting, the O-ring on the fitting
(if equipped). and/or hose end must be replaced
Electrocution hazard. Contact with during installation.
electrically charged circuits could Refer to Section Two, Hydraulic
result in death or serious injury. Hose and Fitting Torque
Remove all rings, watches and Specifications.
other jewelry.
1 Extend the boom until the platform leveling
8 Remove the platform mounting fasteners and cylinder barrel-end pivot pin is accessible.
remove the platform from the machine.
2 Raise the boom slightly and place blocks under
Crushing hazard. The platform the platform.
may become unbalanced and fall
when it is removed from the
machine if it is not properly
supported.

PLATFORM COMPONENTS
3 Lower the boom until the platform is resting on 8 Use a soft metal drift to remove the rod-end
the blocks just enough to support the platform. pivot pin.
Do not rest the entire weight of the Crushing hazard. The platform
boom on the blocks. (S-100 and S-120 models) or jib
boom (S-105 and S-125 models)
4 Tag, disconnect and plug the hydraulic hoses
will fall when the platform leveling
from the platform leveling cylinder at the
cylinder rod-end pivot pin is
bulkhead fittings located inside the boom tube
removed if it is not properly
at the platform end and connect them together
supported.
using a connector. Cap the bulkhead fittings on
the boom tube. Crushing hazard. The platform
leveling cylinder will fall if it is not
properly supported when the rod-
hydraulic oil can penetrate and
end pivot pin is removed.
connections very slowly to allow Component damage hazard. The
the oil pressure to dissipate platform leveling cylinder rod can
gradually. Do not allow oil to become damaged if it is allowed to
squirt or spray. fall.
5 Remove the pin retaining fastener from 9 Use a soft metal drift to remove the barrel-end
the platform leveling cylinder rod-end pivot pin. pivot pin.
Do not remove the pin.
10 Carefully pull the platform leveling cylinder out
6 Remove the external snap ring from the barrel- of the boom.
end pivot pin. Do not remove the pin.
7 Support the platform leveling cylinder with a Hoses can be damaged if they are
suitable lifting device. Protect the cylinder rod kinked or pinched.
from damage.

PLATFORM COMPONENTS
How to Bleed the Platform 2-3

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

PLATFORM COMPONENTS
2 Disconnect the electrical connector from the 7 Remove the weld cable from the platform
platform angle sensor. (if equipped).
3 Tag, disconnect and plug the hydraulic hoses Electrocution hazard. Contact with
from the "V1" and "V2" ports on platform rotator electrically charged circuits could
manifold. Cap the fittings on the manifold. result in death or serious injury.
other jewelry.
burn skin. Loosen hydraulic 8 Support the platform mounting weldment, but do
connections very slowly to allow not apply any lifting pressure.
9 Remove the eight mounting bolts from the
platform mounting weldment.
or spray.
10 Remove the center bolt and slide the platform
4 Remove the platform manifold mounting
mounting weldment off of the platform rotator.
fasteners. Lay the platform manifold to the side.
Crushing hazard. The platform
mounting weldment may become
unbalanced and fall if it is not
are kinked or pinched.
properly supported.
5 Remove the power to platform cover plate from
11 Support the platform rotator. Do not apply
the electrical outlet box. Do not disconnect the
any lifting pressure.
wiring.
S-100 and S-120 models:
electrically charged circuits could 12 Support the rod end of the platform leveling
result in death or serious injury. cylinder. Protect the cylinder rod from damage.
other jewelry. 13 Remove the pin retaining fastener from the
platform level cylinder rod-end connecting link
6 Remove the power to platform electrical outlet pivot pin and the platform rotator pivot pin. Do
box from the platform and lay it to the side. not remove the pins.

PLATFORM COMPONENTS
14 Use a soft metal drift to remove both pins and How to Bleed the Platform
remove the platform rotator from the machine.
Rotator
rotator may become unbalanced Do not start the engine. Use
and fall if it is not properly auxiliary power for all machine
supported. functions in this procedure.
Component damage hazard. The S-105- Before serial number 251

platform angle sensor is a very S-125- Before serial number 999
sensitive instrument. It can be 1 At the ground controls, simultaneously hold the
damaged internally if the platform auxiliary power button and the platform rotate
rotator is dropped or sustains any right button until the platform is fully rotated to
physical shock, even if the the right.
damage is not visible.
2 Connect a clear hose to the top bleed valve.
S-105 and S-125 models: Place the other end of the hose in a container
12 Remove the pin retaining fasteners from the jib to collect any drainage. Secure the container to
boom and jib boom leveling arms to platform the boom.
rotator pivot pins. Do not remove the pins. 3 Slowly open the top bleed valve on the rotator.
13 Support the jib boom leveling arms with a Do not remove the bleed valve from the
suitable lifting device. platform rotator.
14 Use a soft metal drift to remove both pins and Bodily injury hazard. Spraying
remove the platform rotator from the machine. hydraulic oil can penetrate and
Crushing hazard. The jib boom connections very slowly to allow
leveling arms may fall if they are the oil pressure to dissipate
not properly supported when the gradually. Do not allow oil to squirt
jib boom leveling arm pivot pin is or spray.
removed.
Component damage hazard. The
platform angle sensor is a very a
sensitive instrument. It can be
damaged internally if the platform
rotator is dropped or sustains any
physical shock, even if the
damage is not visible.
d c b
a top bleed valve

b bottom bleed valve
c clear hose
d container

REV B PLATFORM COMPONENTS
4 Hold the platform rotate left button until the 2-4

platform is fully rotated. Continue holding the
button until air stops coming out of the bleed Platform Overload System
valve. Close the bleed valve.
Crushing hazard. Keep clear of the
How to Calibrate the Platform
platform during rotation. Overload System (if equipped)
5 Connect the clear hose to the bottom bleed
valve and slowly open the valve. Do not remove
the bleed valve.
Calibration of the platform overload system is
6 Hold the platform rotate right button until the essential to safe machine operation. Continued use
platform is fully rotated. Continue holding the of an improperly calibrated platform overload
button until air stops coming out of the bleed system could result in the system failing to sense
valve. Close the bleed valve. an overloaded platform. The stability of the
Crushing hazard. Keep clear of machine is compromised and it could tip over.
the platform during rotation.
7 Remove the hose from the bleed valve and machine on a firm, level surface.
clean up any hydraulic oil that may have spilled.
1 Turn the key switch to platform control. Start the
8 Rotate the platform full right then left and engine and level the platform.
inspect the bleed valves for leaks.
2 Determine the maximum platform capacity.
9 Clean up any oil that may have spilled during Refer to the machine serial plate.
this procedure.
3 Remove all weight, tools and accessories from
S-100 and S-120 the platform.
S-105- After serial number 250
Failure to remove all weight, tools
S-125- After serial number 998
and accessories from the platform
1. Rotate the platform full right, then full left until air will result in an incorrect
is completely out of the rotator. Bleeding the calibration.
valve is not necessary.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.

PLATFORM COMPONENTS REV B
5 Move the platform up and down by hand, so it 6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The alarm should be off. The platform Result: The alarm should be off. The platform
overload indicator light should be off at the overload indicator light should be off at the
platform controls and there should be no error platform controls and there should be no error
message on the LCD display at the ground message on the LCD display at the ground
controls. Proceed to step 6. controls. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
Result: The alarm is sounding. The platform
in 10 increments until the overload indicator
overload indicator light is flashing at the
light flashes at both the platform and ground
platform controls and PLATFORM
controls, and the alarm sounds. Proceed to step
OVERLOAD should is displayed on the LCD
7.
screen at the ground controls. Slowly tighten the
load spring adjustment nut in a clockwise Result: The alarm should be sounding.
direction in 10 increments until the overload The platform overload indicator light should be
indicator light turns off, and the alarm does not flashing at the platform controls and
sound. Proceed to step 8. PLATFORM OVERLOAD should be displayed
on the LCD screen at the ground controls.
The platform will need to be moved
Repeat this procedure beginning with step 5.
up and down and allowed to settle
between each adjustment. The platform will need to be moved
up and down and allowed to settle
There may be a 2 second delay
between each adjustment.
before the platform overload
indicator light and alarm responds. There may be a 2 second delay
indicator lights and alarm
responds.

REV B PLATFORM COMPONENTS
7 Move the platform up and down by hand, so it 9 Test all machine functions from the platform
bounces approximately 2.5 to 5 cm / 1 to 2 controls.
inches. Allow the platform to settle.
Result: All platform control functions should not
Result: The alarm should be off. The platform operate.
overload indicator light should be off at the
10 Turn the key switch to ground control.
platform controls and there should be no error
message on the LCD display at the ground 11 Test all machine functions from the ground
controls. Proceed to step 8. controls.
Result: The overload indicator lights are flashing Result: All ground control functions should not
at the platform and ground controls, and the operate.
alarm is sounding. Repeat this procedure
beginning with step 5. 12 Using a suitable lifting device, lift the test weight
off the platform floor.
before the platform overload Result: The alarm should be off. The platform
indicator light and alarm responds. overload indicator light should be off at the
8 Add an additional test weight to the platform. message on the LCD display at the ground
S-105 and S-125- 10 lb / 4.5 kg controls.
S-100 and S-120- 12 lb / 5.4 kg.
Result: The alarm should be sounding. before the overload indicator lights
The platform overload indicator light should be and alarm turn off.
flashing at the platform controls and
PLATFORM OVERLOAD should be displayed 13 Test all machine functions from the ground
on the LCD screen at the ground controls. controls.
Proceed to step 9. Result: All ground control functions should
Result: The alarm should be off. The platform operate normally.
overload indicator light should be off at the 14 Turn the key switch to platform control.
message on the LCD display at the ground 15 Test all machine functions from the platform
controls. Remove the additional 10 lb / 4.5 kg controls.
test weight. Repeat this procedure beginning Result: All platform control functions should
with step 6. operate normally.
indicator light and alarm responds.

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

cylinder hydraulic hoses. Cap the fittings on the
Jib Boom, cylinder.
S-105 and S-125 Models Bodily injury hazard. Spraying
How to Remove the Jib Boom burn skin. Loosen hydraulic
boom in the stowed position.
When removing a hose assembly squirt or spray.
6 Support the barrel end of the cylinder with a
suitable lifting device.
during installation. 7 Remove the pin retaining fastener from the jib
Refer to Section Two, Hydraulic boom lift cylinder barrel-end pivot pin.
8 Use a soft metal drift to remove the pin and let
Specifications.
the cylinder hang down.
1 Remove the platform. See 2-1,
9 Attach a lifting strap from an overhead crane to
How to Remove the Platform.
the jib boom.
2 Remove the platform mounting weldment
10 Remove the pin retaining fastener from the jib
and the platform rotator. See 2-3, How to
boom pivot pin.
Remove the Platform Rotator.
11 Use a soft metal drift to remove the pin and
3 Remove the hose and cable cover retaining
remove the jib boom from the primary boom.
fasteners from the jib boom leveling arm.
Remove the hose and cable cover from the Crushing hazard. The jib boom
machine. may become unbalanced and fall
when it is removed from the
4 Support the jib boom with a suitable lifting
machine if it is not properly
device.
supported.

JIB BOOM COMPONENTS, S-105 AND S-125 MODELS
12 Remove the pin retaining fasteners from the jib 19 Use a soft metal drift to remove the platform
boom lift cylinder rod-end pivot pin. Do not leveling cylinder rod-end pivot pin.
remove the pin.
13 Slide both of the jib boom leveling arms off of leveling cylinder may fall if it is not
the jib boom pivot pin and lay them off to the properly supported when the rod-
side. end pivot pin is removed.
14 Attach a lifting strap from an overhead crane to Crushing hazard. The jib boom
the lug on the rod end of the jib boom lift bellcrank may fall if it is not
cylinder. properly supported when the
platform leveling cylinder rod-end
15 Use a soft metal drift to remove the jib boom lift
pivot pin is removed.
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the jib boom bellcrank. 20 Remove the pin retaining fastener from the jib
boom bellcrank pivot pin.
Crushing hazard. The jib boom lift
cylinder may become unbalanced 21 Use a soft metal drift to remove the jib boom
and fall when it is removed from bellcrank pivot pin. Remove the jib boom
the machine if it is not properly bellcrank from the machine.
supported.
Crushing hazard. The jib boom
16 Attach a lifting strap from an overhead crane to bellcrank may become
the jib boom bellcrank. unbalanced and fall if it is not
properly supported when it is
17 Support the rod end of the platform leveling
cylinder with a suitable lifting device. Protect the
cylinder rod from damage.
18 Remove the pin retaining fastener from the
platform leveling cylinder rod-end pivot pin.

JIB BOOM COMPONENTS, S-105 AND S-125 MODELS
3-2 2 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the
Jib Boom Lift Cylinder, cylinder.
How to Remove the Jib Boom burn skin. Loosen hydraulic
Lift Cylinder connections very slowly to allow
Perform this procedure with the gradually. Do not allow oil to
boom in the stowed position. squirt or spray.
When removing a hose assembly 3 Remove the hose and cable cover retaining
or fitting, the O-ring on the fitting fasteners from the jib boom leveling arm.
and/or hose end must be replaced Remove the hose and cable cover from the
and then torqued to specification machine.
Refer to Section Two, Hydraulic 4 Remove the pin retaining fasteners from the jib
Hose and Fitting Torque boom lift cylinder rod-end pivot pin. Do not
Specifications. remove the pin.
1 Raise the jib boom slightly and place blocks 5 Use a soft metal drift to tap the jib boom lift
under the platform mounting weldment. Lower cylinder rod-end pivot pin half way out and
the jib boom until the platform is resting on the lower one of the leveling arms to the ground.
blocks just enough to support the platform. Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
Do not rest the entire weight of the
boom on the blocks. 6 Support the jib boom lift cylinder with a suitable
lifting device.
7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin.
8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder may become unbalanced
supported.


Boom Components
a Number 1
b Number 2
c Number 3
a Number 0
b Number 1
c Number 2
d Number 3

BOOM COMPONENTS
4-1 3 Tag, disconnect and plug all hydraulic hoses

from the boom cable tube to the platform
Cable Track manifold.
The cable track and boom cable tube guides If your machine is equipped with
cables and hoses running up the boom. The cable an airline to platform option and/or
track can be repaired link by link without removing weld cable option, the airline and/
the cables and hoses that run through it. Removing or cable must be disconnected
the entire cable track assembly may be necessary from the platform before the cable
when performing major repairs that involve track is removed.
removing the boom. 4 Tag and disconnect the black electrical
connector from the bottom of the control box.
How to Remove the Boom
5 Remove the platform-end boom cable tube
Cable Track mounting fasteners at the engine side of the
When removing a hose assembly machine.
or fitting, the O-ring on the fitting 6 Remove the cable track mounting fasteners
and/or hose end must be replaced from the cable track support at the engine side
and then torqued to specification of the machine.
Refer to Section Two, Hydraulic 7 Remove the wear pad mounting weldment from
Hose and Fitting Torque the cable track support bracket at the engine
Specifications. side of the machine.
Perform this procedure with the 8 Remove the hose and cable clamp from the
boom fully stowed. cable track support bracket at the engine side
of the machine.
1 Remove the hose and cable cover retaining
fasteners from the jib boom leveling arm. 9 Place blocks between the cable track and the
Remove the hose and cable cover from the boom cable tube for support.
machine.
10 Strap together the boom cable tube, blocks of
2 Remove the protective coil sleeve from the wood, and the cable track at the engine side of
hose and cable bundle at the platform end of the machine.
the boom cable tube.
Cables, hoses, boom cable tube
and cable track can be damaged if
they are kinked or pinched.

BOOM COMPONENTS
11 Remove the limit switch cover retaining If not removing the boom from the machine,
fasteners from the top of the number 2 boom proceed to step 19.
tube at the platform end of the machine.
Remove the limit switch cover. 18 Tag, disconnect and plug the primary extension
cylinder hydraulic hoses on the side of the
12 Tag and disconnect the wiring connectors from number 2 boom tube at the ground controls
the proximity and limit switches on top of the side of the machine. Cap the fittings.
number 2 boom tube at the platform end of the
machine. Bodily injury hazard. Spraying
13 Remove the cable track roller guide mounting burn skin. Loosen hydraulic
fasteners from the ground controls side of the connections very slowly to allow
machine at the platform end. the oil pressure to dissipate
14 Remove the roller guide from the cable track gradually. Do not allow oil to
guide bracket at the engine side of the squirt or spray.
machine. 19 Remove the cable track mounting fasteners
15 Tag, disconnect and plug the hydraulic hoses from the cable track support at the ground
from the bottom of the bulkhead fittings on the controls side of the machine.
cable track support at the ground controls side 20 Remove the side panels from the boom cable
of the machine. tube located under the cable track at the ground
Bodily injury hazard. Spraying controls side of the machine.
hydraulic oil can penetrate and 21 Remove the hose and cable cover mounting
burn skin. Loosen hydraulic fasteners from the pivot end of the boom at the
connections very slowly to allow ground controls side of the machine. Remove
the oil pressure to dissipate the cover.
squirt or spray. 22 Remove the hose and cable clamps from the
hoses and cables located below the boom pivot
16 Remove the bulkhead fitting locknuts from the on the inside of the turntable riser at the ground
bulkhead fittings on the cable track support at controls side of the machine.
the ground controls side of the machine.
Remove and cap the fittings. 23 Tag and disconnect the electrical cables from
the cable track to the ground controls side of
17 Tag and disconnect the wiring connectors. the machine.
The wiring connectors that need to If not removing the boom from the machine,
be disconnected are located next proceed to step 25.
to the hose fittings that were
removed in step 16.

BOOM COMPONENTS
24 Pull the hydraulic hoses from the boom cable 28 Attach a lifting strap from an overhead crane to
tube located under the cable track at the ground each end of the cable track assembly. Carefully
controls side of the machine. lift the assembly from the boom and set it on a
structure capable of supporting it.
25 Place blocks between the cable track and the
cable track tube at the ground controls side of Crushing hazard. If the cable track
the machine. Secure the cable track and the assemblies are not properly
cable track tube together. secured together, the cable track
assemblies may become
unbalanced and fall when it is
they are kinked or pinched. Component damage hazard.
the cable track assembly at the engine side of
they are kinked or pinched.
the boom. Lift the cable track assembly over
the boom and carefully set the assembly on top Component damage hazard. The
of the longer boom cable tube at the ground boom cable tube and cable tracks
controls side of the machine. can be damaged if they are
twisted.
Crushing hazard. If the cable track
assemblies are not properly How to Repair the Boom
secured together, the cable track
may become unbalanced and fall Cable Track
when it is removed from the Component damage hazard.
machine. The boom cable track can be
27 Strap both cable track assemblies together. damaged if it is twisted.
Component damage hazard. A cable track repair kit is available

Cables and hoses can be through the Genie Industries
damaged if they are kinked or Service Parts Department,
pinched. part number 62320. The kit
includes a 3 link section of cable
Component damage hazard. track.
Cable tracks can be damaged if
they are twisted. 1 Visually inspect the cable track and determine
which 3-link section needs to be replaced.
2 Remove the snap-on cable track spacers.

BOOM COMPONENTS
3 Remove the external snap rings from the pivot 4-2

pins at each end of the 3-link section to be
removed. Boom
4 Lift up the hoses and cables and carefully
remove the damaged 3-link section of cable
How to Shim the Boom
track. 1 Measure each upper, side and lower wear pad.
Component damage hazard. 1/2 inch
Boom wear pad specifications
Hoses and cables can be
damaged if they are kinked or
pinched.
5 Remove the snap-on spacers from the If a wear pad is not less than
replacement section of cable track. specification, perform the following
procedure.
6 Lift up the hoses and cables and carefully insert
the new 3-link section of cable track. 2 Remove the retaining fasteners from the
appropriate black plastic boom tube cover at
Component damage hazard. the platform end of the boom. Remove the
Hoses and cables can be cover.
pinched. 3 Extend the boom until the wear pads are
accessible.
7 Connect the ends of the replacement cable
track section to the existing cable track using 4 Loosen the wear pad mounting fasteners.
the pivot pins and external snap rings. 5 Install shims under the upper and lower wear
Be sure that the pivot pins are pads until they are very tight against the boom
installed from the inside out so the tube.
external snap rings are on the 6 Install shims under the side wear pads until they
outside of the cable track. are extremely tight against the boom tube.
8 Install the cable track snap-on spacers. 7 Tighten the mounting fasteners.
8 Extend and retract the boom through an entire
cycle. Check for tight spots that may cause
binding of the boom.
between the outer and inner boom
tubes.

BOOM COMPONENTS
How to Remove the Boom 7 Attach an overhead 10 ton (10,000 kg) crane to
the platform end of the boom for support. Do
Bodily injury hazard. This not lift the boom.
procedure requires specific repair
skills, lifting equipment and a 8 Remove the boom storage area cover retaining
suitable workshop. Attempting this fasteners. Remove the cover from the machine.
procedure without these skills and 9 Place support blocks under the boom lift
tools could result in death or cylinder.
serious injury and significant
component damage. Dealer 10 Remove the pin retaining fastener from the
service is strongly recommended. boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
or fitting, the O-ring on the fitting Crushing hazard. The boom lift
and/or hose end must be replaced cylinder may fall when the rod-end
and then torqued to specification pivot pin is removed if the boom lift
during installation. cylinder is not properly supported
Refer to Section Two, Hydraulic by the overhead crane.
Hose and Fitting Torque Crushing hazard. The boom may
Specifications. fall when the rod-end pivot pin is
1 Remove the platform. See 2-1, removed if the boom is not
How to Remove the Platform. properly supported by the
overhead crane.
2 Remove the platform rotator. See 2-3, How to
Remove the Platform Rotator. 11 Carefully raise the boom with the overhead
crane until the rod end of the boom lift cylinder
3 S-105 and S-125 models: Remove the Jib can be removed.
Boom. See 3-1, How to Remove the Jib Boom.
12 Carefully lower the rod end of the boom lift
4 Remove the cable track. See 4-1, How to cylinder down onto the support blocks.
Remove the Boom Cable Track.
13 Lower the boom with the overhead crane to a
5 Raise the boom approximately 4 feet (1.2 m). horizontal position.
6 Attach a lifting strap from an overhead crane to 14 Remove the boom end cover retaining
the rod end of the boom lift cylinder. fasteners from the pivot end of the boom.
Remove the cover.

BOOM COMPONENTS
15 Locate the cable break limit switch above the 21 Carefully remove the boom assembly from the
primary boom extension cylinder at the pivot machine and place it on a structure capable of
end of the boom. supporting it.
16 Tag and disconnect the wiring connector from Crushing hazard. The boom may
the cable break limit switch. become unbalanced and fall when
it is removed from the machine if it
is not properly supported by the
from the primary boom extension cylinder. Cap
overhead cranes.
the fittings on the cylinder.
burn skin. Loosen hydraulic How to Disassemble the Boom,
connections very slowly to allow S-120 and S-125 Models
gradually. Do not allow oil to Complete disassembly of the
squirt or spray. boom is only necessary
if the outer or inner boom tubes
18 Attach a second overhead 10 ton (10,000 kg) must be replaced. The primary
crane to the pivot end of the boom for support. boom extension cylinder can be
Do not apply any lifting pressure. removed without completely
19 Remove the pin retaining fastener from the disassembling the boom. See 4-4,
boom pivot pin. Do not remove the pin. How to Remove the Primary
Extension Cylinder.
20 Use a soft metal drift to remove the boom pivot
pin. 1 Remove the boom. See 4-2,
How to Remove the Boom.
Component damage hazard. Be
careful not to damage the boom 2 Remove the retaining fasteners from the access
envelope limit switch(s) located on covers on both sides of the boom at the pivot
the inside of the engine side end. Remove the access covers.
turntable riser when removing the
boom assembly. The boom
envelope switch(s) can be
damaged even if the damage is
not visible.
a side access covers

BOOM COMPONENTS
3 Secure the number 2 and number 3 boom tubes 8 Lay the inner cable track and hoses down and
together with a strap or chain to prevent them out of the way.
from moving.
9 Remove the pulley pivot pin retaining fasteners
4 Remove the cable clamp from the cable break from the number 2 boom tube at the pivot end
limit switch wiring. of the boom.
10 Remove the pulley pivot pins, cable guards and
pulleys.
When installing the pulleys, be
a
sure that the side of the pulley with
the taller flange is facing the
center of the boom tube.
11 Locate the number 3 boom tube extension
cable clevis pins on both sides of the number 2
boom tube at the pivot end of the boom.
b
12 Remove the cotter pin and clevis pin from both
cables.
a cable break limit switch
b cable pulley When installing a clevis pin,
always replace the cotter pin with
5 Disconnect the wiring connector from the cable
a new one.
break limit switch.
13 Remove the lower external snap ring and
washer from the cable break limit switch
from the primary boom extension cylinder. Cap
actuator pivot pin.
the fittings on the cylinder.
14 Remove the cable break actuator mounting
plate retaining fasteners. Remove the lower
plate from the machine.
connections very slowly to allow 15 Remove the upper plate and actuator pivot pin.
the oil pressure to dissipate Do not remove the cable break limit switch from
gradually. Do not allow oil to the mounting plate.
squirt or spray.
16 Push the cable break actuator and cables
7 Remove the fasteners from the inner cable towards the platform end of the boom
track mounting bracket at the primary boom approximately 18 inches / 46 cm.
extension cylinder.

BOOM COMPONENTS
17 Remove the red cable adjustment locking 20 Remove the trunnion pin retaining fasteners.
bracket retaining fasteners. Remove the red
21 Use a slide hammer to remove the trunnion pins
locking bracket from the machine.
from the primary boom extension cylinder.
Bodily injury hazard. Failure to
22 Remove the primary boom extension cylinder
install the red cable adjustment
hold down brackets at the pivot end of the
locking bracket will allow the cable
boom.
mounting bolts to loosen and fall
out which could result in death or 23 Attach a lifting strap from an overhead crane to
serious injury. the lifting eye on the primary boom extension
cylinder.
24 Support and slide the primary boom extension
cylinder out of the boom assembly while guiding
the cables out of the boom and place it on a
Crushing hazard. The primary
boom extension cylinder may
become unbalanced and fall when
it is removed from the boom if it is
not properly supported and
attached to the overhead crane.
During removal, the overhead
crane strap will need to be
adjusted for proper balancing.
a red cable adjustment
locking bracket 25 Remove the retaining fasteners from the limit
switch cover on top of the number 2 boom tube
18 Remove the two cable adjustment bolts.
at the platform end of the machine.
19 Remove the cable-end block mounting plate
fasteners. Remove the cable-end block
mounting plate from the machine.

BOOM COMPONENTS
26 Carefully remove the cover with proximity and 32 Remove and label the top and side wear pads
limit switches from the top of the number 2 of the number 3 boom tube at the pivot end of
boom tube at the platform end of the boom. the boom. Do not remove the bottom wear
pads.
Tip-over hazard. Failure to install
the correct proximity and/or limit Pay careful attention to the
switches in the correct location will location and amount of shims
result in the machine tipping over, used with each wear pad.
resulting in death or serious injury.
33 Remove and label the top and side wear pads
27 Tag and disconnect the wiring connectors from from the number 2 boom tube at the platform
the proximity and limit switches at the top of the end of the boom. Do not remove the bottom
number 2 boom tube at the platform end of the wear pads.
boom. Do not remove the proximity or limit
Pay careful attention to the
switches.
location and amount of shims
28 Remove the retaining fasteners from the limit used with each wear pad.
switch cover on the side of the number 0 boom
tube at the platform end of the boom.
the number 3 boom tube at the platform end of
29 Carefully remove the cover with proximity and the boom.
limit switches from the number 0 boom tube at
35 Support and slide the number 3 boom tube out
the platform end of the boom.
of the number 2 boom tube. When the number
Tip-over hazard. Failure to install 3 boom tube is approximately halfway removed,
the correct proximity and/or limit remove the bottom wear pads from the number
switches in the correct location will 2 boom tube at the platform end of the boom.
result in the machine tipping over,
Crushing hazard. The number 3
boom tube may become
30 Tag and disconnect the wiring connectors from unbalanced and fall when it is
the proximity and limit switches at the ground removed from the number 2 boom
controls side of the number 0 boom tube at the tube if it is not properly supported
platform end of the boom. Do not remove the and attached to the overhead
proximity or limit switches. crane.
31 Remove the retaining fasteners from each black During removal, the overhead
plastic boom tube cover at the platform end of crane strap will need to be
the machine. Remove the covers. adjusted for proper balancing.

BOOM COMPONENTS
36 Remove and label the top and side wear pads 40 Remove the secondary boom extend cylinder
from the number 2 boom tube at the pivot end cover retaining fasteners. Remove the covers.
of the boom. Do not remove the bottom wear
pads.
operate the machine unless the
Pay careful attention to the secondary extend cylinder covers
location and amount of shims are properly installed. Operating
used with each wear pad. the machine with the covers
removed could result in death or
serious injury.
from the number 1 boom tube at the platform
end of the boom. Do not remove the bottom 41 Tag, disconnect and plug the secondary boom
wear pads. extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
location and amount of shims Bodily injury hazard. Spraying
used with each wear pad. hydraulic oil can penetrate and
the boom.
39 Support and slide the number 2 boom tube out squirt or spray.
42 Support the secondary boom extension cylinder
2 boom tube is approximately halfway removed,
with an overhead crane or other suitable lifting
remove the bottom wear pads from the number
device.
1 boom tube at the platform end of the boom.
43 Remove the pin retaining fasteners from both
the rod-end and barrel-end pivot pins. Do not
remove the pins.
unbalanced and fall when it is
removed from the number 1 boom
tube if it is not properly supported
and attached to the overhead
crane.

BOOM COMPONENTS
44 Use a soft metal drift to remove both pivot pins 48 Support and slide the number 1 boom tube out
and remove the secondary boom extension of the number 0 boom tube. When the number
cylinder from the machine while guiding the 1 boom tube is approximately halfway removed,
barrel end of the cylinder out of the boom. remove the bottom wear pads from the number
0 boom tube at the platform end of the boom.
Crushing hazard. The secondary
boom extension cylinder may Crushing hazard. The number 1
become unbalanced and fall if it is boom tube may become
not properly supported when it is unbalanced and fall when it is
removed from the machine. removed from the number 0 boom
tube if it is not properly supported
and attached to the overhead
boom lift cylinder rod can become
crane.
damaged if the barrel end of the
secondary boom extension During removal, the overhead
cylinder is allowed to come in crane strap will need to be
contact with it. adjusted for proper balancing.
45 Remove and label the top and side wear pads How to Disassemble the Boom,
from the number 1 boom tube at the pivot end
of the boom. Do not remove the bottom wear S-100 and S-105 Models
pads. Complete disassembly of the
Pay careful attention to the boom is only necessary
location and amount of shims if the outer or inner boom tubes
used with each wear pad. must be replaced. The primary
boom extension cylinder can be
46 Remove and label the top and side wear pads removed without completely
from the number 0 boom tube at the platform disassembling the boom. See 4-4,
end of the boom. Do not remove the bottom How to Remove the Primary
wear pads. Extension Cylinder.
Pay careful attention to the 1 Remove the boom. See 4-2,
location and amount of shims How to Remove the Boom.
used with each wear pad.
the boom.

BOOM COMPONENTS
2 Remove the retaining fasteners from the access 6 Tag, disconnect and plug the hydraulic hoses
covers on both sides of the boom at the pivot from the primary boom extension cylinder. Cap
end. Remove the access covers. the fittings on the cylinder.
squirt or spray.
a side access covers
of the boom.
3 Secure the number 2 and number 3 boom tubes 8 Remove the pulley pivot pins, cable guards and
together with a strap or chain to prevent them pulleys.
from moving.
4 Remove the cable clamp from the cable break sure that the side of the pulley with
limit switch wiring. the taller flange is facing the
center of the boom tube.
9 Locate the number 3 boom tube extension
a
cables.
When installing a clevis pin,
a new one.
b
11 Remove the lower external snap ring and
a cable break limit switch washer from the cable break limit switch
b cable pulley actuator pivot pin.
5 Disconnect the wiring connector from the cable 12 Remove the cable break actuator mounting
break limit switch. plate retaining fasteners. Remove the lower
plate from the machine.

BOOM COMPONENTS
13 Remove the upper plate and actuator pivot pin. 16 Remove the two cable adjustment bolts.
Do not remove the cable break limit switch from
17 Remove the cable-end block mounting plate
the mounting plate.
fasteners. Remove the cable-end block
14 Push the cable break actuator and cables mounting plate from the machine.
towards the platform end of the boom
18 Remove the trunnion pin retaining fasteners.
approximately 18 inches / 46 cm.
15 Remove the red cable adjustment locking
from the primary boom extension cylinder.
bracket retaining fasteners. Remove the red
locking bracket from the machine. 20 Remove the primary boom extension cylinder
hold down brackets at the pivot end of the
Bodily injury hazard. Failure to
boom.
locking bracket will allow the cable 21 Attach a lifting strap from an overhead crane to
mounting bolts to loosen and fall the lifting eye on the primary boom extension
out which could result in death or cylinder.
serious injury.
23 Remove the retaining fasteners from the limit
a red cable adjustment switch cover on top of the number 2 boom tube
locking bracket at the platform end of the machine.

BOOM COMPONENTS
24 Carefully remove the cover with proximity and 30 Remove and label the top and side wear pads
limit switches from the top of the number 2 of the number 3 boom tube at the pivot end of
boom tube at the platform end of the boom. the boom. Do not remove the bottom wear
pads.
Tip-over hazard. Failure to install
the correct proximity and/or limit Pay careful attention to the
switches in the correct location will location and amount of shims
result in the machine tipping over, used with each wear pad.
25 Tag and disconnect the wiring connectors from from the number 2 boom tube at the platform
the proximity and limit switches at the top of the end of the boom. Do not remove the bottom
number 2 boom tube at the platform end of the wear pads.
boom. Do not remove the proximity or limit
switches.
26 Remove the retaining fasteners from the limit used with each wear pad.
switch cover on the side of the number 1 boom
tube at the platform end of the boom.
27 Carefully remove the cover with proximity and the boom.
limit switches from the number 1 boom tube at
33 Support and slide the number 3 boom tube out
the platform end of the boom.
Tip-over hazard. Failure to install 3 boom tube is approximately halfway removed,
the correct proximity and/or limit remove the bottom wear pads from the number
switches in the correct location will 2 boom tube at the platform end of the boom.
result in the machine tipping over,
28 Tag and disconnect the wiring connectors from unbalanced and fall when it is
the proximity and limit switches at the ground removed from the number 2 boom
controls side of the number 1 boom tube at the tube if it is not properly supported
platform end of the boom. Do not remove the and attached to the overhead
proximity or limit switches. crane.
29 Remove the retaining fasteners from each black During removal, the overhead
plastic boom tube cover at the platform end of crane strap will need to be
the machine. Remove the covers. adjusted for proper balancing.

BOOM COMPONENTS
34 Remove and label the top and side wear pads 4-3
of the boom. Do not remove the bottom wear Boom Lift Cylinder
pads.
How to Remove the Boom
location and amount of shims Lift Cylinder
Bodily injury hazard. This
35 Remove and label the top and side wear pads procedure requires specific repair
from the number 1 boom tube at the platform skills, lifting equipment and a
end of the boom. Do not remove the bottom suitable workshop. Attempting this
wear pads. procedure without these skills and
tools could result in death or
component damage. Dealer
service is strongly recommended.
36 Attach a lifting strap from an overhead crane to When removing a hose assembly
the number 2 boom tube at the platform end of or fitting, the O-ring on the fitting
the boom. and/or hose end must be replaced
37 Support and slide the number 2 boom tube out and then torqued to specification
of the number 1 boom tube. When the number during installation.
2 boom tube is approximately halfway removed, Refer to Section Two, Hydraulic
remove the bottom wear pads from the number Hose and Fitting Torque
1 boom tube at the platform end of the boom. Specifications.
Crushing hazard. The number 2 1 Raise the boom until there is approximately 4
boom tube may become feet (1.2 m) between the turntable and boom
unbalanced and fall when it is rest pad.
removed from the number 1 boom 2 Attach a lifting strap from an overhead crane or
tube if it is not properly supported other suitable lifting device to the rod end of the
and attached to the overhead the boom lift cylinder.
crane.
3 Attach an overhead 10 ton / 9071 kg crane to
During removal, the overhead the platform end of the boom for support. Do not
crane strap will need to be lift the boom.
4 Remove the boom storage area cover retaining
fasteners. Remove the cover from the machine.

BOOM COMPONENTS
5 Place support blocks under the boom lift 11 Remove the engine pivot plate retaining
cylinder. fastener. Swing the engine pivot plate out away
from the machine.
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Protect the
Crushing hazard. The boom lift
cylinder may fall when the rod-end
pivot pin is removed if the boom lift
cylinder is not properly supported
by the overhead crane. a b
Crushing hazard. The boom may a engine pivot plate anchor hole
fall when the rod-end pivot pin is b engine pivot plate retaining fastener
removed if the boom is not
properly supported by the 12 Locate the engine pivot plate anchor hole at the
overhead crane. pivot end of the engine pivot plate.
7 Carefully raise the boom with the overhead 13 Install the bolt that was just removed into the
crane until the rod end of the boom lift cylinder anchor hole to secure the engine pivot plate
can be removed. from moving.
8 Carefully lower the rod end of the boom lift Crushing hazard. Failure to install
cylinder down onto the support blocks. the bolt into the engine pivot plate
9 Carefully raise the boom with the overhead
crane until the barrel end of the boom lift
serious injury.
cylinder is accessible.
10 Tag, disconnect and plug the boom lift cylinder
barrel-end pivot pin. Do not remove the pin.
hydraulic hoses. Cap the fittings on the
cylinder. 15 Support the boom lift cylinder with an overhead
Bodily injury hazard. Spraying crane.
squirt or spray.

BOOM COMPONENTS
16 Use a slide hammer to remove the boom lift 4-4

cylinder barrel-end pivot pin through the access
hole in the engine side turntable riser. Extension Cylinders
17 With the boom lift cylinder being supported by The primary boom extension cylinder is located
the overhead crane, pull the boom lift cylinder inside the boom assembly and incorporates cables
toward the platform until it is out. and pulleys that are responsible for extending the
Crushing hazard. The boom lift number 2 and 3 boom tubes. The secondary boom
cylinder may become unbalanced extension cylinder (S-120 and S-125 models) is
and fall if it is not properly located underneath the number 0 boom tube and is
supported when it is removed from responsible for extending the number 1 boom tube.
the machine. The extension cylinders are equipped with
counterbalance valves to prevent movement in the
Component damage hazard. Be event of a hydraulic line failure.
careful not to damage the
proximity and/or limit switches How to Remove the Primary
when removing the boom lift
cylinder.
Boom Extension Cylinder
Component damage hazard. The Bodily injury hazard. This
cables and hydraulic hoses can be procedure requires specific repair
damaged if the boom lift cylinder is skills, lifting equipment and a
pulled across them. suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
component damage. Dealer
service is strongly recommended.
Specifications.

BOOM COMPONENTS
2 Remove the retaining fasteners from the boom 7 Tag, disconnect and plug the hydraulic hoses
end cover at the pivot end of the boom. from the primary boom extension cylinder. Cap
Remove the cover from the machine. the fittings on the cylinder.
3 Remove the access cover retaining fasteners Bodily injury hazard. Spraying
from both sides of the boom. Remove the hydraulic oil can penetrate and
access covers. burn skin. Loosen hydraulic
4 Secure the number 2 and number 3 boom tubes
together with a strap or chain to prevent them
from moving.
squirt or spray.
5 Remove the cable clamp from the cable break
8 S-120 and S-125 models: Remove the
limit switch wiring.
fasteners from the inner cable track mounting
bracket at the primary boom extension cylinder.
9 S-120 and S-125 models: Lay the inner cable
track and hoses down and out of the way.
a
of the boom.
11 Remove the pulley pivot pins, cable guards and
pulleys.
sure that the side of the pulley with
a cable break limit switch the shorter flange is facing the
inside of the boom tube.
6 Disconnect the wiring connector from the cable
break limit switch. 12 Locate the number 3 boom tube extension
cables.
When installing a clevis pin,
a new one.

BOOM COMPONENTS
14 Remove the lower external snap ring and washer 20 Remove the cable-end block mounting plate
from the cable break limit switch actuator pivot fasteners. Remove the cable-end block
pin. mounting plate.
15 Remove the cable break actuator mounting plate 21 Remove the trunnion pin retaining fasteners.
retaining fasteners. Remove the lower plate.
16 Remove the upper plate and actuator pivot pin. from the primary boom extension cylinder.
Do not remove the cable break limit switch from
Use a 1/2 -13 bolt thread on each
the mounting plate.
end of the slide hammer.
17 Push the cable break actuator and cables
towards the platform end of the boom
the lifting eye on the primary boom extension
approximately 18 inches / 46 cm.
cylinder.
18 Remove the retaining fasteners from the red
cable adjustment locking bracket. Remove the
red locking bracket.
Bodily injury hazard. Failure to structure capable of supporting it.
locking bracket would allow the
cable mounting bolts to loosen
and fall out which could result in
death or serious injury.
are kinked, pinched or snagged
during removal.
a red cable adjustment

locking bracket
19 Remove the two cable adjustment bolts.

BOOM COMPONENTS
How to Remove the Secondary 3 Tag, disconnect and plug the secondary boom
extension cylinder hydraulic hoses. Cap the
Boom Extension Cylinder, fittings on the cylinder.
Bodily injury hazard. This hydraulic oil can penetrate and
procedure requires specific repair burn skin. Loosen hydraulic
skills, lifting equipment and a connections very slowly to allow
suitable workshop. Attempting this the oil pressure to dissipate
procedure without these skills and gradually. Do not allow oil to
tools could result in death or squirt or spray.
serious injury and significant 4 Support the secondary boom extension cylinder
component damage. Dealer with an overhead crane or other suitable lifing
service is strongly recommended. device.
When removing a hose assembly 5 Remove the pin retaining fasteners from both
or fitting, the O-ring on the fitting the rod-end and barrel-end pivot pins. Do not
and/or hose end must be replaced remove the pins.
during installation. 6 Protect the boom lift cylinder rod from damage.
7 Use a soft metal drift to remove both pivot pins.
Specifications. 8 Remove the secondary boom extension
cylinder from the machine while guiding the
1 Raise the boom until the secondary boom
barrel end of the cylinder out of the boom.
extension cylinder barrel-end pivot pin is above
the turntable covers. Crushing hazard. The secondary
2 Remove the secondary boom extend cylinder
become unbalanced and fall if it is
cover retaining fasteners. Remove the covers.
not properly supported when it is
Bodily injury hazard. Do not removed from the machine.
operate the machine unless the
secondary extend cylinder covers
boom lift cylinder rod can become
are properly installed. Operating
damaged if the barrel end of the
the machine with the covers
secondary boom extension
removed could result in death or
cylinder is allowed to come in
serious injury.
contact with it.

REV B BOOM COMPONENTS
4-5
Boom Extend/Retract Cables
a
How to Adjust the Boom Extend/

d
Retract Cables
Properly adjusted extend/retract cables are
essential to safe machine operation. Failure to
maintain proper adjustment of the cables could
result in unsafe operating conditions and may
cause component damage. The boom extend and
retract functions should operate smoothly and be b
A flashlight may be necessary to

be able to see the extend/retract c
cables inside of the boom a - limit switch
assembly. b - extend cable adjustment bolts
c - red cable adjustment locking bracket
Perform this procedure with the d - boom tube distance
boom fully retracted. Illustration 1
1 Start the engine from the ground controls. 9 At the pivot end of the boom (illustation 1), turn
2 Raise the boom to a horizontal position. the cable adjustment bolts (b) clockwise to
obtain 6 3/4 inches / 17 cm between the end of
3 Stop the engine. the number 3 boom tube and the end of the
4 Remove the boom end cover from the pivot end number 2 boom tube (d). As a guide (Illustration
of the machine. 2), the end of the extension cable coupling (i)
should be approximately mid-point (k) between
5 Locate the red locking bracket (c) covering the the guide plate (l) and the cable retainer bracket
cable adjustment bolts at the pivot end of the (j). Illustration 2 is visible by removing the boom
boom (illustration 1). side covers.
6 Remove the retaining fastener from the red Adjust the cable adjustment bolts
locking bracket and remove the bracket from evenly so the cable break limit
the machine. switch (a) stays centered in the
limit switch actuator (Illustration 1).
7 Locate the retract cable equalizer bolt under the
number 1 boom tube at the platform end of the If the distance is greater than 6 3/4
boom assembly (illustration 3). inches / 17 cm, loosen the extend
cable adjustment bolts and tighten
8 Loosen the nylock (g) and jam nut (h) on the
the hex jam nut on the cable
cable tension equalizer bracket. Do not remove
tension equalizer bolt until the
the nuts.
distance is less than 6 3/4 inches /
17 cm. Loosen the jam nut and
repeat step 9.

BOOM COMPONENTS REV B
i - extension cable coupling

j - cable retainer bracket
k -equal distance
l - guide plate e- boom tube 1
f- boom tube 2
Illustration 2 g- nylock nut
h- hex jam nut h g
10 At the platform end of the boom, tighten the hex
jam nut (h) on the cable tension equalizer Illustration 3
bracket located underneath the number 1 boom
tube (Illustration 3). Tighten the hex jam nut 14 Install the red locking bracket over the cable
until it is snug. Do not overtighten. adjustment bolts. A flat edge of each bolt head
11 Hold the hex jam nut with a wrench and tighten (b) must be on top for the locking bracket to
the nylock nut (g) against the hex jam nut. secure the bolts.
12 Re-check that the cable break limit switch is Bodily injury hazard. Failure to re-
centered in the limit switch actuator. Adjust the install the red cable adjustment
extension cable adjustment bolts to center it. locking bracket would allow the
cable mounting bolts to loosen and
13 At the pivot end of the boom, measure the fall out which could result in death
distance between the end of the number 3 boom or serious injury.
tube and the end of the number 2 boom tube.
15 Lower the boom to the stowed position.
Result: The measurement between the end of
the number 3 boom tube and the end of the 16 Start the engine from the platform controls.
number 2 boom tube should be
6 3/4 to 6 7/8 inches / 17 to 17.5 cm (d).

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

n Boom Tube One
from the extension cylinder assembly. Discard
the old cables and pulleys.
6 Route the new boom extend cables through the
m
boom extend pulley bracket.
m - figure 3 platform end
n - figure 2, boom tube 3 Be sure before installing the
o - figure 1, pivot end extend cables through the boom
adjustment coupling that the tall
Illustration 4
end of the cable anchors are
facing down.
7 Install the new boom extend cable pulley, pivot
pin and snap rings.
Be sure the boom extend cables
are routed through the grooves of
the pulley and the upper wear pad
on the extension cylinder.
8 Install the boom extend cables to the lower
extend cable bracket that mounts to the number
3 boom tube.

BOOM COMPONENTS
Boom retract cables: 20 Secure the number 2 and number 3 booms

together at the platform end with a chain or
9 Remove the fasteners from the boom retract strap to prevent them from moving.
cables at the platform end of the boom.
21 Install the boom extension cylinder assembly
10 Attach a rope to one of the boom retract cables into the boom.
at the pivot end of the boom.
Before lowering the extension
11 At the platform end of the boom, pull on the cylinder into the saddles of the
boom retract cable that has the rope attached number 1 boom tube, wrap the
to it. boom retract cables around the
12 Pull the old cable completely out of the boom pulleys.
tube. Discard the old boom retract cable. 22 Remove the chain or strap from the platform
13 Remove the rope from the old cable and end of the number 2 and number 3 boom tubes.
securely attach the rope to the same end of the 23 Adjust the boom extend/retract cables.
new boom retract cable. See, How to Adjust the Boom Extend/Retract
14 At the pivot end of the boom, carefully pull the Cables.
rope with the new retract cable attached.
15 Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
the boom tube. Remove the rope.
16 Repeat steps 11 through 16 for the other boom
retract cable.
17 At the platform end of the boom, install the
retract cables and fasteners to the adjustment
plate.
18 Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
19 Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.

Turntable Covers
5-1 4 Mark the location of the hinges on the bulkhead
to ensure proper cover alignment during
Turntable Covers installation.
In addition to the standard hinged turntable covers, 5 Remove the cover hinge to bulkhead retaining
there are two fixed turntable covers. One fixed fasteners.
cover protects the fuel tank on the engine side of 6 Carefully lift and remove the cover from
the machine and the other protects the turntable the machine.
rotator assembly on the ground controls side of the
machine. Crushing hazard. The turntable
cover could become unbalanced
How to Remove a Hinged and fall when it is removed from
Turntable Cover supported and secured to a
1 Raise the turntable cover. Support and secure appropriate lifting device.
the open cover to an overhead crane or forklift. Bodily injury hazard. Safety decals
Do not lift it. are essential to safe machine
Crushing hazard. Due to its heavy operation. Failure to replace all
weight, do not attempt to support safety and instructional decals
the cover by hand. could result in death or serious
injury. If a turntable cover must be
Component damage hazard. replaced, be sure that all
Protect the cover from damage by appropriate safety and
using carpet or padding on the instructional decals are applied to
crane or forklift forks. the new cover.
2 Remove the upper and lower retaining clips Alignment adjustments may be
from the gas strut. necessary when a new cover
3 Gently pry the strut pivot sockets off of the ball is installed.
studs and remove the strut. Protect the strut
cover will fall when the gas struts
are removed if it is not properly
supported.

TURNTABLE COMPONENTS
How to Remove a Fixed

Turntable Cover
1 Ground controls side: Remove the top
retaining fasteners from the power to platform
plug panel and loosen the bottom retaining
fasteners. Do not disconnect the wiring.
2 Support the cover with a suitable lifting device.
Protect the cover from damage.
3 Remove the cover mounting fasteners.
4 Carefully remove the cover from the machine.
cover may become unbalanced
supported.
Bodily injury hazard. Safety decals
are essential to safe machine
operation. Failure to replace all
safety and instructional decals
could result in death or serious
injury. If a turntable cover must be
replaced, be sure that all
appropriate safety and
instructional decals are applied to
the new cover.
Alignment adjustments may be
necessary when a new cover
is installed.

REV B
Engines
6-1 How to Remove the Flex Plate
RPM Adjustment 1 Disconnect the wiring plug at the electronic
proportional controller located on the drive
Refer to Maintenance Procedure B-12, pump.
Check and Adjust the Engine RPM.
2 Remove the hose clamp from the air cleaner
6-2 hose at the air cleaner. Carefully disconnect
the hose from the air cleaner.
Flex Plate
3 Remove the air cleaner mounting fasteners.
The flex plate couples the engine to the pump. The Remove the air cleaner from the machine.
flex plate is bolted to the engine flywheel and has a 4 Remove the fuel filter/water separator retaining
cut-out in the center for the pump coupler. fasteners from the pump mounting plate. Do
not disconnect the fuel hoses.
a b c d e
5 Remove the fuel filter/water separator and lay it
to the side.
6 Support the drive pump assembly with an
appropriate lifting device. Then remove all of
the pump mounting plate to engine bell housing
bolts.
7 Carefully pull the pump away from the engine
f
and secure it from moving.
a pump Component damage hazard.
b pump shaft
c coupler Hoses can be damaged if they are
d flex plate kinked or pinched.
e flywheel
f Deutz models- .245 inch / 6.2 mm gap 8 Remove the flex plate mounting fasteners,
Cummins or Perkins models- then remove the flex plate from the flywheel.
.255 inch / 6.5 mm gap

ENGINES REV B
1
How to Install the Flex Plate
8 3
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Apply Loctite removable thread sealant to the
mounting fasteners. Then torque the flex plate 6 5
mounting bolts in sequence to:
Cummins engines: 23 ft-lbs / 31.2 Nm.
Deutz and Perkins engines: 28 ft-lbs / 38 Nm.
4 7
3 Install the pump coupler onto the pump shaft
2
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump end
plate for your engine. Perkins Engines
Cummins Engines
4 Apply Loctite removable thread sealant to the
pump coupler set screw. Torque the set screw
to 20 ft-lbs / 27 Nm. 1
5 Install the bell housing/mounting plate

assembly. Apply Loctite removable thread 6 3
sealant to the mounting fasteners. Then torque

the pump retaining fasteners to 28 ft-lbs / 38
Nm.
Component damage hazard. Do 4 5
not force the drive pump during
installation or the flex plate teeth
may become damaged. 2
Component damage hazard. When Deutz Engines

installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.

ENGINES
6-3 6-4
Oil Pressure and Coolant Oil Pressure and Temperature
Temperature Sending Units - Sending Units - Deutz Models
The engine oil temperature sending unit is an
The coolant temperature sending unit is an electrical device. If the engine oil temperature
electrical device. If the coolant temperature reaches 275 F / 135 C, the ECM will shut the
reaches 210 F / 99 C, the ECM will shut the engine off to prevent damage and will not start until
engine off to prevent damage and will not start until the engine oil temperature drops below
the coolant temperature drops below 275 F / 135 C. The engine temperature will be
210 F / 99 C. The engine temperature will be shown on the display screen at the ground controls
shown on the display screen at the ground controls when the key is ON and the Emergency Stop Button
when the key is ON and the Emergency Stop Button is pulled out to the ON position. Use the scroll
is pulled out to the ON position. Use the scroll buttons and scroll to the Engine Temperature
buttons and scroll to the Engine Temperature screen.
screen. Component damage hazard.
Component damage hazard. Do not crank the engine with
Do not crank the engine with a oil temperature fault shown on
a water temperature fault shown the display at the ground controls.
on the display at the ground The oil pressure sending unit is an electrical
controls. device. If the oil pressure drops below
The oil pressure sending unit is an electrical 12 psi / 0.8 bar, the ECM will shut the engine off to
device. If the oil pressure drops below prevent damage. The engine oil pressure will be
12 psi / 0.8 bar, the ECM will shut the engine off to indicated on the display screen at the ground
prevent damage. The engine oil pressure will be controls while the engine is running. Use the scroll
indicated on the display screen at the ground buttons and scroll to the Engine Oil Pressure
controls while the engine is running. Use the scroll screen.
buttons and scroll to the Engine Oil Pressure Component damage hazard.
screen. Do not crank the engine with a low
Component damage hazard. oil pressure fault shown on the
Do not crank the engine with a low display at the ground controls.
oil pressure fault shown on the
display at the ground controls.

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

GROUND CONTROLS
7 Locate the ECM circuit board mounted to the 7-2

inside of the platform control box.
Membrane Decal
electrically charged circuits could The membrane decal is a special decal that
result in death or serious injury. consists of a decal with an electronic membrane
Remove all rings, watches and on the backside. The membrane contains touch
other jewelry. sensitive areas that, when pushed, activates the
Component damage hazard. machine functions. The membrane buttons
Electrostatic discharge (ESD) can activate machine functions similar to toggle
damage printed circuit board switches, but do not have any moving parts.
with a metal part of the machine How to Replace the Membrane
that is grounded at all times when Decal
use a grounded wrist strap. 1 Turn the key switch at the ground controls to
the OFF position.
8 Remove the ECM circuit board mounting
fasteners. 2 Push in the Emergency Stop button to the OFF
9 Carefully remove the ECM circuit board from controls.
the platform control box.
3 Remove the ground control box lid fasteners.
Open the control box lid.
4 Carefully disconnect the two ribbon cables from
the membrane decal at the ECM circuit board.
other jewelry.

GROUND CONTROLS
5 Carefully remove the membrane decal from the 7-3

control box lid while guiding the ribbon cables
out of the control box lid. Control Relays
6 Remove any decal adhesive from the control Relays used for single function switching are single
box lid with a mild solvent. pole double throw (SPDT) relays.
Do not allow any solvent to come
in contact with the LCD display How to Test a Single Pole Double
screen. Throw Relay
7 Install the new membrane decal (Genie part Electrocution hazard. Contact with
number 50811) while guiding the ribbon cables electrically charged circuits could
through the control box lid. result in death or serious injury.
8 Connect the ribbon cables to the ECM circuit Remove all rings, watches and
board. other jewelry.
9 Close the control box lid and install the retaining Component damage hazard.
fasteners. Electrostatic discharge (ESD) can
1 Turn the key switch to the OFF position.
2 Open the ground control box and remove the
relay to be tested from the ECM circuit board.

GROUND CONTROLS
3 Connect the leads from an ohmmeter or

continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test Desired result
terminal 85 to 86 85 to 95
terminal 87 to 87a & 30 no continuity

(infinite )
terminal 87a to 30 continuity
(zero )
4 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
terminal combinations.
Test Desired result
terminal 87 to 87a no continuity

(infinite )
terminal 87a to 30 no continuity
(infinite )
(zero )
Control Relay Schematic

Limit Switches
S-100 and S-105 Models S-120 and S-125 Models

LIMIT SWITCHES
8-1 3 Activate the limit switch. Connect the leads from

an ohmmeter or continuity tester to the deutsch
Limit Switches connector terminals in the combination listed
below and check for continuity.
How to Test the Limit Switches
There are 2 types of limit switches: Mechanical (infinite )
(roller arm) and proximity. Mechanical limit
switches are activated by a part of the machine terminal 3 to 4 continuity
physically moving the roller arm of the switch. (zero )
Proximity switches are a magnetic type of switch terminal 1 to 3 and 4 no continuity
and are activated by the close presence of a (infinite )
ferrous metal.
terminal 2 to 3 and 4 no continuity
Mechanical Operational Limit Switch: (infinite )
1 Manually activate the limit switch.

Mechanical Safety Limit Switch:
Result: The limit switch arm should move freely
and spring return to center. A distinct click 1 Connect the leads from an ohmmeter or
should be felt and heard. continuity tester to the deutsch connector
terminals in the combination listed below and
2 Connect the leads from an ohmmeter or check for continuity.
continuity tester to the deutsch connector
terminals in the combination listed below and terminal 1 to 2 continuity
check for continuity. (zero )
(zero )
(zero )
(infinite )
(infinite )
(infinite )
(infinite )
(infinite )

LIMIT SWITCHES
2 Activate the limit switch. Connect the leads from 3 Place a piece of ferrous metal (steel, iron, etc.)
an ohmmeter or continuity tester to the deutsch in front of the target area so it is no more than
connector terminals in the combination listed 1/2 inch / 12.7 mm) away from the target area of
below and check for continuity. the proximity switch.
continuity tester to the deutsch connector
(infinite )
terminals in the combination listed below and
terminal 3 to 4 no continuity check for continuity.
(infinite )
terminal 1 to 3 and 4 no continuity terminal 3 to 4 continuity
(infinite ) (zero )

(infinite ) 5 Move the piece of ferrous metal (steel, iron,
etc.) so it is more than 1/2 inch / 12.7 mm away
from the target area of the proximity switch.
Proximity Switch:
1 Connect the leads from an ohmmeter or continuity tester to the deutsch connector
continuity tester to the deutsch connector terminals in the combination listed below and
terminals in the combination listed below and check for continuity.
check for continuity.
terminal 3 to 4 no continuity (infinite )
(infinite )
2 Locate the target area of the proximity switch.

How to Adjust the Limit Switches
Perform this procedure on a flat
a
and level area and free from
obstructions.
1 Fully retract the boom.
2 Place a digital protractor or digital level on top of
the boom tube.
Proximity switch
a target area

LIMIT SWITCHES
S-120 and S-125 models: All models:

3 Raise boom until the protractor reads 67.5 14 S-100 and S-105 models: Raise the boom to
degrees. 52.5 degrees.
4 Loosen the mounting fasteners from the 68 15 Loosen the mounting fasteners from the 53
degree proximity switch (LSB14AO). degree proximity switch (LSB13AO).
5 Disconnect the deutsch connector from the 68 16 Disconnect the deutsch connector from the 53
degree proximity switch (LSB14AO) and degree proximity switch (LSB13AO) and
connect an ohmmeter or continuity tester to connect an ohmmeter or continuity tester to
terminals 3 and 4 of the deutsch connector. terminals 3 and 4 of the deutsch connector.
6 Adjust LSB14AO until the switch contacts just 17 Adjust LSB13AO until the switch contacts just
open. While observing the digital protractor, open. While observing the digital protractor,
raise the boom until the switch contacts close, raise the boom until the switch contacts close,
then lower the boom until the switch contacts then lower the boom until the switch contacts
open. Repeat the process until the switch open. Repeat the process until the switch
contacts open between 67.5 and 68 degrees. contacts open between 52.5 and 53 degrees.
7 Tighten the 68 degree proximity switch 18 Tighten the 53 degree limit switch mounting
(LSB14AO) mounting fasteners. fasteners.
8 Lower the boom to 65.3 degrees. 19 Lower the boom to 50.3 degrees.
9 Loosen the mounting fasteners from the 65 20 Loosen the mounting fasteners from the 50
degree safety switch (LSB9AS). degree safety switch (LSB8AS).
10 Disconnect the deutsch connector from the 65 21 Disconnect the deutsch connector from the 50
degree safety switch (LSB9AS) and connect an degree safety switch (LSB8AS) and connect an
ohmmeter or continuity tester to terminals 1 and ohmmeter or continuity tester to terminals 1 and
2, and to terminals 3 and 4 of the deutsch 2, and to 3 and 4 of the deutsch connector.
connector.
22 Adjust LSB8AS until the switch contacts just
11 Adjust LSB9AS until the switch contacts just open. While observing the digital protractor,
open. While observing the digital protractor, raise the boom until the switch contacts close,
raise the boom until the switch contacts close, then lower the boom until the switch contacts
then lower the boom until the switch contacts open. Repeat the process until the switch
open. Repeat the process until the switch contacts open between 50 and 50.5 degrees.
contacts open between 65 and 65.5 degrees.
12 Tighten the 65 degree safety switch mounting
fasteners.
13 Lower the boom to 52.5 degrees.

LIMIT SWITCHES REV B
Limit Switch and Angle Sensor

Legend
LSB3RO
LSB3EO
LSB4EO
LSB3RS
LSB4ES
LSB9AS
LSB8AS
LSB7DS LSB1DO
LSB14AO LSB13AO
LSB19LO
LSB6S
LSB2RO
LSB19LO LSB2RS
LSAX2ES PLATFORM
LSAX1EO TURNTABLE LEVEL
LSAX1ES LEVEL LSAX2RO SENSOR
LSAX1RO SENSOR
LSAX2EO
LST1O

REV B LIMIT SWITCHES
Switch Locations: Switch Functions:

Located under the drive chassis end cover at the LSAX1RO: Operational Limit Switch, Front Axle,
center of the square end (blue): LSAX1RO, Retract. This switch activates when the axle is fully
LSAX1EO, LSAX1ES retracted, activating axle retracted LED and
shutting off power to axle retract coils after two
Located under the drive chassis end cover at the
seconds.
center of the round end (yellow): LSAX2RO,
LSAX2EO, LSAX2ES LSAX2RO: Operational Limit Switch, Rear Axle,
Retract. This switch activates when the axle is fully
Located in the center of the swing chassis: LST1O
retracted, activating axle retracted LED and
Located on the hydraulic tank tray: shutting off power to axle retract coils after two
Turntable Level Sensor seconds.
Located on the inside of the swing chassis bulk- LSAX1EO: Operational Limit Switch, Front Axle,
head at the counterweight end: LSB9AS, LSB8AS Extend. This switch is activated when the axle is
fully extended. If this switch is not activated, boom
Located at the base of the swing chassis near the functions are restricted to the stowed range. If unit
counterweight: LSB1LO is out of stowed, all boom functions are disabled.
Located at the counterweight end of Boom tube 0: Axle can be extended while driving to recover.
LSB6S LSAX2EO: Operational Limit Switch, Rear Axle,
Located on the counterweight side of the lift Extend. This switch is activated when the axle is
cylinder support assembly: LSB1DO, LSB7DS, fully extended. If this switch is not activated, boom
LSB13AO, LSB14AO functions are restricted to the stowed range. If unit
is out of stowed, all boom functions are disabled.
Located on the outside of the platform end of Boom Axle can be extended while driving to recover.
tube 0:
LSB2RO, LSB2RS LSAX1ES: Safety Limit Switch, Front Axle,
Extend. If this switch is tripped, then the axle is not
Located on the top of the platform end of Boom fully extended. In this condition, if unit is out of
tube 2: stowed, power is cut to boom up, boom extend and
LSB3EO, LSB3RS, LSB3RO, LSB2RO, LSB4ES axle retract.
Located on the platform rotator: Platform Level LSAX2ES: Safety Limit Switch, Rear Axle,
Sensor Extend. If this switch is tripped, then the axle is not
fully extended. In this condition, if unit is out of
stowed, power is cut to boom up, boom extend and
axle retract.

LIMIT SWITCHES REV B
LSB6S: Safety Limit Switch, Cable Tension. Cuts LSB9AS: Safety Limit Switch, 65O Angle. This
power to the extend directional valve if extend switch cuts power to boom extend, boom down and
cables are out of adjustment or one breaks. the engine fuel solenoid when it is mechanically
activated at 65O if the boom length is more than
LSB1DO: Operational Limit Switch, 10O Angle.
101 feet.
This switch activates anytime the boom is raised
above 10O. If axles are not extended, boom up is LSB3RO: Operational Limit Switch, 3 Extend.
disabled and the extend axle LED and icon will This switch activates anytime the boom is ex-
flash as long as boom up is operated. At this point, tended beyond 3 feet. If axles are not extended,
if axles are extended, the motors are shifted to low boom extend is disabled and the extend axle LED
and drive speed is limited to 0.7 mph. and icon will flash as long as boom extend is
operated. If axles are extended at this point, the
LSB7DS: Safety Limit Switch, 11O Angle. If axles
motors are shifted to low and drive speed is limited
are not extended, this switch is activated when
to 0.7 mph. The boom up/down speed and turntable
boom is raised to 11O, cutting power to boom up
rotate speed are limited to 60% of maximum.
and axle retract.
LSB3RS: Safety Limit Switch, 3.5 Extend. If
LSB13AO: Operational Limit Switch, 53O Angle.
axles are not extended, this switch is activated
This switch activates at 53O boom angle, allowing
when the boom is extended beyond 3.5 feet, cutting
the boom to be extended beyond 75 feet. If the
power to boom extend and axle retract.
boom is lowered past this switch when the boom is
beyond 75 feet, boom extend and boom down are LSB3EO: Operational Limit Switch, 75 Extend.
disabled. The retract boom LED and icon and alarm This switch activates anytime the boom is ex-
will flash as long as boom down is operated. tended to 75 feet or beyond. At this point drive
speed is reduced to 0.4 mph, boom up/down is
LSB8AS: Safety Limit Switch, 50O Angle. This
reduced to 29% of maximum and turntable rotate is
switch cuts power to boom extend, boom down and
reduced to 40% of maximum. If boom angle is less
the engine fuel solenoid when it is mechanically
than 53O, then boom extend is disabled and the
activated at 50O if the boom length is more than
raise boom LED and icon and alarm will flash as
75.5 feet.
long as boom extend is operated.
LSB14AO: Operational Limit Switch, 68O Angle.
LSB4ES: Safety Limit Switch, 75.5 Extend. This
This switch is activated at 68O boom angle and
allows the boom to be extended beyond 100 feet. If
engine fuel solenoid when it is mechanically
the boom is lowered past this switch when ex-
activated at 75.5 feet, if boom angle is less than
tended beyond 100 feet, boom extend and boom
50O.
down are disabled. The boom retract LED and icon
and alarm will flash as long as boom down is
operated.

REV B
LSB4EO: Operational Limit Switch, 100 Extend.

This switch activates anytime the boom is ex-
tended to 100 feet or beyond. The boom up/down is
reduced to 20% of maximum. If boom angle is less
than 68O, then boom extend is disabled and the
raise boom LED and icon and alarm will flash as
long as boom extend is operated. If boom angle is
greater than 65O, the BO lockout valve will activate
allowing hydraulic flow to the external cylinder to
continue to extend to 120 feet.
LSB2RS: Safety Limit Switch, 101 Extend. This
engine fuel solenoid when it is mechanically
activated at 101 feet, if boom angle is less than
65O.
LSB2RO: Operational Limit Switch, 100 Retract.
This switch is activated anytime boom length is
100 or less. Anytime the boom is being retracted
while this switch is activated, the BN lockout valve
is activated allowing hydraulic flow out of the inner
cylinder.
LSB19LO: Operational Limit Switch, Down Over-
load. This switch disables all functions except
boom retract and boom up and activates a medium
frequency alarm and the boom down overload
diagnostic code.
LST1O: Operational Limit Switch, Drive Enable.
This switch is activated when the turntable is
rotated in the standard drive zone.
Turntable Level Sensor: Measures the X axis and
Y axis of the turntable. The alarm sounds at 4.5O.
Platform Level Sensor: Measures the angle of
the platform. The range of measurement is +/- 20O.
The safety cutout is set at +/- 10O from gravity and
will disable the primary and secondary boom up/
down functions and the platform level up/down
functions.

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

engine must not be started with
the hydraulic tank shutoff valves in
the CLOSED position or component
damage will occur.
If the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.

HYDRAULIC PUMPS
9-2 2 Disconnect the electrical connection at the

electronic displacement controller (EDC)
Drive Pump located on the drive pump.
The drive pump is a bi-directional variable 3 Close the two hydraulic tank valves located at
displacement piston pump. The pump output is the hydraulic tank.
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Call the Genie
Industries Service Department to locate your local
authorized service center. open closed
How to Remove the Drive Pump Component damage hazard. The

Component damage hazard. The the hydraulic tank shutoff valves in
work area and surfaces where this the CLOSED position or component
procedure will be performed must damage will occur. If the tank
be clean and free of debris that valves are closed, remove the key
could get into the hydraulic system from the key switch and tag the
and cause severe component machine to inform personnel of the
damage. Dealer service is condition.
recommended.
When removing a hose assembly from the drive pump. Cap the fittings on the
or fitting, the O-ring on the fitting pump.
and then torqued to specification Bodily injury hazard. Spraying
during installation. hydraulic oil can penetrate and
Refer to Section Two, Hydraulic burn skin. Loosen hydraulic
Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
1 Remove the function pumps. See How to squirt or spray.
Remove the Function Pumps.
5 Support the drive pump with a suitable lifting
device and remove the two drive pump
mounting fasteners.

HYDRAULIC PUMPS
6 Carefully pull the drive pump out until the pump Cummins and Perkins models:
coupler separates from the flex plate.
7 Remove the drive pump from the machine. fastener. Swing the engine pivot plate out away
from the machine to access the fuel injection
pump.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
Before installing the pump, verify
proper pump coupler spacing.
Refer to the appropriate flex plate
installation instructions for your
engine.
a b
How to Prime the Pumps
Component damage hazard. Be a engine pivot plate anchor hole
sure that the hydraulic tank shutoff b engine pivot plate retaining fastener
valves are in the OPEN position 3 Locate the engine pivot plate anchor hole at the
before priming the pump. The pivot end of the engine pivot plate.
the hydraulic tank shutoff valves in 4 Install the bolt that was just removed into the
the CLOSED position or component anchor hole to secure the engine pivot plate
damage will occur. from moving.
serious injury.
open closed
1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to one of the test ports located under the
drive pump.

HYDRAULIC PUMPS
5 Deutz models: Disconnect the engine wiring

harness from the fuel shutoff solenoid at the
injector pump.
Perkins models
a fuel shutoff solenoid
6 Have another person crank the engine with the

starter motor for 15 seconds, wait 15 seconds,
Deutz models then crank the engine an additional 15 seconds
or until the pressure reaches 250 psi / 17.2 bar.
Cummins and Perkins models: Disconnect
Bodily injury hazard. Keep hands,
the wire from the fuel shutoff solenoid at the
loose clothing and hair clear of all
injector pump.
moving engine parts while the
engine is cranking.
7 Deutz models: Connect the engine wiring
harness to the fuel shutoff solenoid at the
injector pump.
Cummins and Perkins models: Connect the
wire to the fuel shutoff solenoid at the injector
pump.
8 Start the engine and check for hydraulic leaks.
Cummins models

HYDRAULIC PUMPS
9-3 4 Activate any function using auxiliary power.

Auxiliary Pump Result: If the pressure gauge reads 2500 psi /
172 bar, immediately stop. The pump is good.
How to Test the Auxiliary Pump Result: If pressure fails to reach 2500 psi
/ 172 bar, the internal relief valve setting is
The auxiliary pump is a 2-section, gear-type pump. incorrect or the pump is bad and will need to be
Pump number 1 is the pump section closest to the serviced or replaced.
pump motor and pump number 2 is the pump
section that is farther from the pump motor. Each 5 Turn the key switch to the OFF position.
section of the pump has its own relief valve located
6 Remove the pressure gauge and reconnect the
within the pump body.
hydraulic hose.
When removing a hose assembly 7 Disconnect the hydraulic hose from the high
or fitting, the O-ring on the fitting pressure port from pump number 2.
and then torqued to specification 8 Connect a 0 to 5000 psi / 0 to 345 bar pressure
during installation. gauge to the high pressure port on pump
Refer to Section Two, Hydraulic number 2.
Hose and Fitting Torque 9 Turn the key switch to ground control and pull
Specifications. out the Emergency Stop button to the ON
1 Disconnect and plug the high pressure position.
hydraulic hose from pump number 1. 10 Activate any function using auxiliary power.
Bodily injury hazard. Spraying Result: If the pressure gauge reads 3000 psi /
hydraulic oil can penetrate and 207 bar, immediately stop. The pump is good.
connections very slowly to allow Result: If pressure fails to reach 3000 psi
the oil pressure to dissipate / 207 bar, the internal relief valve setting is
gradually. Do not allow oil to squirt incorrect or the pump is bad and will need to be
or spray. serviced or replaced.
2 Connect a 0 to 5000 psi / 0 to 345 bar pressure 11 Remove the pressure gauge and reconnect the
gauge to the high pressure port on pump hydraulic hose.
number 1.
position.

HYDRAULIC PUMPS
How to Remove the Auxiliary 2 Connect 12V DC to the small post and a ground
wire to the relay case, then test the following
Pump terminal combination.
1 Open the ground controls side turntable cover.
Test Desired result
from the pumps. 2 large posts continuity (zero )
3 Remove the pump mounting fasteners and

remove the pump from the pump motor. a b a
9-4
Power Relay
other jewelry.
How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery
before performing this procedure.
a high amp power contact terminal
1 Connect the leads from an ohmmeter to each (large post)
b solenoid activate coil terminal
terminal combination and check for continuity. (small post)
Test Desired result
small post to relay case 12 to 18

2 large posts no continuity
(infinite )
small post to no continuity
any large post (infinite )

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

Specification
Description Specification
Solenoid valve, 3 position 4 way, 12V DC 9

(schematic item FB and FC)
Proportional solenoid valve, 12V DC 5

(schematic item FF)
3 position 4 way D03 valve, 12V DC 4.6

(schematic item FD)
Proportional solenoid valve, 12V DC 5.4

(schematic item FG)

MANIFOLDS
1 2 3 4
FA FB FC FD
FE
FR 5
17
FQ
16
FF
6
FG
FP 7
15
FH
8
FI
9
FJ
10
FK
11
FM FL
12
14
TP
13

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

Index Schematic
11 Orifice - plug,
0.040 inch / 1.02 mm ......................... FK ........ Differential sensing dampening
12 Check valve ....................................... FL ......... Load sensing circuit,
turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm
13 Diagnostic Nipple ............................................. Testing
14 Check valve ....................................... FM ........ Load sensing circuit,
boom extend/retract .......................... 12-14 ft-lbs / 16-19 Nm
15 Differential sensing valve .................. FP ......... Directs flow to functions .................... 25-27 ft-lbs / 34-37 Nm
16 Solenoid valve, 2 position 3 way ...... FQ ......... Boom retract control ......................... 25-27 ft-lbs / 34-37 Nm
17 Solenoid valve, 2 position 3 way ...... FR ......... Boom extend control ........................ 52-60 ft-lbs / 71-82 Nm

Specification
Solenoid valve, 2 position 3 way, 12V DC 3.4 to 5.4

(schematic item FQ and FR)

MANIFOLDS
1 2 3 4
FA FB FC FD
FE
FR 5
17
FQ
16
FF
6
FG
FP 7
15
FH
8
FI
9
FJ
10
FK
11
FM FL
12
14
TP
13

MANIFOLDS
10-2 How to Adjust the Boom Extend

Valve Adjustments - Function Relief Valve
Manifold, S-100 and S-105 Models Perform this procedure with the
How to Adjust the Function 1 Connect a 0 to 3000 psi / 0 to 207 bar pressure
Manifold Relief Valve gauge to the test port on the function manifold.
3 Fully raise and extend the boom.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
4 Simultaneously push and hold the function
gauge to the test port on the function manifold.
enable/high speed button and the boom extend
2 Start the engine from the ground controls. button with the boom fully extended. Observe
the pressure reading on the pressure gauge.
3 Simultaneously push and hold the function Refer to Section 2, Hydraulic Specifications.
enable/high speed button and the boom retract
button with the boom fully retracted. Observe 5 Turn the engine off. Use a wrench to hold the
the pressure reading on the pressure gauge. relief valve and remove the cap (item FA).
Refer to Section 2, Hydraulic Specifications.
6 Adjust the internal hex socket. Turn it clockwise
4 Turn the engine off. Use a wrench to hold the to increase the pressure or counterclockwise to
relief valve and remove the cap (item FI). decrease the pressure. Install the relief valve
cap.
to increase the pressure or counterclockwise to Tip-over hazard. Do not adjust
decrease the pressure. Install the relief valve the relief valve higher than
cap. specified.
Tip-over hazard. Do not adjust 7 Repeat steps 2 through 6 to confirm the relief
the relief valve higher than valve pressure.
specified.
6 Repeat steps 2 through 5 to confirm the relief
valve pressure.

MANIFOLDS
10-3
Proportional Valves -
Function Manifold
When a proportional valve cartridge
or coil is replaced or moved to a
different valve cartridge or cavity,
the proportional valve cartridge or
coil will need to be calibrated. See
1-3, How to Calibrate a Joystick
Controller.

MANIFOLDS
10-4
Function Manifold Components, S-120 and S-125 Models
Index Schematic
1 Relief valve, 1800 psi / 124.1 bar ..... BA ........ Boom extend pressure limit .............. 18-20 ft-lbs / 24-27 Nm
2 Proportional solenoid valve .............. BB ......... Boom extend/retract
proportional speed control ............... 33-37 ft-lbs / 45-50 Nm
3 Solenoid valve, 3 position 4 way ...... BC ........ Turntable rotate left/right .................. 25-27 ft-lbs / 34-37 Nm
4 DO3 valve, 3 position 4 way ............. BD ........ Boom up/down .................................... 30-35 in-lbs / 3-4 Nm
5 Priority flow regulator valve,
0.1 gpm / 0.38 L/min .......................... BE ......... Bleeds off differential
sensing valves to tank ...................... 18-20 ft-lbs / 24-27 Nm
6 Proportional solenoid valve .............. BF ......... Boom up/down proportional
7 Proportional solenoid valve .............. BG ........ Turntable rotate proportional
8 Counterbalance valve,
3200 psi / 220.6 bar .......................... BH ........ Boom down circuit ............................ 30-35 ft-lbs / 38-41 Nm
9 Relief valve, 2600 psi / 179.3 bar ..... BI .......... Turntable rotate, boom lift and
boom retract pressure limit ............... 25-27 ft-lbs / 34-37 Nm
10 Check valve ....................................... BJ ......... Load sensing circuit,
boom up/down .................................. 12-14 ft-lbs / 16-19 Nm
11 Orifice - plug,
0.040 inch / 1.02 mm ......................... BK ........ Differential sensing dampening

Specification
Proportional solenoid valve, 12V DC 3.3 to 5.3

(schematic item BB and BF) (5 ohm)

(schematic item BC) (7.2 ohm)
3 position 4 way D03 valve, 12V DC 3.3 to 5.3

(schematic item BD)
Proportional solenoid valve, 12V DC 4.3 to 6.3

(schematic item BG) (9.8 ohm)

MANIFOLDS
1 2 3 4
BA BB BC BD
BE
5
BR
19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
8
BI
9
BJ
10
BK
11
BN BM BL TP
15 14 13 12

MANIFOLDS
Function Manifold Components, S-120 and S-125 Models, continued

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

13 Check valve ....................................... BL ......... Load sensing circuit,
turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm
14 Check valve ....................................... BM ........ Load sensing circuit,
boom extend/retract .......................... 12-14 ft-lbs / 16-19 Nm
15 Solenoid valve, N.C. Poppet ............. BN ........ Boom retract sequence control ........ 33-37 ft-lbs / 45-50 Nm
16 Solenoid valve, N.C. Poppet ............. BO ........ Boom extend sequence control ....... 33-37 ft-lbs / 45-50 Nm
17 Differential sensing valve .................. BP ......... Directs flow to functions .................... 25-27 ft-lbs / 34-37 Nm
18 Solenoid valve, 2 position 3 way ...... BQ ........ Boom retract control ......................... 52-60 ft-lbs / 71-82 Nm
19 Solenoid valve, 2 position 3 way ...... BR ........ Boom extend control ........................ 52-60 ft-lbs / 71-82 Nm

Specification

(schematic item BN and BO) (7.2 ohm)

(schematic item BQ and BR) (4.6 ohm)

MANIFOLDS
1 2 3 4
BA BB BC BD
BE
5
BR
19
BQ
18
BF
6
BP
17
BG
7
BO
16
BH
8
BI
9
BJ
10
BK
11
BN BM BL TP
15 14 13 12

MANIFOLDS
10-5 How to Adjust the Boom Extend

Valve Adjustments - Function Relief Valve
Manifold, S-120 and S-125 Models Perform this procedure with the
How to Adjust the Function 1 Connect a 0 to 3000 psi / 0 to 207 bar pressure
Manifold Relief Valve gauge to the test port on the function manifold.
3 Fully raise and extend the boom.
gauge to the test port on the function manifold.
enable/high speed button and the boom extend
2 Start the engine from the ground controls. button with the boom fully extended. Observe
the pressure reading on the pressure gauge.
3 Simultaneously push and hold the function Refer to Section 2, Hydraulic Specifications.
enable/high speed button and the boom retract
button with the boom fully retracted. Observe 5 Turn the engine off. Use a wrench to hold the
the pressure reading on the pressure gauge. relief valve and remove the cap (item BA).
Refer to Section 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the to increase the pressure or counterclockwise to
relief valve and remove the cap (item BI). decrease the pressure. Install the relief valve
cap.
to increase the pressure or counterclockwise to Tip-over hazard. Do not adjust
decrease the pressure. Install the relief valve the relief valve higher than
cap. specified.
Tip-over hazard. Do not adjust 7 Repeat steps 2 through 6 to confirm the relief
the relief valve higher than valve pressure.
specified.
valve pressure.

MANIFOLDS
10-6
Function Manifold
When a proportional valve cartridge
or coil is replaced or moved to a
different valve cartridge or cavity,
the proportional valve cartridge or
coil will need to be calibrated. See
1-3, How to Calibrate a Joystick
Controller.

MANIFOLDS
10-7
Distribution Manifold Components
The distribution manifold is mounted above the function manifold on the turntable cover support plate at
the ground controls side of the machine.
Index Schematic
1 Solenoid valve,
2 position 3 way N.O. Poppet ............ JA ......... Auxiliary drive/steer selector ............ 30-35 ft-lbs / 41-47 Nm
2 Check valve, 50 psi / 3.45 bar ........... JB ......... Blocks flow from pump 1
and 2 to auxiliary pump .................... 20-25 ft-lbs / 27-34 Nm
3 Relief valve, 3000 psi / 206.8 bar ..... JC ......... Platform manifold relief ..................... 20-25 ft-lbs / 27-34 Nm
4 Diagnostic Nipple .............................. TP ......... Testing
5 Flow regulator, 3 gpm / 11.34 L/Min . JD ......... Priority flow to platform
manifold ............................................ 30-35 ft-lbs / 41-47 Nm
6 Check valve ....................................... JE ......... Blocks flow from pump 2
to auxiliary pump ................................ 8-10 ft-lbs / 11-14 Nm
7 Check valve, 50 psi / 3.45 bar ........... JF ......... Blocks flow from auxiliary
pump, (port 2A and 3A) to
pump 2 (port P2) ............................... 30-35 ft-lbs / 41-47 Nm
8 Check valve, 50 psi / 3.45 bar ........... JG ......... Blocks flow from auxiliary
pump, (port 2A) to
pump 1 (port P1) ............................... 30-35 ft-lbs / 41-47 Nm

Specification
Solenoid valve,
2 position 3 way N.O. Poppet 12V DC 7.5 to 9.5
(schematic item JA)

MANIFOLDS
AA
1
AG
8
AF
7 AB
2
AC
3
AE
6
TP
4
AD
5

MANIFOLDS
10-8
Valve Adjustments -
Distribution Manifold
How to Adjust the Distribution

Manifold Relief Valve
gauge to the P1 test port at the platform
manifold.
enable/high speed button and the platform level
up button with the platform fully leveled in the
UP direction. Observe the pressure reading on
the pressure gauge. Refer to Section 2,
Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item AC).
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
valve pressure.

MANIFOLDS

MANIFOLDS
10-9
Platform Manifold Components, S-100 and S-120 Models
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
1 Proportional solenoid valve,

3 position 4 way ................................ GH ........ Platform level up/down ..................... 18-20 ft-lbs / 24-27 Nm
2 Check valve ....................................... GF ......... Platform rotate circuit
3 Check valve ....................................... GJ ......... Platform level circuit
4 Accumulator, 500 psi / 34.5 bar ........ GM ........ Hydraulic dampening .................................. 23 ft-lbs / 31 Nm
5 Differential sensing valve, N.O. ......... GI .......... Platform level differential
sensing circuit ................................... 23-25 ft-lbs / 31-34 Nm
6 Differential sensing valve, N.O. ......... GE ........ Platform rotate differential
7 Orifice - plug, 0.030 inch / 0.762 mm GB ........ Platform rotate left circuit
8 Orifice - plug, 0.030 inch / 0.762 mm GC ........ Platform rotate right circuit
9 Shuttle valve ...................................... GG ........ Platform level load sense circuit ....... 7.4-9 ft-lbs / 10-12 Nm
10 Shuttle valve ...................................... GA ........ Platform rotate load sense circuit ...... 7.4-9 ft-lbs / 10-12 Nm
11 Differential sensing valve, N.C. ......... GC ........ Directs flow to functions .................... 23-25 ft-lbs / 31-34 Nm
3 position 4 way ................................ GD ........ Platform rotate left/right ..................... 18-20 ft-lbs / 24-27 Nm
When a proportional valve

cartridge or coil is replaced or
moved to a different valve
cartridge or cavity, the proportional
valve cartridge or coil will need to
be calibrated.
See 1-3, How to Calibrate a
Joystick Controller.

Specification
Proportional solenoid valve,

3 position 4 way 12V DC 4.4 to 6.4
(schematic items GD and GH)

MANIFOLDS
1 2 3 4
GH GF GJ GQ
GD
12
GO
11
GI
5
GE
6
GA GG GC GB
10 9 8 7

MANIFOLDS
10-10
Platform Manifold Components, S-105 and S-125 Models
The platform manifold is mounted to the platform mounting weldment.
Index Schematic

3 position 4 way ................................ CH ........ Platform level up/down ..................... 18-20 ft-lbs / 24-27 Nm
2 Check valve ....................................... CF ......... Platform rotate circuit
3 Check valve ....................................... CJ ......... Platform level circuit
3 position 4 way ................................ CL ......... Jib boom up/down ............................ 18-20 ft-lbs / 24-27 Nm
5 Check valve ....................................... CN ........ Jib boom circuit
6 Accumulator, 500 psi / 34.5 bar ........ CQ ........ Hydraulic dampening .................................. 23 ft-lbs / 31 Nm
7 Differential sensing valve, N.O. ......... CM ........ Jib boom differential
8 Differential sensing valve, N.O. ......... CI .......... Platform level differential
9 Flow control valve,
0.1 gpm / 0.38 L/min .......................... CP ........ Bleeds off differential sensing
valve to tank
10 Differential sensing valve, N.O. ......... CE ........ Platform rotate differential
11 Shuttle valve ...................................... CK ........ Jib boom load sense circuit
12 Orifice - plug, 0.030 inch / 0.762 mm CB ........ Platform rotate left circuit
13 Orifice - plug, 0.030 inch / 0.762 mm CC ........ Platform rotate right circuit
14 Shuttle valve ...................................... CG ........ Platform level load sense circuit ....... 7.4-9 ft-lbs / 10-12 Nm
15 Shuttle valve ...................................... CA ........ Platform rotate load sense circuit ...... 7.4-9 ft-lbs / 10-12 Nm
16 Differential sensing valve, N.C. ......... CO ........ Directs flow to functions .................... 23-25 ft-lbs / 31-34 Nm
3 position 4 way ................................ CD ........ Platform rotate left/right ..................... 18-20 ft-lbs / 24-27 Nm

Specification
Proportional solenoid valve,

3 position 4 way 12V DC 4.4 to 6.4
(schematic items CD, CH and CL)

MANIFOLDS
1 2 3 4 5 6
CH CF CJ CL CN CQ
CD
17
CO
16
CM
7
CI
8
CP
9
CE
10
CA CG CC CB CK
15 14 13 12 11

MANIFOLDS
10-11
Platform Manifolds
When a proportional valve
cartridge or coil is replaced or
moved to a different valve
cartridge or cavity, the
proportional valve cartridge or coil
will need to be calibrated. See 1-3,
How to Calibrate a Joystick
Controller.
10-12
Platform Rotate Counterbalance Valve Manifold Components
Index Schematic
1 Counterbalance valve ....................... A ........... Platform rotate left ............................. 37-44 ft-lbs / 50-60 Nm
2 Counterbalance valve ....................... B ........... Platform rotate right .......................... 37-44 ft-lbs / 50-60 Nm
123
123
123
123
A
123
A
1
1234
B 1234
1234
1234
B
2 1234

MANIFOLDS
10-13
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
1 Counterbalance valve ....................... A ........... Turntable rotate left ........................... 37-44 ft-lbs / 50-60 Nm
2 Counterbalance valve ....................... B ........... Turntable rotate right ........................ 37-44 ft-lbs / 50-60 Nm
3 Shuttle valve, 2 position 3 way ......... C ........... Turntable rotation brake release ...... 10-12 ft-lbs / 14-16 Nm
12345
12345
12345
12345
A
12345
A
1
12345 123456
12345
12345 123456
123456
12345 123456
B B
12345
C 123456
12345
2
C
3

MANIFOLDS
10-14
Steer and Axle Extend/Retract Manifold Components - View 1
The steer and axle extend/retract manifold is mounted inside the drive chassis at the square end
of the machine.
Index Schematic
1 Solenoid valve, 3 position 4 way ...... EA ........ Right front steer circuit ...................... 18-20 ft-lbs / 24-27 Nm
2 Solenoid valve, 3 position 4 way ...... EB ........ Left front steer circuit ........................ 18-20 ft-lbs / 24-27 Nm
3 Solenoid valve, 3 position 4 way ...... EC ........ Right rear steer circuit ...................... 18-20 ft-lbs / 24-27 Nm
4 Solenoid valve, 3 position 4 way ...... ED ........ Left rear steer circuit ......................... 18-20 ft-lbs / 24-27 Nm
5 Flow regulator valve,
2 gpm / 7.6 L/min ............................... EE ......... Controls the left rear steer
cylinder extend speed ...................... 18-20 ft-lbs / 24-27 Nm
6 Check valve ....................................... EF ......... Left rear steer
cylinder retract circuit ........................ 18-20 ft-lbs / 24-27 Nm
7 Check valve, pilot operated .............. EG ........ Left rear steer
cylinder extend/retract circuit ............ 18-20 ft-lbs / 24-27 Nm
8 Check valve, pilot operated .............. EH ........ Right rear steer
cylinder extend/retract circuit ............ 18-20 ft-lbs / 24-27 Nm
9 Check valve ....................................... EI .......... Right rear steer
1.4 gpm / 5.3 L/min ............................ EJ ......... Controls the right rear steer
cylinder retract speed ....................... 18-20 ft-lbs / 24-27 Nm

Specification
Solenoid valve, 3 position 4 way 12V DC 8.9 to 10.9

(schematic items EA, EB, EC and ED)

MANIFOLDS
1 2 3 4
EA EB EC ED
ES
19
ER
18
EQ
17
EP
16
EO
15
EN
14
EM
13
EL
12
EK EJ EI EH EG EF EE
11 10 9 8 7 6 5

MANIFOLDS
Steer and Axle Extend/Retract Manifold Components - View 1,

continued
of the machine.
Index Schematic
11 Check valve, pilot operated .............. EK ......... Front left steer

cylinder extend circuit ....................... 18-20 ft-lbs / 24-27 Nm
12 Check valve ....................................... EL ......... Front left steer
13 Check valve, pilot operated .............. EM ........ Front right steer
cylinder extend circuit ....................... 18-20 ft-lbs / 24-27 Nm
14 Check valve ....................................... EN ........ Front right steer
0.1 gpm (0.38 L/min) ......................... EO ........ Pressurizes pilot lines to
check valves ..................................... 18-20 ft-lbs / 24-27 Nm
16 Differential sensing valve .................. EP ......... Differential sensing circuit ................ 25-27 ft-lbs / 34-37 Nm
1.4 gpm (5.3 L/min) ........................... EQ ........ Controls the left front steer
2 gpm / 7.6 L/min ............................... ER ........ Controls the right front steer
19 Solenoid valve, 3 position 4 way ...... ES ......... Axle extend/retract ............................ 25-27 ft-lbs / 34-37 Nm

Specification

(schematic items ES)

MANIFOLDS
1 2 3 4
EA EB EC ED
ES
19
ER
18
EQ
17
EP
16
EO
15
EN
14
EM
13
EL
12
EK EJ EI EH EG EF EE
11 10 9 8 7 6 5

MANIFOLDS
10-15
Steer and Axle Extend/Retract Manifold Components - View 2
of the machine.
Index Schematic

1.4 gpm / 5.3 L/min ............................ ET ......... Controls the left rear steer
2 gpm / 7.6 L/min ............................... EU ........ Controls the right rear steer
2 gpm / 7.6 L/min ............................... EV ......... Controls the left front steer
1.4 gpm / 5.3 L/min ............................ EW ........ Controls the right front steer
5 Check valve ....................................... EX ......... Load sense circuit for
front and rear axle extend ................ 12-14 ft-lbs / 16-19 Nm
6 Check valve ....................................... EY ......... Load sense circuit for
front and rear axle retract ................. 12-14 ft-lbs / 16-19 Nm
7 Relief valve, 2200 psi / 152 bar ........ EQQ ...... Axle extend circuit ............................ 18-20 ft-lbs / 24-27 Nm
8 Relief valve, 3000 psi / 207 bar ........ EZ ......... Steer and axle retract relief .............. 18-20 ft-lbs / 24-27 Nm
9 Check valve ....................................... EAA ...... Controls extend reverse flow to
the right front steer cylinder .............. 18-20 ft-lbs / 24-27 Nm
10 Check valve, pilot operated .............. EBB ...... Right front steer cylinder
extend lock ....................................... 18-20 ft-lbs / 24-27 Nm
11 Check valve ....................................... ECC ...... Controls retract reverse flow to
the left front steer cylinder ................ 18-20 ft-lbs / 24-27 Nm

MANIFOLDS
1 2 3 4 5 6
ET EU EV EW EX EY
EQQ
7
EZ
8
EAA
9
EBB
10
ECC
11
EDD
12
EEE
13
EPP EFF
24 14
EGG
15
EOO ENN EMM ELL EKK EJJ EII EHH

23 22 21 20 19 18 17 16

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

continued
of the machine.
Index Schematic
12 Check valve, pilot operated .............. EDD ...... Left front steer cylinder
retract lock ........................................ 18-20 ft-lbs / 24-27 Nm
13 Check valve ....................................... EEE ...... Controls retract reverse flow to
the right rear steer cylinder ............... 18-20 ft-lbs / 24-27 Nm
14 Check valve, pilot operated .............. EFF ....... Right rear steer cylinder
retract lock ........................................ 18-20 ft-lbs / 24-27 Nm
15 Check valve ....................................... EGG ...... Controls extend reverse flow to
the left rear steer cylinder ................. 18-20 ft-lbs / 24-27 Nm
16 Check valve, pilot operated .............. EHH ...... Left rear steer cylinder
extend lock ....................................... 18-20 ft-lbs / 24-27 Nm
17 Check valve ....................................... EII ......... Right front steer cylinder retract
load sense circuit .............................. 12-14 ft-lbs / 16-19 Nm
18 Check valve ....................................... EJJ ....... Left front steer cylinder extend
19 Check valve ....................................... EKK ...... Right front steer cylinder extend
20 Check valve ....................................... ELL ....... Right rear steer cylinder retract
21 Check valve ....................................... EMM ..... Right rear steer cylinder extend
22 Check valve ....................................... ENN ...... Left front steer cylinder retract
23 Check valve ....................................... EOO ...... Left rear steer cylinder retract
24 Check valve ....................................... EPP ...... Left rear steer cylinder extend

MANIFOLDS
1 2 3 4 5 6
ET EU EV EW EX EY
EQQ
7
EZ
8
EAA
9
EBB
10
ECC
11
EDD
12
EEE
13
EPP EFF
24 14
EGG
15
EOO ENN EMM ELL EKK EJJ EII EHH

23 22 21 20 19 18 17 16

MANIFOLDS
10-16 How to Adjust the Axle Extend

Valve Adjustments - Steer and Relief Valve
Axle Extend/Retract Manifold Perform this procedure with the
axles retracted, the boom in the
How to Adjust the Steer and stowed position and the machine
on a paved surface.
Axle Retract Relief Valve
Perform this procedure with the gauge to the test port on the steer and axle
axles retracted and the boom in extend/retract manifold.
the stowed position.
gauge to the test port on the steer and axle 3 Press down the foot switch and push the axle
extend/retract manifold. extend button. Observe the pressure reading
on the pressure gauge. Refer to Section 2,
2 Start the engine from the platform controls. Hydraulic Specifications.
3 Position the machine so that the left front wheel 4 Turn the engine off. Use a wrench to hold the
is against an immoveable object such as a relief valve and remove the cap (item EQQ).
curb.
4 Press down the foot switch and activate the to increase the pressure or counterclockwise to
steer function. Steer the wheel into the curb and decrease the pressure. Install the relief valve
hold. Observe the pressure reading on the cap.
pressure gauge. Refer to Section 2, Hydraulic
Specifications. Tip-over hazard. Do not adjust
5 Turn the engine off. Use a wrench to hold the specified.
relief valve and remove the cap (item EZ).
6 Repeat steps 2 through 5 to confirm relief valve
6 Adjust the internal hex socket. Turn it clockwise pressure.
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
specified.
7 Repeat steps 2 through 6 to confirm relief valve
pressure.

MANIFOLDS

MANIFOLDS
10-17
Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index Schematic
1 Solenoid valve, 2 position 3 way ...... DA ........ 2 speed control ................................. 25-30 ft-lbs / 38-41 Nm
2 gpm / 7.57 L/min ............................. DB ........ Drive slip limit, rear ........................... 35-40 ft-lbs / 47-54 Nm
3 Flow divider/combiner valve ............. DC ........ Controls flow to rear drive
motors in forward and reverse . 130-140 ft-lbs / 176-190 Nm
2 gpm / 7.57 L/min ............................. DD ........ Drive slip limit, front .......................... 35-40 ft-lbs / 47-54 Nm
5 Flow divider/combiner valve ............. DE ........ Controls flow to front drive
motors in forward and reverse . 130-140 ft-lbs / 176-190 Nm
6 Flow divider/combiner valve ............. DF ......... Controls flow to front and
rear flow divider combiner valves
(items DC and DE) ................... 130-140 ft-lbs / 176-190 Nm
7 Check valve ....................................... DG ........ Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm
8 Check valve ....................................... DH ........ Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm
2.7 gpm / 10.22 L/min ........................ DI .......... Drive slip limit, front and rear ............ 35-40 ft-lbs / 47-54 Nm
10 Check valve ....................................... DJ ......... Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm
11 Check valve ....................................... DK ........ Anti-cavitation ................................... 35-40 ft-lbs / 47-54 Nm

Specification
Solenoid valve, 2 position 3 way 12V 7.4 to 9.4

(schematic items DA)

MANIFOLDS
1 2 3
DA DB DC
DO
17
DD
4
DN
16
DM
15 DE
5
DP
14
DF
6
DL
13
TP
12
DG
7
DH
8
DK DJ DI
11 10 9

MANIFOLDS
Traction Manifold Components, continued

The drive manifold is mounted inside the drive chassis at the circle end of the machine.
Index Schematic
12 Diagnostic fitting ................................ TP ......... Testing
13 Shuttle valve,
3 position 3 way ................................ DL ......... Charge pressure circuit that
gets hot oil out of low presure
side of the drive pump ...................... 35-40 ft-lbs / 47-54 Nm
14 Check valve, 50 psi / 3.45 bar ........... DP ........ 2 speed/brake charge
pressure circuit ................................. 25-30 ft-lbs / 38-41 Nm
15 Relief valve, 250 psi / 17.2 bar ......... DM ........ Charge pressure circuit .................... 35-40 ft-lbs / 47-54 Nm
16 Orifice - plug,
0.030 inch / 0.762 mm ....................... DN ........ Brake release and
2 speed shift control
17 Solenoid valve, 2 position 3 way ...... DO ........ Brake control .................................... 25-30 ft-lbs / 38-41 Nm

Specification
Solenoid valve, 2 position 3 way 12V 7.4 to 9.4

(schematic items DO)

MANIFOLDS
1 2 3
DA DB DC
DO
17
DD
4
DN
16
DM
15 DE
5
DP
14
DF
6
DL
13
TP
12
DG
7
DH
8
DK DJ DI
11 10 9

MANIFOLDS
10-18 10-19
Valve Adjustments - Valve Coils
Traction Manifold
How to Test a Coil
How to Adjust the Charge A properly functioning coil provides an
Pressure Relief Valve electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
1 Connect a 0 to 600 psi / 0 to 41 bar pressure within the coil that provides this force field.
gauge to the test port located on the drive
manifold. Electrocution hazard. Contact with
2 Start the engine from the platform controls. result in death or serious injury.
3 Drive the machine slowly in either direction and Remove all rings, watches and
observe the pressure reading on the pressure other jewelry.
gauge. Refer to Section 2, Hydraulic 1 Tag and disconnect the wiring from the coil to be
Specifications. tested.
4 Turn the engine off. Use a wrench to hold the 2 Test the coil resistance.
charge pressure relief valve and remove the
cap (item DM or FF). 3 Compare the value to the Resistance
Specification chart, adjusted to your ambient air
5 Adjust the internal hex socket. Turn it clockwise temperature.
to increase the pressure or counterclockwise
to decrease the pressure. Install the relief valve Coil resistance is senstive to the
cap. ambient air temperature. Adjust the
values in the chart to your air
6 Repeat steps 2 through 5 to confirm the relief temperature. Adjust the resistance
valve pressure. by 4% for each 18F / 20C that
your air temperature varies from
68F / 20C.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.

Valve Coil Resistance How to Test a Coil Diode

Specification Genie incorporates spike suppressing diodes in all
of its directional valve coils except proportional
Description Specification valves and those coils with a metal case. Properly
Solenoid valve, 3 position 4 way, 12V DC 9 functioning coil diodes protect the electrical circuit
(schematic item FB, FC, HB and HC) by suppressing voltage spikes. Voltage spikes
naturally occur within a function circuit following the
Proportional solenoid valve, 12V DC 5 interruption of electrical current to a coil. Faulty
(schematic item FF) diodes can fail to protect the electrical system,
3 position 4 way D03 valve, 12V DC 4.6
resulting in a tripped circuit breaker or component
(schematic item FD) damage.
Proportional solenoid valve, 12V DC 5.4 Electrocution hazard. Contact with

(schematic item FG) electrically charged circuits could
* Resistance at 68F / 20 C. Remove all rings, watches and
other jewelry.
1 Test the coil for resistance. Refer to, How to
Test a Coil.
2 Connect a 10 resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
The battery should read 9V DC or
more when measured across the
terminals.
a
COIL AMMETER
c - b
+
10 W 9V
RESISTOR BATTERY
c
+
b
-
a multimeter
b 9V DC battery
c 10 resistor
d coil
Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6

3 Set a multimeter to read DC current.

The multimeter, when set to read
DC current, should be capable of
reading up to 800 mA.
4 Connect the negative lead to the other terminal
on the coil.
If testing a single-terminal coil,
connect the negative lead to the
internal metallic ring at either end
of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.

Fuel and Hydraulic Tanks

11-1 5 Remove the fuel tank hold down strap retaining
fasteners. Remove the straps from the fuel
Fuel Tank tank.
6 Support and secure the fuel tank to an
How to Remove the Fuel Tank appropriate lifting device.
Explosion and fire hazard. Engine 7 Remove the fuel tank from the machine.
fuels are combustible. Remove the
fuel tank in an open, well- Crushing hazard. The fuel tank
ventilated area away from heaters, may become unbalanced and fall
sparks, flames and lighted if it is not properly supported and
tobacco. Always have an secured to the lifting device.
easy reach.
fuel tank is plastic and may
Explosion and fire hazard. Never become damaged if it is allowed to
drain or store fuel in an open fall.
container due to the possibility of
Clean the fuel tank and inspect
fire.
for cracks and other damage
1 Remove the fixed engine side turntable cover. before installing.
See 5-1, How to Remove a Fixed Turntable
Cover.
2 Tag, disconnect and plug the fuel supply and
return hoses. Cap the fittings on the fuel tank.
3 Remove the fuel filler cap from the tank.
4 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. See
capacity specifications.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Be sure to only use a hand
operated pump suitable for use
with diesel fuel.

FUEL AND HYDRAULIC TANKS
11-2 2 Close the two hydraulic shutoff valves located

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

Hydraulic Tank
Component damage hazard. The sure that the hydraulic tank shutoff
work area and surfaces where this valves are in the OPEN position
procedure will be performed must before priming the pump. The
be clean and free of debris that engine must not be started with
could get into the hydraulic the hydraulic tank shutoff valves in
system. the CLOSED position or component
damage will occur. If the hydraulic
tank shutoff valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Refer to Section Two, Hydraulic 3 Remove the drain plug from the hydraulic tank
Hose and Fitting Torque and allow all of the oil from the tank to drain into
Specifications. a suitable container. See capacity
specifications.
1 Remove the ground controls side turntable
cover. See 5-1, How to Remove a Hinged
Turntable Cover.

FUEL AND HYDRAULIC TANKS
4 Remove the ground controls support bracket 12 Remove the hydraulic tank from the machine.
retaining fasteners. Remove the ground
Crushing hazard. The hydraulic
controls assembly from the machine.
tank could become unbalanced
Component damage hazard. and fall if it is not properly
Be sure to properly support the supported and secured to the
ground control box. Do not allow overhead crane.
the ground controls to hang by the
wiring.
sure to open the two hydraulic
Component damage hazard. tank valves and prime the pump
The ground control box wiring can after installing the hydraulic tank.
be damaged if it is kinked or See 9-2, How to Prime the Pumps.
pinched.
Always use pipe thread sealant
5 Tag and disconnect the wiring from the horn. when installing the drain plug and
strainers.
6 Remove the horn retaining fasteners. Remove
the horn from the machine. Refer to Section 2, Machine
Specifications for hydraulic oil
7 Tag, disconnect and plug the two suction hoses
requirements.
that are attached to the hydraulic tank shutoff
valves.
8 Tag, disconnect and plug the supply hose for
the auxiliary power unit. Cap the fitting on the
hydraulic tank.
9 Disconnect and plug the T-fitting located at the
return filter with the 2 hoses connected to it.
Cap the fitting on the return filter housing.
10 Remove the hydraulic tank retaining fasteners.
11 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.

Turntable Rotation Components

12-1 3 Tag, disconnect and plug the hydraulic hoses
from the manifold that is mounted to the motor.
Turntable Rotation Hydraulic
Motor and Drive Hub hydraulic oil can penetrate and
How to Remove the Turntable connections very slowly to allow
Rotation Hydraulic Motor the oil pressure to dissipate
When removing a hose assembly or spray.
4 Remove the motor/brake mounting fasteners.
Remove the motor from the brake.
during installation. Refer to
a
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
b
turntable rotation lock pin. c
unlocked locked
2 Remove the ground controls side fixed turntable e d

cover. See 5-1, How to Remove a Fixed
a motor
Turntable Cover. b motor/brake mounting bolts
c brake
d drive hub mounting bolts
e drive hub

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

seal on all bolts. Torque the drive hub mounting
c
bolts to 280 ft-lbs / 380 Nm.
8 Install the brake onto the drive hub and torque
the mounting fasteners to 20 ft-lbs / 27 Nm.
9 Install the motor onto the brake and torque the
mounting fasteners to 93 ft-lbs / 126 Nm.
9 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plugs and
install the plugs. Refer to Section 2,
e d Specifications.
a motor 10 Adjust turntable rotation gear backlash.

b motor/brake mounting bolts
c brake
d drive hub mounting bolts
e drive hub

How to Adjust the

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

with the machine on a flat level
surface.
a b
a adjustment bolt with lock nut

b pivot plate mounting bolts
4 Loosen the lock nut on the turntable drive hub

adjustment bolt.
5 Tighten the turntable drive hub adjustment bolt
unlocked locked
until the turntable drive hub gear is fully
2 Remove the ground controls side fixed turntable engaged and tight into the turntable rotate gear.
cover. See 5-1, How to Remove a Fixed 6 Turn the adjustment bolt 3/4 turn
Turntable Cover. counterclockwise. Tighten the lock nut on the
3 Loosen the turntable rotate drive hub mounting adjustment bolt.
bolts. Do not remove them. 7 Rotate the drive hub away from the turntable
It may be necessary to raise the rotate gear until it contacts the adjustment bolt.
boom slightly to access all the Torque the turntable rotate drive hub mounting
turntable rotate drive hub mounting bolts. Refer to Section 2, Specifications.
bolts. 8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.


Axle Components
13-1 Measure the circle-end tires:
Steer Sensors 3 Press the square-end steer mode button.
4 Measure the distance between the inside of one
The steer sensor measures steer angle and
circle-end tire and the chassis side plate on
communicates that information to the ground
both sides of the axle.
controls ECM. The steer sensor on the ground
controls side of the machine at the square end acts
as the lead sensor. The other three sensors follow
the position, or steer angle, of the lead sensor.
There is a steer sensor mounted to the top of each
upper yoke pivot pin.
If the square-end steering function

becomes inoperative, switch to
circle-end steer mode and the
ground controls side circle-end
steer sensor will become the lead
sensor.
This procedure will require a Result: Both measurements should be the
minimum of two people. same to indicate that the tires are parallel with
the chassis.
axles extended. If the measurements are different
or if a tire is not parallel with the
How to Measure the Tire chassis, the steer sensor of that
Alignment tire will need to be adjusted. See
How to Adjust a Steer Sensor.
5 Repeat step 4 for the other circle-end tire.
2 Press down the foot switch and push the engine
idle select button until the engine switches to
high rpm.

AXLE COMPONENTS
Measure the square-end tires: How to Adjust a Steer Sensor

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

same to indicate that the tires are parallel with
the chassis.
If the measurements are different
or if a tire is not parallel with the
chassis, the steer sensor of that
tire will need to be adjusted. See
8 Repeat step 4 for the other square-end tire. 5 Repeat step 4 until the tire is parallel with the
chassis.
6 Tighten the steer sensor cover fasteners.
7 Repeat steps 2 through 6 for the other square-
end steer sensor.

AXLE COMPONENTS
Circle-end steer sensors: 13-2

8 At the platform controls, press the square-end Yoke and Hub
steer mode button.
9 Locate the steer sensor on top of the yoke pivot How to Remove the Yoke
pin. and Hub
10 Loosen the steer sensor cover retaining The yoke installation utilizes bushings and a thrust
fasteners. Do not remove them. washer that may require periodic replacement.
11 Rotate the steer sensor cover either clockwise There is a steer sensor mounted to the upper yoke
or counterclockwise. Measure the distance pivot pin.
between the inside of tire and the chassis side
plate on both sides of the axle.
Specifications.
1 Remove the hose hanger bracket retaining
fasteners mounted to the top of the yoke.
Remove the hose hanger bracket from the
machine.
12 Repeat step 4 until the tire is parallel with the from the drive motor and brake assembly. Cap
chassis. the fittings on the drive motor and brake.
13 Tighten the steer sensor cover fasteners. Bodily injury hazard. Spraying
14 Repeat steps 9 through 13 for the other circle- burn skin. Loosen hydraulic
end steer sensor. connections very slowly to allow
or spray.

AXLE COMPONENTS
3 Mark the mounting position of the steer sensor 7 Remove the steer sensor activator pin retaining
cover on the yoke. fasteners. Remove the steer sensor activator
pin from the machine.
It is very important that the steer
sensor is installed in the exact It is very important that the steer
position it was in prior to removal. sensor activator pin is installed in
If the steer sensor is not installed the exact position it was in prior to
correctly, the steer function may removal. If the steer sensor
operate improperly. If any steer activator pin is not installed
functions operate improperly after correctly, the steer function may
removing and installing a steer operate improperly. If any steer
sensor, see 13-1, How to Adjust a functions operate improperly after
Steer Sensor. removing and installing a steer
sensor activator pin, see 13-1,
4 Remove the steer sensor cover retaining
fasteners. Carefully remove the steer sensor
cover and lay it out of the way. 8 Loosen the wheel lug nuts. Do not remove
them.
steer sensor is a very sensitive 9 Center a lifting jack of ample capacity under the
instrument. It can be damaged axle of the yoke and drive hub to be removed.
internally if it is dropped or Do not raise the machine.
sustains any physical shock, even
10 Block the wheels at the opposite end of the
if the damage is not visible.
machine.
5 Lay the hoses and steer sensor cable out of the
11 Raise the machine approximately 6 inches
way.
(15 cm) and place blocks under the chassis for
Component damage hazard. support.
Cables and hoses can be
12 Remove the lug nuts and remove the tire and
wheel assembly.
pinched.
13 Remove the drive motor mounting fasteners.
6 Mark the mounting position of the steer sensor
activator pin mounted to the top of the yoke 14 Slide the drive motor shaft out of the drive hub
pivot pin. and remove the drive motor from the machine.
15 Remove the pin retaining fasteners from the
steering cylinder rod-end pivot pins. Remove
the pins.

AXLE COMPONENTS
16 Remove the pin retaining fasteners from the 13-3

upper and lower yoke pivot pins.
Drive Motor
17 Support the yoke/drive hub assembly with a
lifting jack. Secure the yoke/drive hub assembly
to the lifting jack.
How to Remove a Drive Motor
18 Use a soft metal drift to remove both yoke pivot Component damage hazard.
pins. Repairs to the motor should only
be performed by an authorized
19 Remove the yoke/drive hub assembly from the Rexroth dealer.
machine.
Crushing hazard. The yoke/hub work area and surfaces where this
assembly may become procedure will be performed must
unbalanced and fall when the yoke be clean and free of debris that
pivot pins are removed if it is not could get into the hydraulic system
properly supported and secured to and cause severe component
the lifting jack. damage. Dealer service is
recommended.
20 Place the yoke/drive hub assembly on a flat
surface with the drive hub facing down. When removing a hose assembly
21 Remove the drive hub mounting fasteners that
attach the yoke to the drive hub. Remove the
yoke weldment from the drive hub.
Replace the thrust washer with a Refer to Section Two, Hydraulic
new one when installing the yoke/ Hose and Fitting Torque
drive hub assembly onto the axle. Specifications.
Refer to Section 2, Machine
Torque Specifications.
from the drive motor. Cap the fittings on the
drive motor.
or spray.
2 Remove the drive motor mounting fasteners.
3 Slide the drive motor shaft out of the brake and
drive hub. Remove the drive motor from the
machine.

AXLE COMPONENTS
13-4 7 Remove the wheel lug nuts. Remove the tire and
wheel assembly.
Drive Hub
8 Place a second lifting jack under the drive hub
for support and secure the drive hub to the
How to Remove a Drive Hub lifting jack.
When removing a hose assembly 9 Remove the drive hub mounting bolts that attach
or fitting, the O-ring on the fitting the drive hub to the yoke. Remove the drive hub
and/or hose end must be replaced from the machine.
during installation. Crushing hazard. The drive
Refer to Section Two, Hydraulic hub may become unbalanced and
Hose and Fitting Torque fall if it is not properly supported
Specifications. and secured to the lifting jack.
Refer to Section 2, Machine
1 Remove the drive motor. See 13-3, How to Torque Specifications.
Remove a Drive Motor.
2 Tag, disconnect and plug the hydraulic hose
from the brake. Cap the fittting on the brake.
or spray.
3 Loosen the wheel lug nuts. Do not remove
them.
4 Center a lifting jack of ample capacity under the
axle of the drive hub to be removed. Do not
raise the machine.
machine.
6 Raise the machine approximately 6 inches
(15 cm) and place blocks under the chassis for
support.

AXLE COMPONENTS
13-5 6 Support the steer cylinder with a suitable lifting

device.
Steering Cylinders
7 Place a rod through each steer cylinder pivot
pin and twist to remove the pins.
How to Remove a
Steering Cylinder
Specifications. 8 Remove the steering cylinder from the machine.
1 Locate the hose bracket mounted to the steer Crushing hazard. The steer
cylinder. cylinder may become unbalanced
2 Remove the hose bracket cover retaining and fall if it is not properly
fasteners. Remove the hose bracket cover. supported by the lifting device.
3 Remove the hose bracket retaining fasteners

from the steering cylinder.
from the steering cylinder. Cap the fittings on
the cylinder.
or spray.
5 Remove the pin retaining fasteners from the
steer cylinder pivot pins.

AXLE COMPONENTS
13-6 Top and bottom wear pads:

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

AXLE COMPONENTS
How to Remove an Inner Axle 6 Attach a lifting strap from an overhead crane of
ample capacity to the inner axle for support. Do
When removing a hose assembly not lift it.
and/or hose end must be replaced 7 Remove the retaining fasteners from the upper
and then torqued to specification and lower wear pads at the outer axle. Do not
during installation. remove the side wear pads.
Refer to Section Two, Hydraulic Pay careful attention to the
Hose and Fitting Torque location and amount of shims
Specifications. used with each wear pad.
Perform this procedure with the 8 Remove the pin retaining fasteners from the
tires parallel to the chassis and the axle stop pin. Use a slide hammer to remove
axles fully extended. the pin.
1 Remove the top drive chassis cover. 9 Remove the access cover fasteners from the
2 Remove the yoke and hub assembly. See 13-2, end of the inner axle to access the axle
How to Remove the Yoke and Hub. extension cylinder clevis pin. Remove the
cover.
3 Remove the steering cylinder. See 13-5, How to
Remove a Steering Cylinder. 10 Place support blocks under the end of the axle
extension cylinder for support.
4 Remove the axle cover retaining fasteners
located above the axle. Remove the chassis 11 Remove the cotter pin from the axle extension
cover from the machine. cylinder clevis pin.
5 Remove the upper wear pad retainer plate Alwayse use a new cotter pin
retaining fasteners. Remove the plate from the when installing a clevis pin.
machine.

AXLE COMPONENTS
12 Use a soft metal drift to remove the axle How to Remove the Axle
extension cylinder clevis pin.
Extension Cylinder
13 Carefully support and slide the inner axle out of
the chassis. Remove the axle from the 1 Remove a yoke and hub assembly. See 13-2,
machine. How to Remove the Yoke and Hub.
Crushing hazard. The inner axle 2 Remove the axle. See How to Remove an Inner
may become unbalanced and fall Axle.
when it is removed from the 3 Remove the access covers from the end of the
machine if it is not properly remaining axle.
supported by the overhead crane.
4 Tag, disconnect and plug the axle extension
Component damage hazard. The cylinder hydraulic hoses. Cap the fittings on the
aluminum limit switch track and cylinder.
the axle extension cylinder may
become damaged if the axle is Bodily injury hazard. Spraying
allowed to fall when it is removed hydraulic oil can penetrate and
from the machine. burn skin. Loosen hydraulic
During removal, the overhead the oil pressure to dissipate
crane strap will need to be gradually. Do not allow oil to squirt
carefully adjusted for proper or spray.
balancing.
5 Tag and disconnect the wiring connectors from
When installing an inner axle, the proximity switches and limit switch. Do not
there needs to be a minimum of remove the switches.
1/8 inch / 3.1 mm gap between the
proximity switches and the The wiring connectors for the
aluminum limit switch track. switches can be accessed through
Measure the gap with the axles in the access holes on either side of
both the retracted and extended the chassis end plate.
positions. Adjust the proximity
6 Place blocks under the axle extension cylinder
switches as necesary to obtain a
1/8 inch / 3.1 mm gap.
for support.

AXLE COMPONENTS

the end of the axle extension cylinder.
Attach the lifting strap to the end of
the cylinder that has the inner axle
removed.
8 Remove the cotter pin from the axle extension
cylinder clevis pin on the remaining inner axle.
Alwayse use a new cotter pin
when installing a clevis pin.
9 Use a soft metal drift to remove the pin.
Crushing hazard. The axle
extension cylinder may fall if it is
not properly supported.
axle extension cylinder and limit
switches can become damaged if
the axle extension cylinder is
allowed to fall.
10 Carefully support and slide the axle extension
cylinder out of the axle.
carefully adjusted for proper
balancing.

First Edition First Printing Section 8 Software
Software
About This Section
This section explains various parts of the machine
software operating system and how to access
some of the adjustable parameters of the control
system.
Observe and Obey:

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-120 and Genie S-125 Operator's
Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 62401 Genie S-120 & Genie S-125 8-1

Section 3 Software First Edition First Printing
Diagnostic Codes
Boom Module
Sensor or Location Diagnostic Codes
Up/Down Joystick Not calibrated and fault check
Extend/Retract Joystick Not calibrated and fault check
Up/Down Buttons Fault check (both buttons pressed)
Extend/Retract Buttons Fault check (both buttons pressed)
Boom Length Fault check (unknown length)
Boom Angle Fault check (unknown length)
Boom Up/Down Speed Not calibrated
Boom Extend/Retract Speed Not calibrated
Boom Extend/Retract Flow Valve Not calibrated and fault check
Boom Up/Down Flow Valve Not calibrated and fault check
Boom Extend Valve Fault check
Boom Retract Valve Fault check
Boom Up Valve Fault check
Boom Down Valve Fault check
Lock Out Valve P1 Fault check
Lock Out Valve P2 Fault check
Engine Module
Engine Speed Range check
Oil Pressure Range check
Water/Oil Temperature Range check
Oil Pressure Sensor Range check
Water/Oil Temperature Sensor Range check
Axle Module
Axle Extend/Retract Buttons Fault check
Axle Valve Fault check
Platform Level Module

Platform Level Sensor Fault check
Platform Level Valve Not calibrated and fault check
8-2 Genie S-120 & Genie S-125 Part No. 62401

DIAGNOSTIC CODES
Jib Module
Jib Switches Fault check
Jib Valve Fault check
Turntable Rotate Module

Turntable Rotate Joystick Not calibrated and fault check
Turntable Rotate Buttons Fault check (both buttons depressed)
Turntable Rotate Speed Not calibrated
Turntable Rotate Flow Valve Not calibrated and fault check
Turntable Rotate Clockwise Valve Fault check
Turntable Rotate CounterClockwise Valve Fault check
Turntable Level Module

Turntable Level Sensor X- Direction Fault check
Turntable Level Sensor Y- Direction Fault check
Platform Rotate Module

Platform Rotate Switches Fault check
Platform Rotate Valve Fault check
Propel Module
Propel Joystick Not calibrated and fault check
Propel Valves Not calibrated and fault check
Motor Coil Fault check
Brake Valve Fault check
Auxiliary Propel Valve Fault check

DIAGNOSTIC CODES
Common Module
Can BUS Fault check
Safety Switch P3 Fault check
Safety Switch P6R1 Fault check
Safety Switch P6R2 Fault check
Safety Switch P7
Safety Switch P7R
Safety Switch 9A
Safety Switch 9B
Safety Switch P10
Safety Switch P11
Safety Switch P12
Safety Switch P14
Safety Switch P18
Safety Switch P22
Safety Switch P22R
Platform Overload Sensor IF active
Boom Up Overload IF active
Boom Down Overload IF active
Shut Down Mode IF active
Steering Module
Steering Joystick Not calibrated and fault check
Left Front Steer Angle Sensor Fault check
Right Front Steer Angle Sensor Fault check
Left Rear Steer Angle Sensor Fault check
Right Rear Steer Angle Sensor Fault check
Left Front Steer Valve Fault check
Right Front Steer Valve Fault check
Left Rear Steer Valve Fault check
Right Rear Steer Valve Fault check

Display Module
Screen To Enter Information Displayed

Operator Default Hour meter
Engine speed
Engine oil pressure PSI
Engine oil pressure KPA
Engine temperature F
Engine temperature C
TT level sensor X
TT level sensor Y
Platform level sensor
Battery voltage
Status Press and at the Hydraulic pressure

same time Boom length
Boom angle
Axle status
Unit/Language Press on power on, Metric/English display language

then press (measurement units)
Drive Functions Press on power on, then Drive output max forward
press Drive output max reverse
Elevated drive % (>80 feet, >24.4 m)
Elevated drive % (<80 feet, <24.4 m)
Stowed drive %
Drive acceleration %
Drive deceleration %
Speed limit on steer angle
Boom function Press on power on, Boom up/down speed stowed %

speeds then press Boom up/down speed % (<80 feet, <24.4 m)
Boom up/down speed % (>80 feet, >24.4 m)
Boom up/down speed % (>100 feet, 30.5 m)
(<80 feet, <24.4 m)
(>80 feet, >24.4 m)

DISPLAY MODULE
Screen To Enter Information Displayed

Lift function ramps Press on power on, then Boom up/down ramp acceleration
press Boom up/down ramp deceleration
Boom extend/retract ramp deceleration
Turntable rotate ramp acceleration
Turntable rotate ramp deceleration
Valve calibration Press on power on, then Reset drive valve defaults
press Reset boom up/down valve defaults
Reset boom extend/retract defaults
Reset turntable rotate valve defaults
Reset platform level valve defaults
Allow boom up/down speed calibration
Allow boom extend/retract speed calibration
Allow turntable rotate speed calibration
Reset drive joystick defaults
Reset boom up/down joystick defaults
Reset boom extend/retract joystick defaults
Reset turntable rotate joystick defaults
Reset steer joystick defaults
Options Press on power on, then Limit boom height to 100 feet (30.5 m)
press Limit boom height to 80 feet (24.4 m)
AC generator: no, regulated, none (0,1,2)
Alarm: no, motion, travel, decent, travel and
decent (0,1,2,3,4,5)
Lift/drive cut outs: no, drive cut out while not
stowed, Lifting, driving
Boom extend cut out if boom angle >5
Auxilliary drive enable: yes, no
Proximity kill switch OR platform overload
sensing: none, prox, plat overload
Work light: yes, no
Flashing beacon: yes, no
Drive lights: yes, no
Steer mode change while driving: yes, no

Electrical System Legend

Circuit numbering Wire Coloring
1 Circuit numbers consist of three parts, the circuit 1 All cylinder extension colors are solid and all
prefix, circuit number, and circuit suffix. The cylinder retract functions striped black, except
prefix tells what type of circuit it is. The circuit when the wire is black the stripe is white.
number tells the function of the circuit. The
2 All rotations that are LEFT or CW are solid and
circuit suffix provides an abbreviation for the
all RIGHT or CCW are striped black, except
number or may be used to further define the
when the wire is black the stripe is white.
function of this portion of the circuit or it may be
used to indicate the final end of the circuit i.e. 3 All proportional valve wiring is striped.
LS or limit switch.
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 number 1. C stands for control, number 74 is
the circuit for the primary number 1 lock out valve.
PRLO stands for Primary Lockout.
S 62 BSTO This is the circuit that tells the

computer on the machine that the boom is fully
stowed. S stands for safety, number 62 is the
circuit for boom stowed. BSTO stands for Boom
Stowed.
P 48 LP P stands for power. Number 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. Number 61

stands for axle retracted circuit, AXRT stands for
Axle Retracted.

Wire Circuit Legend

Wire Circuit Wire Circuit
Color Number Function Color Number Function
RD 1 Primary boom up BK 22 Key switch power to
RD/BK 2 Primary boom down platform Emergency Stop
button
RD/WH 3 Primary boom up/down
proportional valve WH 23 Power to platform
WH 4 Turntable rotate left valve WH 24 Power to warning senders
WH/BK 5 Turntable rotate right valve WH/BK 25 Power to oil pressure
WH/RD 6 Turntable rotate sender
proportional valve WH/RD 26 Power to temperature
BK 7 Primary boom extend sender
BK/WH 8 Primary boom retract RD 27 Auxiliary Power
BK/RD 9 Primary boom extend/retract RD/BK 28 Platform level alarm

proportional valve RD/WH 29 Drive Motor shift (2-speed)
BL 10 Secondary boom up valve WH 30 Drive forward
BL/BK 11 Secondary boom down WH/BK 31 Drive reverse
valve WH/RD 32 Brake
BL/WH 12 Secondary boom up/down BK 33 Engine start
proportional valve
BK/WH 34 Engine starting aid
BL/RD 13 Drive enable (glow plug)
OR 14 Platform level up valve BK/RD 35 Engine speed select
OR/BK 15 Platform level down valve BL 36 Steer right
OR/RD 16 Platform level up/down BL/BK 37 Steer left
proportional valve
BL/WH 38 Gas
GR/RD 17 Platform rotate left valve
BL/RD 39 LPG
GR/BK 18 Platform rotate right valve
OR 40 Limit switch signal boom
GR/WH 19 Jib boom select valve circuit stowed position
RD 20 12V DC battery supply OR/BK 41 RPM signal
WH 21 12V DC ignition supply OR/RD 42 Boom retracted signal

WIRE CIRCUIT LEGEND
Wire Circuit Wire Circuit

Color Number Function Color Number Function
GR 43 Jib Up BL/WH 65 Low fuel indicator
GR/BK 44 Jib Down BL 66 Drive Enable
GR/WH 45 AC Generator BL 67 Secondary boom not stowed
WH 46 Horn RD 68 Primary Boom lowered
WH/BK 47 Output Power Enable (operational)
WH/RD 48 Work Lamp

WH/BK 49 Motion Lamp
BL 50 Auxiliary Boom
BL/WH 51 Auxiliary Steer
BL/RD 52 Auxiliary Platform
WH/BK 53 Boom envelope safety
valve cut off
BK/WH 54 Power to safety interlock
switches (engine)
GR/BK 55 Axle oscillation
RD 56 Foot switch/Ground controls
Emergency Stop power
RD/WH 57 Boom down safety interlock
RD/BK 58 Safety interlock to engine
GR/WH 59 Cable break circuit
GR/WH 60 Axle extend
GR 61 Axle retract
OR 62 Boom stowed (safety)
OR/RD 63 Power to boom envelope
safety switch
OR/BL 64 Power to operational
switches

Web GPI
The software system used on the machine is
called Web GPI. It is a software application that is
typically used with a laptop computer. The laptop
can be connected to the ground controls via a tee
harness connector (Genie part number 75094).
The Web GPI software can access all adjustable
parameters for the machine. It can also be used to
aid in troubleshooting and viewing fault code
history.
8 - 10 Genie S-120 & Genie S-125 Part No. 62401

California Proposition 65
WARNING
The exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada

Distributed By:
800.536.1800
Fax 425.883.3475
Genie Holland Genie Australia Pty Ltd.

Phone 31 70 51 78836 Phone 1 61 7 3375 1660
Fax 31 70 51 13993 Fax 1 61 7 3375 1002
Genie Denmark Genie China

Phone 45 6612 5544 Phone 86 21 53852570
Fax 45 6612 5530 Fax 86 21 53852569
Genie France Genie Mayalsia

Phone 33 2 37 26 09 99 Phone 604 228 1235
Fax 33 2 37 31 11 95 Fax 604 226 6872
Genie Spain Genie Japan

Phone 34 93 579 5042 Phone 81 3 3453 6082
Fax 34 93 579 5059 Fax 81 3 3453 6083
Genie Germany Genie Korea

Phone 49 4202 8852-0 Phone 82 2 558 7267
Fax 49 4202 8852-20 Fax 82 2 558 3910
Genie U.K. Genie Africa

Phone 44 1636 614700 Phone 27 11 974 6838
Fax 44 1636 611090 Fax 27 11 974 6797
Genie Mexico City Genie Latin America

Phone 52 5 653 03 84 Phone 55 11 4055 2499
Fax 52 5 664 40 16 Fax 55 11 713 1661

A B C D E F G H I J K L M N O P
1 H3 TS1 TS2 TS3 JC1

BOOM UP/DOWN
JC2 JC3
DRIVE
P2
PLATFORM
1
AND BOOM AND EMERGENCY
TURNTABLE ROTATE EXTEND/RETRACT STEERING STOP
DRIVE CHASSIS CONTROLLER PLATFORM PLATFORM PLATFORM

ALARM ROTATE LEVEL JIB BOOM
JOYSTICK JOYSTICK NOT USED JOYSTICK
P 12
P 6R1
(DCON)
P 7R
H1 H2 H3 H4
PLATFORM CONTROLS (PCON) MEMBRANE DECAL PANEL
2 2
J1 J2
10 PIN 10 PIN
J2 J1
3 3
MEMBRANE/LED INTERFACE CARD J3
WHITE 23 PIN BLACK 23 PIN
10 PIN
DRIVE CHASSIS HARNESS DRIVE CHASSIS HARNESS
P20
ELECTRICAL ROTARY COUPLER J20
J16 P16 J6 P6
DRIVE CHASSIS HARNESS BOOM HARNESS
A A A A
YEL 88 CAN HIGH YEL D82CAN(+) -YL
B B B B
GRN 88 CAN LOW GRN D81CAN(-) -GR
C C C C
88 CAN SHIELD D80SHLD-N/A
P7R
P6R
4 J18 P18
ELECTRICAL ROTARY COUPLER
J8 P8
CR6
1 30
87a
87
3
4
4
DRIVE CHASSIS HARNESS LIMIT SWITCH HARNESS 86 85
1 1 1 1
K1 5
WH 88 P7R WH S56PRV-RD 2
2 2 2 2
BK 88 DCON GND BK GNDDCON-BR
CURRENT
U20 LIMITING
PLATFORM CONTROLLER
J17 P17 J7 P7 DEVICE 87a 3
DRIVE CHASSIS HARNESS LIMIT SWITCH HARNESS
1 1 1 1
RD 88 DCON PWR RD P21DCON-RD 1 30 87 4
2
3
2
3
OR 88 P9A OR
2
3
2
3
P57PBD-RD/WH (PCON) 2
86 85
5
BR 88 P12 BR C61AXRT-GR K2
4 4 4 4 CR7
BL 88 P18 BL P63LS-OR/RD
5 5 5 5
YL 88 P11 YL C60AXEX-GR/WH
6 6 6 6
GR 88 P6R1 GR P53LS-WH/BK
5 5
J2 J1
WHITE 23 PIN BLACK 23 PIN
PCON MANIFOLD BOOM HARNESS
J2-BL/RD
J1-BL/BK J4-GR/BK J3-OR/BK
3 4 3 4 3 4 3 4 3 1 2 4 3 1 2 4
A B C A B C A B C A B C
6 6
P33
P P P P PCON MANIFOLD
LSAX1RO LSAX2RO LSAX1EO LSAX2EO LSAX1ES LSAX2ES J33
TILT SENSOR OPTIONAL
AXLE RETRACTION AXLE EXTENSION AXLE NOT EXTENDED PROXIMITY
LIMIT SWITCHES LIMIT SWITCHES LIMIT SWITCHES KILL SWITCH
WHEN AXLES ARE RETRACTED, WHEN AXLES ARE EXTENDED, WIRING P23PCON-BK
CIRCLE END CIRCLE END SQUARE END SQUARE END TERMINALS 3 & 4 ARE CLOSED TERMINALS 3 & 4 ARE CLOSED
YELLOW SIDE BLUE SIDE YELLOW SIDE BLUE SIDE GNDPCON-BR
A
(RIGHT REAR) (LEFT REAR) (RIGHT FRONT) (LEFT FRONT)
P52PCON-BL/RD
STEER SENSOR STEER SENSOR STEER SENSOR STEER SENSOR
PLATFORM
SS1 SS2 SS3 SS4 TILT SENSOR
C46HN-WH
ASSEMBLY S56PRV-RD
C47OUT-WHT/BLK
3 1 2 4 3 1 2 Go to A on
Ground Controls
PROXIMITY FOOT SWITCH
P56PRV-RD Schematic
KILL SWITCH
3 1 2 4
7 7
3 1 2
PROXIMITY
FS1
B
KILL SWITCH
(OPTIONAL) FOOT SWITCH D82CAN+ -YL
1 2 3
D81CAN- -GR
LOAD
SENSOR D80SHLD-N/A
ASSEMBLY
(OPTION) Go to B on
Ground Controls
Schematic
C
D82CAN(+) -YL
D81CAN(-) -GR
8 8
D80SHLD-N/A
Go to C on
Ground Controls
Schematic
PLUG JACK CONNECTOR DESCRIPTION AND/OR LOCATION
Genie S-100 & S-105 & S-120 & S-125 P1

P2
J1
J2
Black 23 Pin AMP Connector - Platform Controls to Drive Chassis Harness
White 23 Pin AMP Connector - Platform Controls to Drive Chassis Harness
Electrical Schematic
P1 J1 Platform Controls PC Board to Membrane Decal
P2 J2 Platform Controls PC Board to Membrane Decal S56PRV-RD
1 of 2
GNDDCON-BR
Genie Part number 62304 P1

P2
J1
J2
Black 23 Pin AMP connector - Drive Chassis Controller to Drive Chassis Harness
White 23 Pin AMP connector - Drive Chassis Controller to Drive Chassis Harness
P21DCON-RD
9 9
P6 J6 3 Way Deutsch CAN Connector - Boom Harness to Electrical Rotary Coupler
P7 J7 6 Way Deutsch Connector - Drive Chassis Controller Safety Limit Switch to Electrical Rotary Coupler P57PBD-RD/WH
To
P8 J8 2 Way Deutsch Connector - Drive Chassis Controller Power Limit Switch Harness to Electrical Rotary Coupler
Drive Chassis and Platform Controls

C61AXRT-GR
P16 J16 3 Way Deutsch CAN Connector - Electrical Rotary Coupler to Drive Chassis Controller Harness
Limit Switch
P63LS-OR/RD
P17 J17 6 Way Deutsch Connector - Drive Chassis Controller Electrical Rotary Coupler to DCON Harness Harness
C60AXEX-GR/WH
P18 J18 2 Way Deutsch Connector - Electrical Rotary Coupler to Drive Chassis Controller Harness Schematic"
P53LS-WH/BK
P33 J33 Platform Manifold/Tilt Sensor
1 1
KS2 OFF
KS1
RUN
SERVICE BYPASS/ MAIN
RECOVERY SERVICE BYPASS A-A PCON A-A
KEYSWITCH
KEY SWITCH 1 2 1 2
RECOVERY TCON
A-B A-B
3 4 3 4
TCON MEMBRANE PANEL
P1
EMERGENCY
STOP
B-B B-A
3 4 1 2
C-B B-B
2 2
3 4 3 4
CURRENT
LIMITING
DEVICE
PWR TO TCON ESTOP

C-A
H1 1 2
ALARM 87a
CR10 P10 P11
1
P 9B 87 4
30
86 85
OUT PWR ENABLE
B-A 5 J10 J11
1 2 CR11 87a
1
K6
87
TO MICRO
P 6R2 30
85 86
5
K3
CR12 87a
1
87 30
85 86
3 3
5
K4
TO MICRO
CR13 87a
1
TO MICRO
87 30
P7 5
85 86
K5
TCON MODE
1
87a CR14
30 87 4
86 85
P7
5
K2
1
87a CR15
30 87 4 P 22R
4 4
86 85
P 22
TO MICRO 5
K1
TO MICRO
TO MICRO
P7R P7R
P10 P10
CURRENT
LIMITING
DEVICE
PCON POWER
P9A P9A
P6R1 P6R1
OUT PWR ENABLE P11 P11
TCON MODE
1
87a CR16
P_7
TO MICRO 30 87 4
P_22 86 85
P7R TO MICRO 5
K8
5 5
PCON POWER TO MICRO TO MICRO
P6R1
1
87a
CR17
30 87 4
P11
86 85
5
K7
J1 J2 J5 J3 J4
BLACK 23 PIN BLACK 35 PIN BLACK 4 PIN WHITE 23 PIN WHITE 35 PIN
BOOM HARNESS LIMIT SWITCH HARNESS POWER HARNESS ENGINE HARNESS MANIFOLD HARNESS
12 VOLT
6 6
CR8
WORK
12 V
LIGHT
RELAY
TO WORK LIGHTS 87a
To "Limit Switch To "Engine
87 30 Harness Schematic" Harness Schematic" CR18
P23PCON-BK R48LP-WH/RD 86 85 87a 3
1 30 87 4 TO DRIVE LAMPS
GNDPCON-BR
A
86 85
P52PCON-BL/RD FB 87a
2 5
C46HN-WH 87 30
86 85
S56PRV-RD R49LP-WH/BK
C47OUT-WHT/BLK
Go to A on CR9
FLASHING
Drive Chassis and BEACON
P56PRV-RD
Platfom Controls RELAY
Schematic TETHER INTERFACE

P24 J24 3 4 3 1
7 A DIAG/TETHER GROUND
P 7
B
B DIAG/TETHER POWER
LSB20LO
C CAN HIGH
D82CAN+ -YL N.O.
D
D81CAN- -GR CAN LOW
D80SHLD-N/A E
CAN SHIELD
Go to B on F
Drive Chassis and G

TETHER FUNCTION ENABLE
TO AUXILIARY
HYDRAULIC
Platfom Controls H TETHER EMERGENCY STOP POWER RELAY
PR1
Schematic J TETHER EMERGENCY STOP RETURN
C
D82CAN(+) -YL
P P P
D81CAN(-) -GR
8 8
D80SHLD-N/A
Go to C on J27 P27
Drive Chassis and BOOM HARNESS LIMIT SWITCH To "Limit Switch
Platfom Controls Harness Schematic"
Schematic
Genie S-100 & S-105 & S-120 & S-125 PLUG JACK CONNECTOR DESCRIPTION AND/OR LOCATION
Electrical Schematic P1
P2
J1
J2
Black 23 Pin AMP connector - Ground Controls to Boom Harness
Black 35 Pin AMP connector - Ground Controls to Limit Switch Harness
2 of 2
P3 J3 White 23 Pin AMP connector - Ground Controls to Engine Harness
Genie Part number 62304 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
Ground Controls
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
P27 J27 2 Way Deutsch Connector - Boom Harness/Limit Switch Harness

S 100 Bef 136 S125 Bef 404

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Available Formats

Introduction First Edition First Printing

This manual provides detailed scheduled

Copyright 2001 by Genie Industries

Printed on recycled paper

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

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Many of the hazards identified in the operator's

Do Not Perform Maintenance

Personal Safety Be sure to wear protective eye wear and

Section One Safety Rules

Section Two Specifications

Section Three Theory of Operation

Section Four Scheduled Maintenance Procedures

Section Four Scheduled Maintenance Procedures, continued

Section Four Scheduled Maintenance Procedures, continued

Section Four Scheduled Maintenance Procedures, continued

Section Five Troubleshooting Flow Charts

Section Five Troubleshooting Flow Charts, continued

Section Six Schematics

Section Six Schematics, continued

Section Seven Repair Procedures

Section Seven Repair Procedures, continued

Section Seven Repair Procedures, continued

Section Seven Repair Procedures, continued

Appendix Electrical Schematic , Genie part number 62304

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Turning radius, outside, 20 ft 8 in 20 ft 8 in

Length, transport position 39 ft 11 in 39 ft 11 in Turning radius, inside, 10 ft 1 in 10 ft 1 in

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

Weight 44,340 lbs 44,640 lbs Platform dimensions

Platform height, maximum 120 ft 125 ft Tires and wheels

Horizontal reach maximum 75 ft 80 ft Overall tire diameter 46.5 in

Maximum load capacity 750 lb 500 lb Wheel diameter 22.5 in

Turntable tailswing, 66 in 66 in Wheel width 13 in

Turntable tailswing 48 in 48 in Wheel lugs 10 @ 3/4 -16

Fluid capacities Performance Specifications,

Gradeability (boom stowed) 40%

Jib boom up (S-125 models) 28 to 32 seconds

Jib boom down (S-125 models) 28 to 32 seconds

Boom fully retracted 80 to 88 seconds

Boom fully retracted 80 to 88 seconds

Boom extend Machine Specifications,

Turntable rotate, 360 Width, axles retracted 8 ft 6 in 8 ft 6 in

Ground clearance 151/2 in 151/2 in

Platform height, maximum 100 ft 105 ft

Working height, maximum 106 ft 111 ft

Horizontal reach maximum 75 ft 80 ft

Maximum load capacity 750 lb 500 lb

Turning radius, outside, 24 ft 4 in 24 ft 4 in

Turning radius, inside, 16 ft 4 in 16 ft 4 in

Turning radius, outside, 20 ft 8 in 20 ft 8 in Fluid capacities

Platform rotation 160 Fuel tank capacity 40 gallons

Tires and wheels

Tire size 15 x 22.5, 18 pr FF

Tire ply rating 18

Overall tire diameter 43.1 in

Wheel diameter 22.5 in

Wheel width 11.75 in

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs

Lug nut torque, lubricated 320 ft-lbs

Performance Specifications, Boom extend, boom fully raised