Genie S-100 - Service Manual

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Table of Contents7
Hydraulic Specifications24
Perkins Engine 1004-42 Specifications25
Cummins Engine B3.9L Specifications26
Hydraulic Hose and Fitting Torque Specifications28
Theory of Operation29
Pre-Delivery Preparation35
Maintenance Inspection Report37
Inspect the Manuals and Decals39
Perform Pre-Operation Inspection40
Perform Function Tests40
Perform Engine Maintenance - Perkins Models41
Perform Engine Maintenance - Cummins Models41
Perform Engine Maintenance - Deutz Models42
Check the Hydraulic Filter Condition Indicators42
Test the Auxiliary Power Operation44
Test the Tilt Sensor and Alarm44
Test the Operating Envelope45
Perform 30 Day Service46
Perform Engine Maintenance - Perkins Models46
Perform Engine Maintenance - Deutz Models47
Grease the Turntable Rotation Bearing and Rotate Gear47
Extendable Axle Lubrication System48
Replace the Drive Hub Oil49
Inspect the Batteries50
Inspect the Electrical Wiring51
Check the Oil Cooler and Cooling Fins - Deutz Models53
Inspect the Engine Air Filter53
Test the Alarm Package (if Equipped)54
Perform Engine Maintenance - Deutz Models55
Perform Engine Maintenance - Cummins Models55
Check the Exhaust System56
Inspect the Tires, Wheels and Lug Nut Torque57
Check the Drive Hub Oil Level and Fastener Torque57
Confirm the Proper Brake Configuration58
Check and Adjust the Engine RPM59
Test the Key Switches62
Test the Ground Control Override63
Test the Platform Self-Leveling64
Test the Safety Envelope and Circuits65
Test the Engine Idle Select Operation72
Test the Drive Brakes73
Test the Drive Speed - Stowed Position73
Test the Drive Speed - Raised or Extended Position74
Perform Hydraulic Oil Analysis75
Inspect the Boom Extend/Retract Cables75
Perform Engine Maintenance - Deutz Models77
Perform Engine Maintenance - Cummins Models77
Perform Engine Maintenance - Perkins Models78
Replace the Engine Air Filter Element78
Grease the Platform Overload Mechanism (if Equipped)79
Test the Platform Overload System (if Equipped)79
Check the Boom Wear Pads82
Check the Extendable Axle Wear Pads83
Check the Free-Wheel Configuration84
Check the Turntable Rotation Bearing Bolts85
Check the Turntable Rotation Gear Backlash86
Replace the Drive Hub Oil88
Grease the Turntable Rotatiion Bearing and Rotate Gear90
Inspect for Turntable Bearing Wear90
Perform Engine Maintenance - Deutz Models91
Perform Engine Maintenance - Perkins Models92
Perform Engine Maintenance - Cummins Models92
Replace the Hydraulic Filter Elements93
Test or Replace the Hydraulic Oil95
Perform Engine Maintenance - Cummins Models97
Perform Engine Maintenance - Perkins Models97
Perform Engine Maintenance - Perkins Models98
Perform Engine Maintenance - Deutz Models98
Perform Engine Maintenance - Perkins Models99
Perform Engine Maintenance - Deutz Models99
Perform Engine Maintenance - Perkins Models100
Perform Engine Maintenance - Deutz Models101
Perform Engine Maintenance - Perkins Models101
Perform Engine Maintenance - Deutz Models102
Replace the Boom Extend/Retract Cables102
Fault Code Chart105
Platform105
Display Not Active113
Engine will Not Crank over118
Engine Cranks over but will Not Start124
Engine High Idle Inoperative130
Engine Low Idle Inoperative132
All Functions Inoperative, Engine Starts and Runs133
Boom Up/Down, Extend/Retract, Turntable Rotate and134
Drive, Steer and Axle Extend/Retract Functions Operational134
All Platform, Steering and Axle Functions Inoperative135
All Other Functions Operational135
Ground Controls Inoperative, Platform Controls Operate Normally140
Platform Controls Inoperative, Ground Controls Operate Normally142
Boom Angle Switch Fault144
Boom up Function Inoperative147
Boom down Function Inoperative151
Boom Length Switch Fault156
Boom Extend Function Inoperative160
Boom Retract Function Inoperative169
Electrical Components318
Relay Layout326
Drive Chassis Controller Pin Legend327
Platform Controller Pin Legend328
Turntable Controller Pin Legend329
Electrical Schematic Legend - Drive Chassis (DCON) and Platform Controls (PCON)330
Electrical Schematic330
Electrical Schematic Legend - Ground Controls (TCON)331
Electrical Schematic331
Safety Circuit Schematic335
Electrical Schematic - Generators336
Electrical Schematic - Deutz Models337
Electrical Schematic - Cummins and Perkins Models338
Hydraulic Symbols Legend340
Repair Procedures353
Display Module354
Platform Controls356
Joystick Controllers356
Circuit Boards357
Membrane Decal358
Foot Switch366
Toggle Switches367
Platform Components368
Platform Leveling Cylinder368
Platform Rotator370
Platform Overload System373
Limit Switches415
Wire Circuit Legend492

Genie S-100 - Service Manual

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