Operator`s Manual - Genie Industries
Contents
1. Soft N RAR AD AN o p o o o nw fF AA F F F F F sa S N N o SN ON ON ono wp o SS ia sx M ra U w 3 3 3 3 3a S 5 PartNo 62756 Genie S 120 amp Genie S 125 M 9 Operator s Manual First Edition Fourth Printing SPECIFICATIONS S 125 S 125 Height working maximum 131 ft 39 9 m Controls 12V DC proportional Height platform maximum 125 ft 38 1 m Platform dimensions 96 x 36 in i length x width 2 4 m x 91 cm Height stowed maximum 10 ft 1 in 3 1 m Platform leveling self leveling Horizontal reach maximum 80 ft 24 4 m Platform rotation 160 Width axles retracted 8 ft 6 in 2 6m AC outlet in platform standard Width axles extended 11 ft6in 3 5 m 3 Hydraulic pressure maximum 4250 psi 293 bar Length stowed 39 ft 11 in 12 2 m drive functions Maximum load capacity 500 ID 227 kg Tire size 18 x 22 5 18 pr FF Wheelbase 12 ft 3 7 M gt Gradeability stowed 40 Turning radius outside 24 ft 4 in 74m gt Ground clearance 153 4 in 40 cm axles retracted Hydraulic tank capacity 55 gallons 208 liters Turning radius inside 16 ft 4 in 4 9 m axles retracted Fuel tank capacity 40 gallons 151 liters Turning radius outside 20 ft 8 in 6 3 m Weight 44 640 Ibs 20 248 kg axles extended Airborne noise emissions 80 dB Turning radius inside 102. A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual 10 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing SS ______ Pre operation Inspection a Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Be sure that all decals are legible and in place See Decals section Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for damage and improper
3. Result The fluid level should be in the NORMAL range Bodily injury hazard Fluids in the AWARNING radiator are under pressure and extremely hot Use caution when removing cap and adding fluids Scheduled Maintenance The scheduled maintenance items must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Inspections and maintenance described below require the qualified entity to record and retain records of all inspections and maintenance items for four years Machines that have been out of service for more than three months must receive the quarterly inspection before placing the machine back into service The Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual two year To account for repeated procedures the Scheduled Maintenance Procedures Section and the Maintenance Inspection Reporthave been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report
4. button for crab Ad ky steer 50 Press down the foot switch 51 Slowly move the drive steer control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue traingle Result All wheels should turn in the direction that the blue triangles point on the drive chassis 18 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual 52 Push the steer mode select button for coordinated steer 53 Press down the foot switch 54 Slowly move the drive steer control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue traingle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis Test Drive and Braking 55 Press down the foot switch 56 Slowly move the drive steer control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 57 Slowly move the drive steer control handle in the direction indicated by
5. 120 amp Genie S 125 Operators Manual First Edition Fourth Printing SAFETY RULES Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct athorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate service manual Be sure all decals are in place and legible Be sure safety and operator s manuals are complete legible and in the storage container located on the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Decal Legend Genie product decals use symbols color coding and signal words to identify the following messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety Yellow with
6. Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 05 50KV to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 500KV to 750KV 35 10 67 750KV to 1000KV 45 13 72 Allow for platform movement electrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not use the machine as a ground for welding unless the machine is equipped with the weld line to platform option and it is properly connected Tip over Hazards Occupants and equipment shall not exceed the maximum platform capacity Maximum platform capacity S 120 750 Ibs 340 kg S 125 500 Ibs 227 kg Maximum occupants 2 Do not raise or extend the boom unless the machine is on a firm level surface Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope 2 Genie S 120 amp Genie S 125 PartNo 62756 First Edition Fourth Printing Operator s Manual If the tilt alarm sounds Do not extend rotate or raise the boom above horizontal Move the machine to a firm level surface before raising the platform If the tilt alarm sounds when the platform is raised use extreme caution to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to a
7. S A Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the above principle before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the work place 5 Only use the machine as it was intended M You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You are properly trained to safely operate the machine Part No 62756 Genie S 120 amp Genie S 125 1 Operators Manual First Edition Fourth Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Ve sd E a Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance Feet
8. contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 14 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the above principles before going on to the next section 4 Inspect the work place 5 Only use the machine as it was intended Fundamentals The Function Tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Function Tests 1 Select a test area that is firm level and free of obstruction At the Ground Controls 2 Turn the key switch to ground
9. control 3 Pull out the red Emergency Stop button to the on position Result The LCD screen will come on and display no error messages The beacon if equipped should flash Note In cold climates the LCD readout screen will need to warm up before the display appears 4 Start the engine see Operating Instructions section Test Emergency Stop 5 Push in the red Emergency Stop button to the OFF position Result The engine should turn off and no functions should operate 6 Pull out the red Emergency Stop button to the on position and restart the engine Test the Extendable Axles Note Start this test with the axles retracted 7 Atthe ground controls push and hold a function enable speed select button and push the boom up button Result The boom should raise to 10 above horizontal and then stop The boom should not raise above the limit switch unless both axles are extended 8 Push and hold a function enable speed select button and push the boom down button Result The boom should lower and return to the stowed position PartNo 62756 Genie S 120 amp Genie S 125 15 Operators Manual First Edition Fourth Printing FUNCTIONTESTS 9 Push and hold a function enable speed select button and press the boom extend button Result The boom will extend approximately 3 feet 1 m and then stop The boom should not extend farther unless both axles are extended 10 Push and hold a
10. ft 1 in 3 1 m Maximum sound level at normal operating workstations axles extended A weighted Turntable rotation degrees 360 continuous Turntable tailswing 66 in 168 cm axles retracted Turntable tailswing 48 in 122 cm axles extended Perkins Diesel 1004 42 Deutz Diesel F4L913 Cummins Diesel 4B3 9 Power source choice 4 4 km h Drive speed stowed 3 0 mph 40 ft 9 1 sec 12 2 m 9 1 sec Drive speed 0 7 mph 1 1 km h raised or extended 40 ft 40 sec 12 2 m 40 sec Drive speed 0 4 mph 0 6 km h fully extended 40 ft 70 sec 12 2 m 70 sec Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 130 ft 39 6 m 120 ft 36 6 m 110 ft 33 5 m 100 ft 30 5 m 90 ft 27 4 m 80 ft 24 4 m 70 ft 21 3 m 60 ft 18 3 m 50 ft 15 2 m 40 ft 12 2 m 30 ft 9 1 m 20 ft 6 1 m 10ft 3m 01t 0 m UI E 1 01 Wwe YOL W 9 14 02 u 6 U 0E W gel Or W gel H OS West H 09 Oo gt ro Ek Go 3 evo 4 08 30 Genie S 120 amp Genie S 125 PartNo 62756 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other repro
11. function enable speed select button and push the boom retract button Result The boom should retract 11 At the platform controls move the drive control handle in the forward direction and push the extend axle button Result The machine should drive and the axles should extend The indicator light will flash while the axles are moving and stay on when the axles are fully extended Note The extend axle function will only work while the machine is moving 12 Return to the ground controls At the ground controls push and hold a function enable speed select button and push the boom up button and the boom down button Result The boom should raise and lower normally 13 At the ground controls push and hold a function enable speed select button and push the boom extend button and the boom retract button Result The boom should extend and retract normally Test the Machine Functions 14 Do not press and hold a function enable speed select button Attempt to activate each boom and platform function button Result No boom and platform functions should operate 15 Press and hold a function enable speed select button and activate each boom and platform function button Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while boom is lowering Test Auxiliary Controls 16 Turn the key switch to ground control and shut the engine o
12. functions Maximum load capacity 750 Ib 340 kg Tire size 18 x 22 5 18 pr FF Wheelbase 12 ft 3 7M Gradeability stowed 40 Turning radius outside 24 ft 4 in 7 4 m Ground clearance 153 4 in 40 cm axles retracted i a i Hydraulic tank capacity 55 gallons 208 liters Turning radius inside 16 ft 4 in 4 9 m axles retracted Fuel tank capacity 40 gallons 151 liters Turning radius outside 20 ft 8 in 6 3 m Weight 44 340 Ibs 20 112 kg axles extended f f T Airborne noise emissions 80 dB Turning radius inside 10 ft 1 in 3 1 m Maximum sound level at normal operating workstations axles extended A weighted Turntable rotation degrees 360 continuous Turntable tailswing 66 in 168 cm axles retracted Turntable tailswing 48 in 122 cm axles extended Perkins Diesel 1004 42 Deutz Diesel F4L913 Cummins Diesel 4B3 9 Power source choice Drive speed stowed 3 0 mph 4 4 km h 40 ft 9 1 sec 12 2 m 9 1 sec Drive speed 0 7 mph 1 1 km h raised or extended 40 ft 40 sec 12 2 m 40 sec Drive speed 0 4 mph 0 6 km h fully extended 40 ft 70 sec 12 2 m 70 sec Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 120 ft 36 6 m 110 ft 33 5 m 100 ft 30 5 m 90 ft 27 4 m 80 ft 24 4 m 70 ft 21 3 m 60 ft 18 3 m 50 ft 15 2 m 40 ft 12 2m 30 ft 9 1 m 20 ft 6 1 m 10ft 3 m Oft Om
13. safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information 6 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Controls pe EMERGENCY STOP Is RAISE BOOM i OF AE amp RETRACT BOOM g E HAI O Se Va wa EXTEND AXLE F NIZI NIZI NIZ N ZN EN EN NN ioe AUXILIARY POWER HIGH SPEED FUNCTION ENABLE OO LOW SPEED FUNCTION ENABLE GESE 6 IN Ground Control Panel 1 Boom down button 11 Engine start button 2 Boom extend retract buttons 12 Auxiliary power button 3 Boom up button 13 High speed function enable button 4 Engine speed select button 14 Low speed function enable button 5 LCD screen control buttons 15 Alarm 6 Gasoline LPG select button 16 Platform level up down buttons 7 LCD readout screen 17 S 125 models Ji
14. the platform or the load Part No 62756 Genie S 120 amp Genie S 125 Operators Manual First Edition Fourth Printing SAFETY RULES Do not place or attach overhanging loads to any part of this machine A Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition and lug nuts are properly tightened Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchorage point provided in the platform It is recommended that operators wear an approved hard hat when operating the machine Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times N s Fi 4 a gt Do not climb down from the platform when raised Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position and tailswing when rotating turntable Check work area for overhead obstructions or other possible hazards Be aware of crushing hazard when grasping the platform guard rail 4 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Ma
15. ALS 28177 72130 27564 28175 72051 28171 72168 65264 159 28164 72052 72169 or 65267 65274 or 65275 or 65276 65272 Og 72053 A 4 27564 OTO O 28161 Aw aar 65428 65273 65266 28161 27204 65428 33952 27206 k i 65182 65278 Ed PET 65269 pa Seo 39700 27207 E de 40434 65278 HOT ARE O n E 28236 n AL 28176 65278 4 LI EA 79997 EN OO fa N 30080 or A OER 43594 65278 4 28165 27206 S 44981 ri 28174 or 28235 or Pe 28163 or 44986 28157 Ti N 25994 o ae 28181 65269 28174 or 61227 27564 28161 72119 32 00 65428 65273 65273 65428 28161 27564 72087 28235 44981 72131 28177 72130 28 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Specifications S 120 S 120 Height working maximum 126 ft 38 4 m Controls 12V DC proportional Height platform maximum 120 ft 36 6 m Platform dimensions 96 x 36 in 7 length x width 2 4 m x 91 cm Height stowed maximum 10 ft 1 in 3 1 m Platform leveling self leveling Horizontal reach maximum 75 ft 22 9m 3 Platform rotation 160 Width axles retracted 8 ft 6 in 2 6m f 7 AC outlet in platform standard Width axles extended 11 ft6in 3 5 m 3 Hydraulic pressure maximum 4250 psi 293 bar Length stowed 39 ft 11 in 12 2 m drive
16. Genie Operator s Manual with Maintenance Information First Edition Fourth Printing Part No 62756 120 9 12b Operator s Manual First Edition Fourth Printing Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Safety Rules iese ek ee nen 1 seile RE EE N 7 Pre operation InspectiON ee ee ee ke ee ee 10 Maintenance sessen esse ee kn 12 Funcion Tesis EE EER eee 15 Work Place Inspection ee ee ee ee 21 Operating Instructions sesse ee ee ee ee 22 TEAMS POM ia sesse dees nee Ee dee ke ee De ee 26 DOCAS EE EE ees 27 else lies le SE EE OE 29 Contact us Internet http www genielift com N Z E mail techpub genieind com Genie Industries Copyright 2000 by Genie Industries First Edition First Printing May 2000 Second Printing July 2000 Third Printing July 2000 Fourth Printing January 2001 Genie is a registered trademark of Genie Industries in the U S A and many other countries S is a trademark of Genie Industries These machines comply with ANSI SIA 92 5 1992 gt Printed on recycled paper Printed in U
17. activate each function control handle toggle switch or button Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Machines equipped with the auxiliary power drive option The drive function should operate 20 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Work Place Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the work place Know and understand the above principles before going on to the next section 5 Only use the machine as it was intended Fundamentals The Work Place Inspection helps the operator determine if the work place is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the work place It is the operator s responsibility to read and remember the work place hazards then watch for and avoid them while moving setting up and operating the machine Work Place Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris overhead obstructions and high voltage conductors hazardous locations inadequate surfa
18. b boom up down buttons 8 Emergency Stop button 18 Platform rotate left right buttons 9 Gasoline LPG models Choke button 19 Turntable rotate left right buttons Deutz Diesel models Glow plug button 10 Key switch for off platform ground selection Part No 62756 Genie S 120 amp Genie S 125 7 Operator s Manual First Edition Fourth Printing CONTROLS 000 DE 69 PLATFORM AUXILIARY GLOW PLUG ROTATE HORN GENERATOR POWER CHOKE E S RETRACT BOOM PLATFORM LEVEL 1 z BOOM 3 UP DOWN JIB BOOM TURNTABLE ROTATE T ROTATE o TURNTABLE jy DRIVE ENABLE OPERATION Light on indicates that i BOOM la noved asti BOOM circle end tire and drive RETRACT 2 function is turned off To drive push drive enable button and slowly move drive control handle achine may drive in opposite direction that drive and steer controls are moved Use color coded direction arrows on this panel and drive chassis to identify the direction machine will ishinin TS Platform Control Panel 1 Platform rotate switch 2 Platform level switch 3 Platform Not Level indicator indicator light Gasoline LPG models 9 Auxiliary power button with 10 Diesel models Glow plug button with indicator light 12 Engine idle rpm select button with indicator lights Rabbit 8 Foot Switch foot switch activated high idle Tu
19. ce support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Part No 62756 Genie S 120 amp Genie S 125 21 Operator s Manual First Edition Fourth Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the work place 5 Only use the machine as it was intended Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel and tools to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a work place inspecti
20. ductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Holland Phone 31 7051 78836 Fax 31 70 51 13993 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 60 4 228 1235 Fax 60 4 226 6872 Genie Ib rica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Africa Phone 27 11 455 0373 Fax 27 11 455 0355 Genie Mexico City Phone 52 5 653 03 84 Fax 52 5 664 40 16 Genie Latin America Phone 55 11 4055 2499 Fax 55 11 4043 1661
21. ed 62 Press down the foot switch 63 Raise the boom to 10 above horizontal 64 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom raised should not exceed 1 foot per second 0 3 meters per second Note The machine will travel 40 feet in 40 seconds 12 2 meters in 40 seconds 65 Lower the boom to the stowed position 66 Extend the boom 4 feet 1 2 m 67 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom extended should not exceed 1 foot per second 0 3 meters per second Note The machine will travel 40 feet in 40 seconds 12 2 meters in 40 seconds If the drive speed with the boom raised or extended exceeds 1 foot per second 0 3 meters per second immediately tag and remove the machine from service 68 Raise the boom to horizontal Extend the boom as far as it will go 69 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom fully extended should not exceed 0 6 feet per second 0 2 meters per second Note The machine will travel 40 feet in 70 seconds 12 2 meters in 70 seconds Test Auxiliary Controls 70 Shut off the engine 71 Pull out the red Emergency Stop button to the on position 72 Press down the foot switch 73 Simultaneously press and hold the auxiliary power button and
22. ff 17 Pull out the red Emergency Stop button to the ON position 18 Simultaneously push and hold the auxiliary power button and push each boom function button or activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions should operate 16 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Test the Tilt Sensor 19 Push one of the LCD screen buttons until 4 TURNTABLE LEVEL SENSOR X DIRECTION appears Result The LCD screen should display the angle in degrees 20 Push one of the LCD screen buttons until TURNTABLE LEVEL SENSORY DIREGTION appears Result The LCD screen should display the angle in degrees 2 Push one of the LCD screen buttons until PLATFORM LEVEL SENSOR DEGREES appears Result The LCD screen should display the angle in degrees Test the Operating Envelope 22 Simultaneously push the LCD screen buttons shown to activate status mode af 23 Push one of the LCD screen buttons shown until BOOM 4 pa ANGLE is displayed 24 Raise the boom and observe the LCD screen Result The LCD screen should display lt 10 gt 10 gt 50 gt 65 FUNCTION TESTS 25 Push one of the LCD screen buttons shown until BOOM LENGTH is displayed 26 Extend the boom and
23. firm level surface before raising the platform Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability ry Use extreme care and slow speeds while driving the machine in stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended SAFETY RULES Maximum allowable side force 150 Ibs ANSI amp CSA 667 N Maximum allowable 90 Ibs side force CE 400 N Do not push off or pull toward any object Aa outside a of the platform ik ASS SS Do not alter or disable machine components that in any way affect safety and stability de Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of
24. ition Fourth Printing Operator s Manual Check Engine Light OPERATING INSTRUCTIONS Stopping the Engine Light on and engine stopped Tag the machine and Push in the red Emergency Stop button and turn remove from service the key switch to the orF position Light on and engine still running Contact service After Each Use personnel within 24 hours 1 Select a safe parking location firm level Operating Envelope Indicator surface clear of obstruction and traffic Lights 2 Retract and lower the boom to the stowed The operating envelope indicator lights will come positon on to notify the operator that a function has been 3 Rotate the turntable so that the boom is interrupted in some cases and or an action is between the circle end wheels required by the operator Raise Boom indicator light flashing To continue extending the boom raise the boom until the indicator light is off Retract Boom indicator light flashing To continue lowering the boom retract the boom until the indicator light is off Machine Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing Move the machine to a firm level surface Platform Not Level indicator light flashing The tilt alarm will be sounding when this light is 4 Turn the key switch to the orF position and remove the key to secure from unauthorized t use P O 5 Chock the wheels Z A o flashing The Platform Level toggle
25. label Ko og 65428 Danger Tip over Hazard Tires 4 28174 Label Power to Platform 230V 2 72051 Label 20 amp Circuit Breaker 28175 Caution Compartment Access 1 72052 Label 40 amp Circuit Breaker 1 Eat ML MiSsing Manuals 1 72058 Label 30 amp Circuit Breaker 1 A EDEN 72087 Warning Weld Line to Platform 2 Sete Warning No SIED OCR igs 1 72119 Label Range of Motion Chart 1 28235 Label Power to Platform 115V 2 72130 Warning Bodily Injury Hazard 2 28236 Warning Failure To Read 1 72131 Label Cylindar Cover 2 30080 Notice Maximum Capacity 500 Ibs S 125 1 72168 Notice Starter Battery 1 Bente anger Gencral Eg 2 72169 Notice Controls Battery 1 93952 Danger Tip over Hazard i 72866 Warning Explosion Hazard 2 40434 Label Lanyard Anchorage Point 2 43594 Notice Maximum Capacity 750 lbs S 120 1 44986 Notice Max Manual Force 90 lbs CE 1 Shading indicates decal is hidden from view i e 61227 Ground Control Panel 1 under covers Part No 62756 Genie S 120 amp Genie S 125 27 Operator s Manual First Edition Fourth Printing DEC
26. ly installed loose or missing parts u Electrical components wiring and electrical cables 4 Hydraulic hoses fittings cylinders and manifolds o Fuel and hydraulic tanks u Drive and turntable motors and drive hubs 4 Boom and axle wear pads u Tires and wheels u Engine and related components u Limit switches and horn 4 Alarms and beacons if equipped 4 Nuts bolts and other fasteners u Platform entry mid rail or gate Operator s Manual PRE OPERATION INSPECTION Check entire machine for a Crack in welds or structural components 4 Dents or damage to machine a Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened a After you complete your inspection be sure that all compartment covers are in place and latched Part No 62756 Genie S 120 amp Genie S 125 11 Operator s Manual First Edition Fourth Printing Maintenance Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbol
27. nual Observe and use the circle and square markings and the color coded direction arrows on the platform controls and drive chassis for drive and steer functions Do not lower the boom unless the area below is clear of personnel and obstructions j NEE 1 al ex i 2 4 W Limit travel speed according to the condition of ground surface congestion slope location of personnel and any other factors which may cause collision Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine SAFETY RULES Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine Do not use the machine as a ground for welding Be sure the hydraulic shutoff valves located by hydraulic tank are open before starting the engine Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in an open well ventilated area away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Part No 62756 Genie S
28. observe the LCD screen Result The LCD screen should display at 0 gt 0 gt 80 100 gt 100 27 Retract the boom At the Platform Controls Test Emergency Stop 28 Turn the key switch to platform control 29 Push in the platform red Emergency Stop button to the orF position Result The engine should turn off and no functions should operate 30 Pull out the red Emergency Stop button and restart the engine Test the Hydraulic Oil Return Filter 31 Press the engine idle speed select button until the indicator light next to high idle rabbit symbol is on 32 Locate and check the hydraulic filter condition indicator Result The filter should be operating with the plunger in the green area Filter condition indicator 33 Press the engine idle speed select button until the indicator light next to foot switch activated high idle rabbit and foot switch symbol is on Part No 62756 Genie S 120 amp Genie S 125 17 Operators Manual First Edition Fourth Printing FUNCTIONTESTS Test the Horn 34 Push the horn button Result The horn should sound Test the Tilt Sensor Alarm 35 Push a button such as the engine RPM button or the fuel select button Result The alarm should sound at the platform controls Test the Foot Switch 36 Push in the platform red Emergency Stop button to the orF position 37 Pull out the red Emergency Stop button to the on position but do not
29. on before using the machine Starting the Engine 1 At the ground controls turn the key switch to the desired position 2 Be sure both the ground and platform control red Emergency Stop buttons are pulled out to the on position 3 Gasoline LPG models Choose fuel by pressing the fuel select button If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again 4 Press the engine start button If the engine fails to start or dies the restart delay will disable the start button for 3 seconds All models In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes to prevent hydraulic system damage Gasoline LPG models In extreme cold conditions 20 F 6 C and below the machine should be started on gasoline then switched to LPG Emergency Stop Push in either the ground or platform red Emergency Stop button to the orF position to stop all functions and turn the engine off Repair any function that operates when the Emergency Stop button is pushed in to the OFF position Selecting and operating the ground controls will override the platform Emergency Stop button 22 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Auxiliary Controls Use auxiliary power if the primary power source engine fails 1 Turn the key switch to ground or pla
30. ons Reverse procedures described to re engage brakes Disengage Position Engage Position Transport configuration S 125 26 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions Part No Description Quantity Part No Description Quantity 25994 Caution Component Damage Hazard 1 65182 Platform Control Panel 1 27204 Arrow Blue 1 65264 Cosmetic Genie S 125 1 27205 Arrow Yellow 1 65265 Cosmetic S 125 1 27206 Triangle Blue 2 65266 Cosmetic 4x4 1 27207 Triangle Yellow 2 65267 Cosmetic Genie S 120 1 27564 Danger Electrocution Hazard 4 65268 Cosmetic S 120 1 28157 Label Dexron 1 65269 Notice Operating Instructions 2 28159 Label Diesel 1 65272 Serial Plate 1 28161 Warning Crush Hand 4 65273 Notice Tire Specifications 4 28163 Notice Max Side Force 150 lbs 65274 Notice Engine Specifications Deutz 1 SSIS eee d 65275 Notice Engine Specifications Cummins 1 59154 Nonce Hazel ol Materials i 65276 Notice Engine Specifications Perkins 1 28165 Notice Footswitch 1 65278 Caution No Step 4 eos
31. properties of API classification CC SE or CC SF grades 12 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual Perkins 1004 42 Engine 8 9 quarts Oil capacity including filter 8 4 liters Perkins 1004 42 Engine Oil viscosity requirements below 32 F 0 C ow 13 F to 68 F 25 C to 20 C 5W 20 10 F to 104 F 12 C to 40 C 10W 30 14 F to 122 F 10 C to 50 C 15W 40 above 23 F 5 C 20W 50 Engine oil should have properties of API classification CF4 grade Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron equivalent MAINTENANCE Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Electrocution hazard Con
32. ressing a steer mode button The indicator light next to the current steer mode will be on 3 Slowly move the drive steer control handle in the blue or yellow triangle direction OR press the thumb rober switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn Part No 62756 Genie S 120 amp Genie S 125 23 Operator s Manual First Edition Fourth Printing OPERATINGINSTRUCTIONS To Drive 1 Press down the foot switch 2 Increase speed Slowly move the drive steer control in the blue or yellow arrow direction Decrease speed Slowly move the drive steer control handle toward center Stop Return the drive steer control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the boom is raised or extended Drive Enable Light on indicates that the boom has moved past either circle end wheel and drive function is turned off To drive push the drive enable button and slowly move the drive steer control handle off center If the drive steer control handle is not moved within two seconds of pushing the drive enable button the drive function will not operate Release and push the drive enable button again Be aware tha
33. rtle low idle ont l MN Choke button with indicator Rabbit high idle 4 Machine Not Level indicator light 13 Gasoline LPG models light o l 11 Engine start button with Gasoline LPG select 5 Retract Boom indicator light indicator light button with indicator lights 6 Raise Boom indicator light 14 Fault indicator light 7 Horn button 15 Low fuel indicator light 8 Generator button with 16 Check engine indicator light indicator light option 8 Genie S 120 amp Genie S 125 Part No 62756 First Edition Fourth Printing Operator s Manual CONTROLS 9 5 9 D ENGINE START RPM FUEL SELECT EMERGENCY STOP LOW FUEL FAULT CHECK ENGINE POWER T0 start STEER MODE SELECT s 10 stor ESSENS 17 Emergency Stop button 18 Power indicator light 19 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 20 Used for optional equipment 21 Steer mode select buttons with indicator lights 22 Drive select button with indicator lights Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed 23 Single axis proportional control handle for boom extend retract function 9 8 24 Extend axle button with indicator light 25 Retract axle b
34. s appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure a Z Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the engine oil dipstick Add oil as needed Cummins models Result The oil level should be within the L and H marks on the dipstick Deutz models Result The oil level should be within the two marks on the dipstick Perkins models Result The oil level should be within the two notches on the dipstick Cummins B3 9L Engine 11 5 quarts Oil capacity including filter 10 9 liters Cummins B3 9L Engine Oil viscosity requirements below 68 F 20 C 5W 30 10 to 68 F 23 to 20 C 10W 30 above 15 F 9 C 15W 40 Use oils meeting API classification CE labeled CE SG Deutz F4L 913 Engine 14 quarts Oil capacity including filter 13 5 liters Deutz F4L 913 Engine Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have
35. start the engine 38 Press down the foot switch and attempt to start the engine by pushing the engine start button Result The engine should not start 39 Do not press down the foot switch and restart the engine 40 Do not press down the foot switch and test each machine function Result No machine functions should operate Test Machine Functions 41 Press down the foot switch 42 Activate each machine function control handle toggle switch or button Result All functions should operate through a full cycle Test the Steering 43 Push the steer mode select button for square end blue arrow steer 44 Press down the foot switch 45 Slowly move the drive steer control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis 46 Push the steer mode select button for circle end yellow arrow steer 47 Press down the foot switch 48 Slowly move the drive steer control handle in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis 49 Push the steer J O O O
36. switch will only work in the direction that will level the platform Level the platform until the indicator light is off Part No 62756 Genie S 120 amp Genie S 125 25 Operator s Manual First Edition Fourth Printing Transport Instructions Transport Instructions Observe and Obey M Transport vehicle must be parked on a level surface M Transport vehicle must be secured to prevent rolling while machine is being loaded M Be sure vehicle capacity loading surfaces and straps or lines are sufficient to withstand machine weight see Specifications section M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Always chock machine wheels in preparation for transport Use tie points on drive chassis for anchoring down to transport surface Use chains or straps of ample load capacity Turn key switch to the oFF position and remove key before transporting Inspect entire machine for loose or unsecured items Free wheel Configuration for Winching Chock wheels to prevent machine from rolling 4WD models Release wheel brakes by turning over all four torque hub disconnect caps see below Be sure winch line is properly secured to drive chassis tie points and path is clear of all obstructi
37. t the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Non regulated Generator if equipped To operate the generator press the generator button The indicator light will come on and the engine rpm will automatically be in turtle symbol mode The engine will continue to run the drive functions and the platform functions will operate If the rabbit symbol or the rabbit and footswitch symbol are selected the generator will shut off and the indicator light will go off Plug power tools into the power to platform GFCI outlet To turn off the generator push the generator button The indicator light will turn off Regulated Generator if equipped To operate the generator press the generator button The indicator light will come on and the engine will continue to run Plug power tools into the power to platform GFCI outlet To turn off the generator push the generator button The indicator light will turn off Engine Idle Select rpm Select the engine idle rpm by pressing the select button The indicator light next to the current setting will be on Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle 24 Genie S 120 amp Genie S 125 Part No 62756 First Ed
38. tact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Besure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight 4 Remove the battery vent caps 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Tank capacity 55 gallons 208 liters Hydraulic system 65 gallons 246 liters including tank Part No 62756 Genie S 120 amp Genie S 125 13 Operators Manual First Edition Fourth Printing MAINTENANCE Check the Engine Coolant Level Liguid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed
39. tform control 2 Pull out the red Emergency Stop button to the ON position 3 Press down the foot switch when operating the auxiliary controls from the platform 4 Simultaneously hold the auxiliary power button and activate the desired function Machines equipped with the auxiliary power drive option The drive function will operate Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Gasoline LPG models Choose fuel by pressing the fuel select button 4 Start the engine To Position Platform 1 Push and hold a function enable speed select button ad 2 Push the appropriate function button according to the markings on the control panel Drive and steer functions are not available from the ground controls OPERATING INSTRUCTIONS Operation from Platform 1 Turn the key switch to platform control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Gasoline LPG models Choose fuel by pressing the fuel select button 4 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Press down the foot switch 2 Slowly move the appropriate function control handle or toggle switch or press the appropriate button according to the markings on the control panel To Steer 1 Press down the foot switch 2 Select the steer mode by p
40. the yellow arrow on the FUNCTION TESTS Test the Drive Enable System 58 Press down the foot switch and lower the boom to the stowed position 59 Rotate the turntable until the boom moves past one of the circle end tires Result The drive enable indicator light should come on while the boom is anywhere in the range shown 60 Move the drive steer control handle off center Result No drive function should operate 61 Push the drive enable button and slowly move the drive steer control handle off center Result The drive function should operate Note When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved Use the color coded direction arrows on the platform Blue t controls and the drive chassis to identify the direction of travel If the drive steer control Yellow control panel until the machine begins to move handle is not moved within then return the handle to the center position two seconds of pushing the Result The machine should move in the drive enable button the drive direction that the yellow arrow points on the function will not operate drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Part No 62756 Genie S 120 amp Genie S 125 19 Operators Manual First Edition Fourth Printing FUNCTIONTESTS Test Limited Drive Spe
41. utton with indicator light 26 Drive enable button with indicator light 27 Dual axis proportional control handle for boom up down and turntable rotate left right functions 28 S 125 models Jib boom up down toggle switch Part No 62756 Genie S 120 amp Genie S 125 Operator s Manual First Edition Fourth Printing Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the above principles before going on to the next section 3 Always perform function tests prior to use 4 Inspect the work place 5 Only use the machine as it was intended Fundamentals It is the responsibility of the operator to perform a Pre operation Inspection and routine maintenance The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items and locations for modifications damage or loose or missing parts
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