Operator s Manual with Maintenance Information. First Edition Third Printing Part No

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1 Operatr s Manual with Maintenance Infrmatin First Editin Third Printing Part N

2 Operatr's Manual First Editin Third Printing Imprtant Read, understand and bey these safety rules and perating instructins befre perating this machine. Only trained and authrized persnnel shall be permitted t perate this machine. This manual shuld be cnsidered a permanent part f yur machine and shuld remain with the machine at all times. If yu have any questins, call Genie Industries. Cntents Page Safety Rules... 1 Cntrls... 7 Pre-peratin Inspectin Maintenance Functin Tests Wrk Place Inspectin Operating Instructins Transprt Decals Specificatins Cntact us: Internet: techpub@genieind.cm Cpyright 2000 by Genie Industries First Editin: First Printing, June 2000 Secnd Printing, July 2000 Third Printing, January 2001 "Genie" is a registered trademark f Genie Industries in the U.S.A. and many ther cuntries. "S" is a trademark f Genie Industries. These machines cmply with ANSI/SIA Printed n recycled paper Printed in U.S.A. Genie S-100 & Genie S-105 Part N

3 First Editin Third Printing Operatr's Manual Safety Rules Danger Failure t bey the instructins and safety rules in this manual will result in death r serius injury. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. Knw and understand the abve principle befre ging n t the next sectin. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. 5 Only use the machine as it was intended. Yu read, understand and bey: Manufacturer's instructins and safety rules safety and peratr's manuals and machine decals emplyer's safety rules and wrksite regulatins applicable gvernmental regulatins Yu are prperly trained t safely perate the machine. Part N Genie S-100 & Genie S-105 1

4 Operatr's Manual First Editin Third Printing SAFETY RULES Electrcutin Hazards This machine is nt electrically insulated and will nt prvide prtectin frm cntact with r prximity t electrical current. Allw fr platfrm mvement, electrical line sway r sag and beware f strng r gusty winds. Keep away frm the machine if it cntacts energized pwer lines. Persnnel n the grund r in the platfrm must nt tuch r perate the machine until energized pwer lines are shut ff. D nt use the machine as a grund fr welding unless the machine is equipped with the weld line t platfrm ptin and it is prperly cnnected. Tip-ver Hazards Occupants and equipment shall nt exceed the maximum platfrm capacity. Maintain safe distances frm electrical pwer lines and apparatus in accrdance with applicable gvernmental regulatins and the fllwing chart. Vltage Minimum Safe Phase t Phase Apprach Distance Feet Meters 0 t 300V Avid Cntact 300V t 50KV Maximum platfrm capacity S lbs 340 kg S lbs 227 kg Maximum ccupants 2 D nt raise r extend the bm unless the machine is n a firm, level surface. 50KV t 200KV KV t 350KV KV t 500KV KV t 750KV KV t 1000KV D nt depend n the tilt alarm as a level indicatr. The tilt alarm sunds in the platfrm nly when the machine is n a severe slpe. 2 Genie S-100 & Genie S-105 Part N

5 First Editin Third Printing Operatr's Manual SAFETY RULES If the tilt alarm sunds: D nt extend, rtate r raise the bm abve hrizntal. Mve the machine t a firm, level surface befre raising the platfrm. If the tilt alarm sunds when the platfrm is raised, use extreme cautin t retract the bm and lwer the platfrm. D nt rtate the bm while lwering. Mve the machine t a firm, level surface befre raising the platfrm. D nt use the platfrm cntrls t free a platfrm that is caught, snagged r therwise prevented frm nrmal mtin by an adjacent structure. All persnnel must be remved frm the platfrm befre attempting t free the platfrm using the grund cntrls. D nt perate the machine in strng r gusty winds. D nt increase the surface area f the platfrm r the lad. Increasing the area expsed t the wind will decrease machine stability. Maximum allwable side frce 150 lbs - ANSI & CSA 667 N Maximum allwable side frce - CE D nt push ff r pull tward any bject utside f the platfrm. D nt alter r disable machine cmpnents that in any way affect safety and stability. D nt replace items critical t machine stability with items f different weight r specificatin. 90 lbs 400 N D nt mdify r alter an aerial wrk platfrm. Munting attachments fr hlding tls r ther materials nt the platfrm, tebards r guard rail system can increase the weight in the platfrm and the surface area f the platfrm r the lad. Use extreme care and slw speeds while driving the machine in stwed psitin acrss uneven terrain, debris, unstable r slippery surfaces and near hles and drp-ffs. D nt drive the machine n r near uneven terrain, unstable surfaces r ther hazardus cnditins with the bm raised r extended. Part N Genie S-100 & Genie S-105 3

6 Operatr's Manual First Editin Third Printing SAFETY RULES D nt place r attach verhanging lads t any part f this machine. D nt sit, stand r climb n the platfrm guard rails. Maintain a firm fting n the platfrm flr at all times. D nt place ladders r scafflds in the platfrm r against any part f this machine. D nt use the machine n a mving r mbile surface r vehicle. Be sure all tires are in gd cnditin and lug nuts are prperly tightened. Fall Hazards Occupants must wear a safety belt r harness in accrdance with gvernmental regulatins. Attach the lanyard t the anchrage pint prvided in the platfrm. It is recmmended that peratrs wear an apprved hard hat when perating the machine. D nt climb dwn frm the platfrm when raised. Keep the platfrm flr clear f debris. Lwer the platfrm entry mid-rail r clse the entry gate befre perating. Cllisin Hazards Be aware f limited sight distance and blind spts when driving r perating. Be aware f bm psitin and tailswing when rtating turntable. Check wrk area fr verhead bstructins r ther pssible hazards. Be aware f crushing hazard when grasping the platfrm guard rail. 4 Genie S-100 & Genie S-105 Part N

7 First Editin Third Printing Operatr's Manual SAFETY RULES Observe and use the circle and square markings and the clr-cded directin arrws n the platfrm cntrls and drive chassis fr drive and steer functins. D nt lwer the bm unless the area belw is clear f persnnel and bstructins. Cmpnent Damage Hazards D nt use any battery r charger greater than 12V t jump-start the engine. D nt use the machine as a grund fr welding. Be sure the hydraulic shutff valves (lcated by hydraulic tank) are pen befre starting the engine. Explsin and Fire Hazards D nt start the engine if yu smell r detect liquid petrleum gas (LPG), gasline, diesel fuel r ther explsive substances. D nt refuel the machine with the engine running. Limit travel speed accrding t the cnditin f grund surface, cngestin, slpe, lcatin f persnnel, and any ther factrs which may cause cllisin. D nt perate a bm in the path f any crane unless the cntrls f the crane have been lcked ut and/r precautins have been taken t prevent any ptential cllisin. Refuel the machine and charge the battery nly in an pen, well-ventilated area away frm sparks, flames and lighted tbacc. D nt perate the machine in hazardus lcatins r lcatins where ptentially flammable r explsive gases r particles may be present. N stunt driving r hrseplay while perating a machine. Part N Genie S-100 & Genie S-105 5

8 Operatr's Manual First Editin Third Printing SAFETY RULES Damaged Machine Hazards D nt use a damaged r malfunctining machine. Cnduct a thrugh pre-peratin inspectin f the machine and test all functins befre each wrk shift. Immediately tag and remve frm service a damaged r malfunctining machine. Be sure all maintenance has been perfrmed as specified in this manual and the apprpriate service manual. Be sure all decals are in place and legible. Be sure safety and peratr s manuals are cmplete, legible and in the strage cntainer lcated n the platfrm. Bdily Injury Hazard D nt perate the machine with a hydraulic il r air leak. An air leak r hydraulic leak can penetrate and/r burn skin. Always perate the machine in a well-ventilated area t avid carbn mnxide pisning. Decal Legend Genie prduct decals use symbls, clr cding and signal wrds t identify the fllwing: Safety alert symbl used t alert persnnel t ptential persnal injury hazards. Obey all safety messages that fllw this symbl t avid pssible injury r death. Red used t indicate the presence f an imminently hazardus situatin which, if nt avided, will result in death r serius injury. Orange used t indicate the presence f a ptentially hazardus situatin which, if nt avided, culd result in death r serius injury. Yellw with safety alert symbl used t indicate the presence f a ptentially hazardus situatin which, if nt avided, may cause minr r mderate injury. Yellw withut safety alert symbl used t indicate the presence f a ptentially hazardus situatin which, if nt avided, may result in prperty damage. Green used t indicate peratin r maintenance infrmatin. 6 Genie S-100 & Genie S-105 Part N

9 First Editin Third Printing Operatr's Manual Cntrls Grund Cntrl Panel 1 Bm dwn buttn 2 Bm extend/retract buttns 3 Bm up buttn 4 Engine speed select buttn 5 LCD screen cntrl buttns 6 Gasline/LPG select buttn 7 LCD readut screen 8 Emergency Stp buttn 9 Gasline/LPG mdels: Chke buttn Deutz Diesel mdels: Glw plug buttn 10 Key switch fr ff/platfrm/grund selectin 11 Engine start buttn 12 Auxiliary pwer buttn 13 High speed functin enable buttn 14 Lw speed functin enable buttn 15 Alarm 16 Platfrm level up/dwn buttns 17 S-105 mdels: Jib bm up/dwn buttns 18 Platfrm rtate left/right buttns 19 Turntable rtate left/right buttns Part N Genie S-100 & Genie S-105 7

10 Operatr's Manual First Editin Third Printing CONTROLS Platfrm Cntrl Panel 1 Platfrm rtate switch 2 Platfrm level switch 3 Platfrm Nt Level indicatr light 4 Machine Nt Level indicatr light 5 Retract Bm indicatr light 6 Raise Bm indicatr light 7 Hrn buttn 8 Generatr buttn with indicatr light (ptin) 9 Auxiliary pwer buttn with indicatr light 10 Diesel mdels: Glw plug buttn with indicatr light Gasline/LPG mdels: Chke buttn with indicatr light 11 Engine start buttn with indicatr light 12 Engine idle (rpm) select buttn with indicatr lights: Rabbit & Ft Switch: ft switch activated high idle Turtle: lw idle Rabbit: high idle 13 Gasline/LPG mdels: Gasline/LPG select buttn with indicatr lights 14 Fault indicatr light 15 Lw fuel indicatr light 16 Check engine indicatr light 8 Genie S-100 & Genie S-105 Part N

11 First Editin Third Printing Operatr's Manual CONTROLS Emergency Stp buttn 18 Pwer indicatr light 19 Dual axis prprtinal cntrl handle fr drive and steer functins OR Prprtinal cntrl handle fr drive functin and thumb rcker fr steer functin 20 Used fr ptinal equipment 21 Steer mde select buttns with indicatr lights 22 Drive select buttn with indicatr lights: Machine n incline symbl: Lw range peratin fr inclines Machine n level surface symbl: High range peratin fr maximum drive speed 23 Single axis prprtinal cntrl handle fr bm extend/retract functin 24 Extend axle buttn with indicatr light 25 Retract axle buttn with indicatr light 26 Drive enable buttn with indicatr light 27 Dual axis prprtinal cntrl handle fr bm up/dwn and turntable rtate left/right functins 28 S-105 mdels: Jib bm up/ dwn tggle switch Part N Genie S-100 & Genie S-105 9

12 Operatr's Manual First Editin Third Printing Pre-peratin Inspectin Fundamentals It is the respnsibility f the peratr t perfrm a Pre-peratin Inspectin and rutine maintenance. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. Knw and understand the abve principles befre ging n t the next sectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. 5 Only use the machine as it was intended. The Pre-peratin Inspectin is a visual inspectin perfrmed by the peratr prir t each wrk shift. The inspectin is designed t discver if anything is apparently wrng with a machine befre the peratr perfrms the functin tests. The Pre-peratin inspectin als serves t determine if rutine maintenance prcedures are required. Only rutine maintenance items specified in this manual may be perfrmed by the peratr. Refer t the list n the next page and check each f the items and lcatins fr mdificatins, damage r lse r missing parts. A damaged r mdified machine must never be used. If damage r any variatin frm factry delivered cnditin is discvered, the machine must be tagged and remved frm service. Repairs t the machine may nly be made by a qualified service technician, accrding t the manufacturer's specificatins. After repairs are cmpleted, the peratr must perfrm a pre-peratin inspectin again befre ging n t the functin tests. Scheduled maintenance inspectins shall be perfrmed by qualified service technicians, accrding t the manufacturer's specificatins and the requirements listed in the respnsibilities manual. 10 Genie S-100 & Genie S-105 Part N

13 First Editin Third Printing Operatr's Manual PRE-OPERATION INSPECTION Pre-peratin Inspectin Be sure that the peratr s, safety and respnsibilities manuals are cmplete, legible and in the strage cntainer lcated in the platfrm. Be sure that all decals are legible and in place. See Decals sectin. Check fr engine il leaks and prper il level. Add il if needed. See Maintenance sectin. Check fr hydraulic il leaks and prper il level. Add il if needed. See Maintenance sectin. Check fr engine clant leaks and prper level f clant. Add clant if needed. See Maintenance sectin. Check fr battery fluid leaks and prper fluid level. Add distilled water if needed. See Maintenance sectin. Check the fllwing cmpnents r areas fr damage and imprperly installed, lse r missing parts: Electrical cmpnents, wiring and electrical cables Hydraulic hses, fittings, cylinders and maniflds Fuel and hydraulic tanks Drive and turntable mtrs and drive hubs Bm and axle wear pads Tires and wheels Engine and related cmpnents Limit switches and hrn Alarms and beacns (if equipped) Nuts, blts and ther fasteners Platfrm entry mid-rail r gate Check entire machine fr: Crack in welds r structural cmpnents Dents r damage t machine Be sure that all structural and ther critical cmpnents are present and all assciated fasteners and pins are in place and prperly tightened. After yu cmplete yur inspectin, be sure that all cmpartment cvers are in place and latched. Part N Genie S-100 & Genie S

14 Operatr's Manual First Editin Third Printing Maintenance Check the Engine Oil Level Observe and Obey: Only rutine maintenance items specified in this manual shall be perfrmed by the peratr. Scheduled maintenance inspectins shall be cmpleted by qualified service technicians, accrding t the manufacturer's specificatins and the requirements specified in the respnsibilities manual. Maintenance Symbls Legend The fllwing symbls have been used in this manual t help cmmunicate the intent f the instructins. When ne r mre f the symbls appear at the beginning f a maintenance prcedure, it cnveys the meaning belw. Indicates that tls will be required t perfrm this prcedure. Indicates that new parts will be required t perfrm this prcedure. Indicates that a cld engine is required befre perfrming this prcedure. Maintaining the prper engine il level is essential t gd engine perfrmance and service life. Operating the machine with an imprper il level can damage engine cmpnents. Check the il level with the engine ff. 1 Check the engine il dipstick. Add il as needed. Cummins mdels: Result: The il level shuld be within the "L" and "H" marks n the dipstick. Deutz mdels: Result: The il level shuld be within the tw marks n the dipstick. Perkins mdels: Result: The il level shuld be within the tw ntches n the dipstick. Cummins B3.9L Engine Oil capacity (including filter) Cummins B3.9L Engine Oil viscsity requirements 11.5 quarts 10.9 liters belw 68 F / 20 C 5W t 68 F / -23 t 20 C 10W-30 abve 15 F / -9 C 15W-40 Use ils meeting API classificatin CE (labeled CE/ SG). Deutz F4L 913 Engine Oil capacity (including filter) Deutz F4L 913 Engine Oil viscsity requirements 14 quarts 13.5 liters belw 60 F / 15.5 C (synthetic) 5W F t 90 F / -23 C t 32 C 10W-40 abve -4 F / -34 C 15W-40 Engine il shuld have prperties f API classificatin CC/SE r CC/SF grades. 12 Genie S-100 & Genie S-105 Part N

15 First Editin Third Printing Operatr's Manual MAINTENANCE Perkins Engine Oil capacity (including filter) 8.9 quarts 8.4 liters Check the Batteries Perkins Engine Oil viscsity requirements belw 32 F / 0 C 0W -13 F t 68 F / -25 C t 20 C 5W F t 104 F / -12 C t 40 C 10W F t 122 F / -10 C t 50 C 15W-40 abve 23 F / -5 C 20W-50 Engine il shuld have prperties f API classificatin CF4 grade. Check the Hydraulic Oil Level Maintaining the hydraulic il at the prper level is essential t machine peratin. Imprper hydraulic il levels can damage hydraulic cmpnents. Daily checks allw the inspectr t identify changes in il level that might indicate the presence f hydraulic system prblems. 1 Be sure that the bm is in the stwed psitin, then visually inspect the sight gauge lcated n the side f the hydraulic il tank. Result: The hydraulic il level shuld be within the tp 2 inches (5 cm) f the sight gauge. Hydraulic il specificatins Prper battery cnditin is essential t gd engine perfrmance and peratinal safety. Imprper fluid levels r damaged cables and cnnectins can result in engine cmpnent damage and hazardus cnditins. Electrcutin hazard. Cntact with ht r live circuits may result in death r serius injury. Remve all rings, watches and ther jewelry. Bdily injury hazard. Batteries cntain acid. Avid spilling r cntacting battery acid. Neutralize battery acid spills with baking sda and water. 1 Put n prtective clthing and eye wear. 2 Be sure that the battery cable cnnectins are free f crrsin. 3 Be sure that the battery hld dwns and cable cnnectins are tight. 4 Remve the battery vent caps. 5 Check the battery acid level. If needed, replenish with distilled water t the bttm f the battery fill tube. D nt verfill. 6 Install the vent caps. Adding terminal prtectrs and a crrsin preventative sealant will help eliminate crrsin n the battery terminals and cables. Hydraulic il type Dexrn equivalent Tank capacity 55 gallns 208 liters Hydraulic system 65 gallns 246 liters (including tank) Part N Genie S-100 & Genie S

16 Operatr's Manual First Editin Third Printing MAINTENANCE Check the Engine Clant Level - Liquid Cled Mdels Maintaining the engine clant at the prper level is essential t engine service life. Imprper clant level will affect the engine's cling capability and damage engine cmpnents. Daily checks will allw the inspectr t identify changes in clant level that might indicate cling system prblems. The Schedule There are five types f maintenance inspectins that must be perfrmed accrding t a schedule daily, quarterly, six mnths, annual, tw year. T accunt fr repeated prcedures, the Scheduled Maintenance Prcedures Sectin and the Maintenance Inspectin Reprt have been divided int five subsectins A, B, C, D and E. Use the fllwing chart t determine which grup(s) f prcedures are required t perfrm a scheduled inspectin. 1 Check the fluid level in the clant recvery tank. Add fluid as needed. Result: The fluid level shuld be in the NORMAL range. Bdily injury hazard. Fluids in the radiatr are under pressure and extremely ht. Use cautin when remving cap and adding fluids. Inspectin Daily r every 8 hurs Quarterly r every 250 hurs Six mnths r every 500 hurs Annual r every 1000 hurs Tw year r every 2000 hurs Table r Checklist A A + B A + B + C A + B + C + D A + B + C + D + E Scheduled Maintenance The scheduled maintenance items must be cmpleted by a persn trained and qualified t perfrm maintenance n this machine accrding t the prcedures fund in the service manual fr this machine. Inspectins and maintenance described belw require the qualified entity t recrd and retain recrds f all inspectins and maintenance items fr fur years. Maintenance Inspectin Reprt The maintenance inspectin reprt cntains checklists fr each type f scheduled inspectin. Make cpies f the Maintenance Inspectin Reprt t use fr each inspectin. Stre cmpleted frms fr three years. Machines that have been ut f service fr mre than three mnths must receive the quarterly inspectin befre placing the machine back int service. 14 Genie S-100 & Genie S-105 Part N

17 First Editin Third Printing Operatr's Manual Functin Tests D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. Knw and understand the abve principles befre ging n t the next sectin. 4 Inspect the wrk place. 5 Only use the machine as it was intended. Fundamentals The Functin Tests are designed t discver any malfunctins befre the machine is put int service. The peratr must fllw the step-by-step instructins t test all machine functins. A malfunctining machine must never be used. If malfunctins are discvered, the machine must be tagged and remved frm service. Repairs t the machine may nly be made by a qualified service technician, accrding t the manufacturer's specificatins. After repairs are cmpleted, the peratr must perfrm a pre-peratin inspectin and functin tests again befre putting the machine int service. 1 Select a test area that is firm, level and free f bstructin. At the Grund Cntrls 2 Turn the key switch t grund cntrl. 3 Pull ut the red Emergency Stp buttn t the ON psitin. Result: The LCD screen will cme n and display n errr messages. The beacn (if equipped) shuld flash. Nte: In cld climates, the LCD readut screen will need t warm up befre the display appears. 4 Start the engine (see Operating Instructins sectin). Test Emergency Stp 5 Push in the red Emergency Stp buttn t the OFF psitin. Result: The engine shuld turn ff and n functins shuld perate. 6 Pull ut the red Emergency Stp buttn t the ON psitin and restart the engine. Test the Extendable Axles Nte: Start this test with the axles retracted. 7 At the grund cntrls, push and hld a functin enable/speed select buttn and push the bm up buttn. Result: The bm shuld raise t 10 abve hrizntal and then stp. The bm shuld nt raise abve the limit switch unless bth axles are extended. 8 Push and hld a functin enable/speed select buttn and push the bm dwn buttn. Result: The bm shuld lwer and return t the stwed psitin. Part N Genie S-100 & Genie S

18 Operatr's Manual First Editin Third Printing FUNCTION TESTS 9 Push and hld a functin enable/speed select buttn and press the bm extend buttn. Result: The bm shuld nt extend. The bm shuld nt extend unless bth axles are extended. 10 Push and hld a functin enable/speed select buttn and push the bm retract buttn. Result: The bm shuld retract. 11 At the platfrm cntrls, mve the drive cntrl handle in the frward directin and push the extend axle buttn. Result: The machine shuld drive and the axles shuld extend. The indicatr light will flash while the axles are mving and stay n when the axles are fully extended. Nte: The extend axle functin will nly wrk while the machine is mving. 12 Return t the grund cntrls. At the grund cntrls, push and hld a functin enable/speed select buttn and push the bm up buttn and the bm dwn buttn. Result: The bm shuld raise and lwer nrmally. 13 At the grund cntrls, push and hld a functin enable/speed select buttn and push the bm extend buttn and the bm retract buttn. Result: The bm shuld extend and retract nrmally. Test the Machine Functins 14 D nt press and hld a functin enable/speed select buttn. Attempt t activate each bm and platfrm functin buttn. Result: N bm and platfrm functins shuld perate. 15 Press and hld a functin enable /speed select buttn and activate each bm and platfrm functin buttn. Result: All bm and platfrm functins shuld perate thrugh a full cycle. Descent alarm (if equipped) shuld sund while bm is lwering. Test Auxiliary Cntrls 16 Turn the key switch t grund cntrl and shut the engine ff. 17 Pull ut the red Emergency Stp buttn t the ON psitin. 18 Simultaneusly push and hld the auxiliary pwer buttn and push each bm functin buttn r activate each bm functin tggle switch. Nte: T cnserve battery pwer, test each functin thrugh a partial cycle. Result: All bm functins shuld perate. 16 Genie S-100 & Genie S-105 Part N

19 First Editin Third Printing Operatr's Manual FUNCTION TESTS Test the Tilt Sensr 19 Push the LCD screen buttns until TURNTABLE LEVEL SENSOR X-DIRECTION appears. Result: The LCD screen shuld display the angle in degrees. 20 Push the LCD screen buttns until TURNTABLE LEVEL SENSOR Y-DIRECTION appears. Result: The LCD screen shuld display the angle in degrees. 21 Push the LCD screen buttns until PLATFORM LEVEL SENSOR DEGREES appears. Result: The LCD screen shuld display the angle in degrees. Test the Operating Envelpe 22 Simultaneusly push the LCD screen buttns shwn t activate status mde. 23 Push the LCD screen buttns shwn until BOOM ANGLE is displayed. 24 Raise the bm and bserve the LCD screen. Result: The LCD screen shuld display: < 10 >= 5 >= 50 > Push the LCD screen buttns shwn until BOOM LENGTH is displayed. 26 Extend the bm and bserve the LCD screen. Result: The LCD screen shuld display: at 0 > 0 > 80 = 100 > Retract the bm. At the Platfrm Cntrls Test Emergency Stp 28 Turn the key switch t platfrm cntrl. 29 Push in the platfrm red Emergency Stp buttn t the OFF psitin. Result: The engine shuld turn ff and n functins shuld perate. 30 Pull ut the red Emergency Stp buttn and restart the engine. Test the Hydraulic Oil Return Filter 31 Press the engine idle speed select buttn until the indicatr light next t high idle (rabbit symbl) is n. 32 Lcate and check the hydraulic filter cnditin indicatr. Result: The filter shuld be perating with the plunger in the green area. 33 Press the engine idle speed select buttn until the indicatr light next t ft switch activated high idle (rabbit and ft switch symbl) is n. Part N Genie S-100 & Genie S

20 Operatr's Manual First Editin Third Printing FUNCTION TESTS Test the Hrn 34 Push the hrn buttn. Result: The hrn shuld sund. Test the Tilt Sensr Alarm 35 Push a buttn, such as the engine RPM buttn r the fuel select buttn. Result: The alarm shuld sund at the platfrm cntrls. Test the Ft Switch 36 Push in the platfrm red Emergency Stp buttn t the OFF psitin. 37 Pull ut the red Emergency Stp buttn t the ON psitin but d nt start the engine. 38 Press dwn the ft switch and attempt t start the engine by pushing the engine start buttn. Result: The engine shuld nt start. 39 D nt press dwn the ft switch and restart the engine. 40 D nt press dwn the ft switch and test each machine functin. Result: N machine functins shuld perate. Test Machine Functins 41 Press dwn the ft switch. 42 Activate each machine functin cntrl handle, tggle switch r buttn. Result: All functins shuld perate thrugh a full cycle. Test the Steering 43 Push the steer mde select buttn fr squareend (blue arrw) steer. 44 Press dwn the ft switch. 45 Slwly mve the drive/steer cntrl handle in the directin indicated by the blue triangle n the cntrl panel. Result: The square-end wheels shuld turn in the directin that the blue triangles pint n the drive chassis. 46 Push the steer mde select buttn fr circleend (yellw arrw) steer. 47 Press dwn the ft switch. 48 Slwly mve the drive/steer cntrl handle in the directin indicated by the yellw triangle n the cntrl panel. Result: The circle-end wheels shuld turn in the directin that the yellw triangles pint n the drive chassis. 49 Push the steer mde select buttn fr crab steer. 50 Press dwn the ft switch. 51 Slwly mve the drive/steer cntrl handle in the directin indicated by the blue triangle n the cntrl panel. Result: All wheels shuld turn in the directin that the blue triangles pint n the drive chassis. 18 Genie S-100 & Genie S-105 Part N

21 First Editin Third Printing Operatr's Manual FUNCTION TESTS 52 Push the steer mde select buttn fr crdinated steer. 53 Press dwn the ft switch. 54 Slwly mve the drive/steer cntrl handle in the directin indicated by the blue triangle n the cntrl panel. Result: The square-end wheels shuld turn in the directin that the blue triangles pint n the drive chassis. The circle-end wheels shuld turn in the directin that the yellw triangles pint n the drive chassis. Test Drive and Braking 55 Press dwn the ft switch. 56 Slwly mve the drive/steer cntrl handle in the directin indicated by the blue arrw n the cntrl panel until the machine begins t mve, then return the handle t the center psitin. Result: The machine shuld mve in the directin that the blue arrw pints n the drive chassis, then cme t an abrupt stp. 57 Slwly mve the drive/steer cntrl handle in the directin indicated by the yellw arrw n the cntrl panel until the machine begins t mve, then return the handle t the center psitin. Result: The machine shuld mve in the directin that the yellw arrw pints n the drive chassis, then cme t an abrupt stp. Nte: The brakes must be able t hld the machine n any slpe it is able t climb. Test the Drive Enable System 58 Press dwn the ft switch and lwer the bm t the stwed psitin. 59 Rtate the turntable until the bm mves past ne f the circle-end tires. Result: The drive enable indicatr light shuld cme n while the bm is anywhere in the range shwn. 60 Mve the drive/steer cntrl handle ff center. Result: N drive functin shuld perate. 61 Push the drive enable buttn and slwly mve the drive/steer cntrl handle ff center. Result: The drive functin shuld perate. Nte: When the drive enable system is in use, the machine may drive in the ppsite directin that the drive and steer cntrl handle is mved. Use the clr-cded directin arrws n the platfrm cntrls and the drive chassis t identify the directin f travel. If the drive/steer cntrl handle is nt mved within tw secnds f pushing the drive enable buttn, the drive functin will nt perate. Blue Yellw Part N Genie S-100 & Genie S

22 Operatr's Manual First Editin Third Printing FUNCTION TESTS Test Limited Drive Speed 62 Press dwn the ft switch. 63 Raise the bm t 10 abve hrizntal. 64 Slwly mve the drive cntrl handle t the full drive psitin. Result: The maximum achievable drive speed with the bm raised shuld nt exceed 1 ft per secnd (0.3 meters per secnd). Nte: The machine will travel 40 feet in 40 secnds (12.2 meters in 40 secnds). 65 Lwer the bm t the stwed psitin. 66 Extend the bm 4 feet (1.2 m). 67 Slwly mve the drive cntrl handle t the full drive psitin. Result: The maximum achievable drive speed with the bm extended shuld nt exceed 1 ft per secnd (0.3 meters per secnd). Nte: The machine will travel 40 feet in 40 secnds (12.2 meters in 40 secnds). Test Auxiliary Cntrls 70 Shut ff the engine. 71 Pull ut the red Emergency Stp buttn t the ON psitin. 72 Press dwn the ft switch. 73 Simultaneusly press and hld the auxiliary pwer buttn and activate each functin cntrl handle, tggle switch r buttn. Nte: T cnserve battery pwer, test each functin thrugh a partial cycle. Result: All bm and steer functins shuld perate. Machines equipped with the auxiliary pwer drive ptin: The drive functin shuld perate. If the drive speed with the bm raised r extended exceeds 1 ft per secnd (0.3 meters per secnd), immediately tag and remve the machine frm service. 68 Raise the bm t hrizntal. Extend the bm as far as it will g. 69 Slwly mve the drive cntrl handle t the full drive psitin. Result: The maximum achievable drive speed with the bm fully extended shuld nt exceed 0.6 feet per secnd (0.2 meters per secnd). Nte: The machine will travel 40 feet in 70 secnds (12.2 meters in 70 secnds). 20 Genie S-100 & Genie S-105 Part N

23 First Editin Third Printing Operatr's Manual Wrk Place Inspectin Wrk Place Inspectin Be aware f and avid the fllwing hazardus situatins: drp-ffs r hles D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. Knw and understand the abve principles befre ging n t the next sectin. 5 Only use the machine as it was intended. bumps, flr bstructins r debris verhead bstructins and high vltage cnductrs hazardus lcatins inadequate surface supprt t withstand all lad frces impsed by the machine wind and weather cnditins the presence f unauthrized persnnel ther pssible unsafe cnditins Fundamentals The Wrk Place Inspectin helps the peratr determine if the wrk place is suitable fr safe machine peratin. It shuld be perfrmed by the peratr prir t mving the machine t the wrk place. It is the peratr's respnsibility t read and remember the wrk place hazards, then watch fr and avid them while mving, setting up and perating the machine. Part N Genie S-100 & Genie S

24 Operatr's Manual First Editin Third Printing Operating Instructins Starting the Engine 1 At the grund cntrls, turn the key switch t the desired psitin. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. 5 Only use the machine as it was intended. Fundamentals The Operating Instructins sectin prvides instructins fr each aspect f machine peratin. It is the peratr's respnsibility t fllw all the safety rules and instructins in the peratr's, safety and respnsibilities manuals. Using the machine fr anything ther than lifting persnnel and tls t an aerial wrk site is unsafe and dangerus. Only trained and authrized persnnel shuld be permitted t perate a machine. If mre than ne peratr is expected t use a machine at different times in the same wrk shift, they must all be qualified peratrs and are all expected t fllw all safety rules and instructins in the peratr's, safety and respnsibilities manuals. That means every new peratr shuld perfrm a pre-peratin inspectin, functin tests, and a wrk place inspectin befre using the machine. 2 Be sure bth the grund and platfrm cntrl red Emergency Stp buttns are pulled ut t the ON psitin. 3 Gasline/LPG mdels: Chse fuel by pressing the fuel select buttn. 4 Press the engine start buttn. If the engine fails t start r dies, the restart delay will disable the start buttn fr 3 secnds. If the engine fails t start after 15 secnds f cranking, determine the cause and repair any malfunctin. Wait 60 secnds befre trying t start again. All mdels: In extreme cld cnditins, 20 F (-6 C) and belw, warm the engine fr 5 minutes t prevent hydraulic system damage. Gasline/LPG mdels: In extreme cld cnditins, 20 F (-6 C) and belw, the machine shuld be started n gasline, then switched t LPG. Emergency Stp Push in either the grund r platfrm red Emergency Stp buttn t the OFF psitin t stp all functins and turn the engine ff. Repair any functin that perates when the Emergency Stp buttn is pushed in t the OFF psitin. Selecting and perating the grund cntrls will verride the platfrm Emergency Stp buttn. 22 Genie S-100 & Genie S-105 Part N

25 First Editin Third Printing Operatr's Manual OPERATING INSTRUCTIONS Auxiliary Cntrls Use auxiliary pwer if the primary pwer surce (engine) fails. 1 Turn the key switch t grund r platfrm cntrl. 2 Pull ut the red Emergency Stp buttn t the ON psitin. 3 Press dwn the ft switch when perating the auxiliary cntrls frm the platfrm. 4 Simultaneusly hld the auxiliary pwer buttn and activate the desired functin. Machines equipped with the auxiliary pwer drive ptin: The drive functin will perate. Operatin frm Grund 1 Turn the key switch t grund cntrl. 2 Pull ut the red Emergency Stp buttn t the ON psitin. 3 Gasline/LPG mdels: Chse fuel by pressing the fuel select buttn. 4 Start the engine. T Psitin Platfrm 1 Push and hld a functin enable/ speed select buttn. 2 Push the apprpriate functin buttn accrding t the markings n the cntrl panel. Drive and steer functins are nt available frm the grund cntrls. Operatin frm Platfrm 1 Turn the key switch t platfrm cntrl. 2 Pull ut bth grund and platfrm red Emergency Stp buttns t the ON psitin. 3 Gasline/LPG mdels: Chse fuel by pressing the fuel select buttn. 4 Start the engine. D nt press dwn the ft switch when starting the engine. T Psitin Platfrm 1 Press dwn the ft switch. 2 Slwly mve the apprpriate functin cntrl handle r tggle switch r press the apprpriate buttn accrding t the markings n the cntrl panel. T Steer 1 Press dwn the ft switch. 2 Select the steer mde by pressing a steer mde buttn. The indicatr light next t the current steer mde will be n. 3 Slwly mve the drive/steer cntrl handle in the blue r yellw triangle directin. Use the clr-cded directin arrws n the platfrm cntrls and the drive chassis t identify the directin the wheels will turn. Part N Genie S-100 & Genie S

26 Operatr's Manual First Editin Third Printing OPERATING INSTRUCTIONS T Drive 1 Press dwn the ft switch. 2 Increase speed: Slwly mve the drive/steer cntrl in the blue r yellw arrw directin. Decrease speed: Slwly mve the drive/steer cntrl handle tward center. Stp: Return the drive/steer cntrl handle t center r release the ft switch. Use the clr-cded directin arrws n the platfrm cntrls and the drive chassis t identify the directin the machine will travel. Machine travel speed is restricted when the bm is raised r extended. Drive Enable Light n indicates that the bm has mved past either circle-end wheel and drive functin is turned ff. T drive, push the drive enable buttn and slwly mve the drive/steer cntrl handle ff center. If the drive/steer cntrl handle is nt mved within tw secnds f pushing the drive enable buttn, the drive functin will nt perate. Release and push the drive enable buttn again. Be aware that the machine may mve in the ppsite directin that the drive and steer cntrls are mved. Always use the clr-cded directin arrws n the platfrm cntrls and the drive chassis t identify the directin the machine will travel. Nn-regulated Generatr (if equipped) T perate the generatr, press the generatr buttn. The indicatr light will cme n and the engine rpm will autmatically be in turtle symbl mde. The engine will cntinue t run the drive functins and the platfrm functins will perate. If the rabbit symbl r the rabbit and ftswitch symbl are selected, the generatr will shut ff and the indicatr light will g ff. Plug pwer tls int the pwer t platfrm GFCI utlet. T turn ff the generatr, push the generatr buttn. The indicatr light will turn ff. Regulated Generatr (if equipped) T perate the generatr, press the generatr buttn. The indicatr light will cme n and the engine will cntinue t run. Plug pwer tls int the pwer t platfrm GFCI utlet. T turn ff the generatr, push the generatr buttn. The indicatr light will turn ff. Engine Idle Select (rpm) Select the engine idle (rpm) by pressing the select buttn. The indicatr light next t the current setting will be n. Rabbit and ft switch symbl: ft switch activated high idle Turtle symbl: lw idle Rabbit symbl: high idle 24 Genie S-100 & Genie S-105 Part N

27 First Editin Third Printing Operatr's Manual OPERATING INSTRUCTIONS Check Engine Light Light n and engine stpped: Tag the machine and remve frm service. Light n and engine still running: Cntact service persnnel within 24 hurs. Operating Envelpe Indicatr Lights The perating envelpe indicatr lights will cme n t ntify the peratr that a functin has been interrupted (in sme cases) and/r an actin is required by the peratr. Raise Bm indicatr light flashing: T cntinue extending the bm, raise the bm until the indicatr light is ff. Stpping the Engine Push in the red Emergency Stp buttn and turn the key switch t the OFF psitin. After Each Use 1 Select a safe parking lcatin firm level surface, clear f bstructin and traffic. 2 Retract and lwer the bm t the stwed psitin. 3 Rtate the turntable s that the bm is between the circle-end wheels. 4 Turn the key switch t the OFF psitin and remve the key t secure frm unauthrized use. 5 Chck the wheels. Retract Bm indicatr light flashing: T cntinue lwering the bm, retract the bm until the indicatr light is ff. Machine Nt Level indicatr light flashing: The tilt alarm will be sunding when this light is flashing. Mve the machine t a firm level surface. Platfrm Nt Level indicatr light flashing:the tilt alarm will be sunding when this light is flashing. The Platfrm Level tggle switch will nly wrk in the directin that will level the platfrm. Level the platfrm until the indicatr light is ff. Part N Genie S-100 & Genie S

28 Operatr's Manual First Editin Third Printing Transprt Instructins Free-wheel Cnfiguratin fr Winching Chck wheels t prevent machine frm rlling. Transprt Instructins Observe and Obey: Transprt vehicle must be parked n a level surface. Transprt vehicle must be secured t prevent rlling while machine is being laded. Be sure vehicle capacity, lading surfaces and straps r lines are sufficient t withstand machine weight (see Specificatins sectin). Be sure the turntable is secured with the turntable rtatin lck befre transprting. Be sure t unlck the turntable fr peratin. 4WD mdels: Release wheel brakes by turning ver all fur trque hub discnnect caps (see belw). Be sure winch line is prperly secured t drive chassis tie pints and path is clear f all bstructins. Reverse prcedures described t re-engage brakes. Disengage Psitin Engage Psitin Securing t Truck r Trailer fr Transit Always use the turntable rtatin lck pin each time the machine is transprted. Always chck machine wheels in preparatin fr transprt. Use tie pints n drive chassis fr anchring dwn t transprt surface. Use chains r straps f ample lad capacity. Turn key switch t the OFF psitin and remve key befre transprting. Transprt cnfiguratin: S-100 Inspect entire machine fr lse r unsecured items. Transprt cnfiguratin: S Genie S-100 & Genie S-105 Part N

29 First Editin Third Printing Operatr's Manual Decals Decal Inspectin Use the pictures n the next page t verify that all decals are legible and in place. Belw is a numerical list with quantities and descriptins. Part N. Descriptin Quantity Cautin, Cmpnent Damage Hazard Arrw, Blue Arrw, Yellw Triangle, Blue Triangle, Yellw Danger - Electrcutin Hazard Label - Dexrn Label, Diesel Warning, Crush Hand Ntice, Max. Side Frce, 150 lbs, ANSI & CSA Ntice, Hazardus Materials Ntice, Ftswitch Label, N Smking Label, Pwer t Platfrm, 230V Cautin, Cmpartment Access Ntice, Missing Manuals Warning, Cllisin Hazard Warning, N Step r Ride Label, Pwer t Platfrm, 115V Warning, Failure T Read Ntice, Maximum Capacity, 500 lbs, S Danger, General Safety Danger, Tip-ver Hazard Label, Lanyard Anchrage Pint Ntice, Maximum Capacity, 750 lbs, S Ntice, Max. Manual Frce, 90 lbs, CE Grund Cntrl Panel 1 Part N. Descriptin Quantity Platfrm Cntrl Panel Csmetic, 4x Ntice, Operating Instructins Serial Plate Ntice, Engine Specificatins, Deutz Ntice, Engine Specificatins, Cummins Ntice, Engine Specificatins, Perkins Cautin, N Step Danger, Tip-ver Hazard, Tires Label, 20 amp Circuit Breaker Label, 40 amp Circuit Breaker Label, 30 amp Circuit Breaker Warning, Weld Line t Platfrm Warning, Bdily Injury Hazard Label, Cylinder Cver Csmetic, Genie S Csmetic, Genie S Csmetic, S Csmetic, S Ntice, Tire Specificatins Label, Range f Mtin Chart Ntice, Starter Battery Ntice, Cntrls Battery 1 Shading indicates decal is hidden frm view, i.e. under cvers Part N Genie S-100 & Genie S

30 Operatr's Manual First Editin Third Printing DECALS 28 Genie S-100 & Genie S-105 Part N

31 First Editin Third Printing Operatr's Manual Specificatins S-100 Height, wrking maximum 106 ft 32.3 m S-100 Cntrls 12V DC prprtinal Height, platfrm maximum 100 ft 30.5 m Height, stwed maximum 10 ft 1 in 3.1 m Hrizntal reach maximum 75 ft 22.9 m Width, axles retracted 8 ft 6 in 2.6 m Width, axles extended 11 ft 6 in 3.5 m Length, stwed 39 ft 11 in 12.2 m Maximum lad capacity 750 lb 340 kg Wheelbase 12 ft 3.7 m Turning radius, utside, 24 ft 4 in 7.4 m axles retracted Turning radius, inside, 16 ft 4 in 4.9 m axles retracted Turning radius, utside, 20 ft 8 in 6.3 m axles extended Turning radius, inside, 10 ft 1 in 3.1 m axles extended Platfrm dimensins, length x width Platfrm leveling 96 x 36 in 2.4 m x 91 cm self-leveling Platfrm rtatin 160 AC utlet in platfrm Hydraulic pressure (maximum) 4250 psi (drive functins) Tire size standard 293 bar 15 x 22.5, 18 pr FF Gradeability, stwed 40 % Grund clearance 15 1 /2 in 39.4 cm Hydraulic tank capacity 55 gallns 208 liters Fuel tank capacity 40 gallns 151 liters Weight 39,700 lbs kg Airbrne nise emissins 80 db Maximum sund level at nrmal perating wrkstatins (A-weighted) Turntable rtatin (degrees) 360 cntinuus Turntable tailswing, 66 in 168 cm axles retracted Turntable tailswing 48 in 122 cm axles extended Pwer surce Perkins Diesel (chice) Deutz Diesel F4L913 Cummins Diesel 4B3.9 Drive speed, stwed 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 r 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 Cntinuus imprvement f ur prducts is a Genie plicy. Prduct specificatins are subject t change withut ntice r bligatin. Part N Genie S-100 & Genie S

32 Operatr's Manual First Editin Third Printing SPECIFICATIONS S-105 Height, wrking maximum 111 ft 33.8 m S-105 Cntrls 12V DC prprtinal Height, platfrm maximum 105 ft 32 m Height, stwed maximum 10 ft 1 in 3.1 m Hrizntal reach maximum 80 ft 24.4 m Width, axles retracted 8 ft 6 in 2.6 m Width, axles extended 11 ft 6 in 3.5 m Length, stwed 39 ft 11 in 12.2 m Maximum lad capacity 500 lb 227 kg Wheelbase 12 ft 3.7 m Turning radius, utside, 24 ft 4 in 7.4 m axles retracted Turning radius, inside, 16 ft 4 in 4.9 m axles retracted Turning radius, utside, 20 ft 8 in 6.3 m axles extended Turning radius, inside, 10 ft 1 in 3.1 m axles extended Platfrm dimensins, length x width Platfrm leveling 96 x 36 in 2.4 m x 91 cm self-leveling Platfrm rtatin 160 AC utlet in platfrm Hydraulic pressure (maximum) 4250 psi (drive functins) Tire size standard 293 bar 15 x 22.5, 18 pr FF Gradeability, stwed 40 % Grund clearance 15 3 /4 in 40 cm Hydraulic tank capacity 55 gallns 208 liters Fuel tank capacity 40 gallns 151 liters Weight 40,000 lbs kg Airbrne nise emissins 80 db Maximum sund level at nrmal perating wrkstatins (A-weighted) Turntable rtatin (degrees) 360 cntinuus Turntable tailswing, 66 in 168 cm axles retracted Turntable tailswing 48 in 122 cm axles extended Pwer surce Perkins Diesel (chice) Deutz Diesel F4L913 Cummins Diesel 4B3.9 Drive speed, stwed 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 r 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 Cntinuus imprvement f ur prducts is a Genie plicy. Prduct specificatins are subject t change withut ntice r bligatin. 30 Genie S-100 & Genie S-105 Part N

33 Califrnia Prpsitin 65 WARNING The exhaust frm this prduct cntains chemicals knwn t the State f Califrnia t cause cancer, birth defects r ther reprductive harm. Genie Hlland Phne Fax Genie Scandinavia Phne Fax Genie France Phne + 33 (0) Fax + 33 (0) Genie Iberica Phne Fax Genie Germany Phne + 49 (0) Fax + 49 (0) Genie U.K. Phne + 44 (0) Fax + 44 (0) Genie Mexic City Phne Fax Genie Nrth America Phne Tll Free USA and Canada Fax Genie Australia Pty Ltd. Phne Fax Genie China Phne Fax Genie Malaysia Phne Fax Genie Japan Phne Fax Genie Krea Phne Fax Genie Africa Phne Fax Genie Latin America Phne Fax Distributed By:

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