Genie S-100 / S-105 ANSI/CSA Operator's Manual

Page 1
T d
Page 2
Operator's Manual Fifth Edition • Third Printing
Contents
Introduction ..............................................................1
Symbol and Hazard Pictorials Denitions.................3
General Safety..........................................................5
Personal Safety.......................................................11
Work Area Safety....................................................12
Legend....................................................................22
Controls..................................................................23
Inspections..............................................................31
Operating Instructions.............................................50
Transport and Lifting Instructions............................61
Maintenance...........................................................64
Specications..........................................................67
Copyright © 2000 by Terex Corporation
Sixth Edition:Third Printing, September 2015
Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries.
These machines comply with ANSI/SIA 92.5 CAN B.354.4
S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 3
Owners, Users and Operators:
Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators:
Operator's ManualFifth Edition • Third Printing
Introduction
Danger
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this machine.
3 Use good safe work practices in a
commonsense way.
4 Onlyhavetrained/certiedoperators,
directed by informed and knowledgeable supervision, running the machine.
If there is anything in this manual that is not clear or which you believe should be added, please contact us.
Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Failure to obey the instructions and safety rules in this manual will result in death or serious injury.
Do Not Operate Unless:
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 workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer's instructions and safety rules— safety and operator's manuals and machine decals.
You read, understand and obey employer's
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Part No. T111108 S-100 • S-105 • S-120 • S-125 1
Page 4
Operator's Manual Fifth Edition • Third Printing
Introduction
HazardClassication
Genie uses symbols, color coding and signal words to identify the following:
Safety alert symbol—used to
alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation
Red
Orange
Yellow
Blue
which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result in minor or moderate injury.
Indicates a property damage
message.
Intended Use
This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site.
Safety Sign Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.
2 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 5
Operator's ManualFifth Edition • Third Printing
SymbolandHazardPictorialsDenitions
Crush Hazard
Maintain required clearance.
Only trained maintenance personnel should access compartments.
Keep away from moving parts.
Crush Hazard
Read the operator’s manual.
Explosion Hazard
Keep away from path of moving platform.
Do not alter or disable limit switch(es)
No smoking. No ame. Stop engine.
Fall Hazard
Tip-over Hazard
Electrocution Hazard
Keep off this surface.
Fall Hazard
Recovery procedure if tilt alarm sounds while elevated.
Tip-over Hazard
Part No. T111108 S-100 • S-105 • S-120 • S-125 3
Platform downhill:
1. Retract boom.
2. Lower boom.
Platform uphill:
1. Lower boom.
2. Retract boom.
Tip-over Hazard
Do not overload platform. Welder power supply weighs 75 lb / 34 kg
Page 6
Operator's Manual Fifth Edition • Third Printing
SymbolandHazardPictorialsDenitions
Lanyard attachment point
Electrocution Hazard
Explosion Hazard
Wheel load
Avoid contact.
Do not use ether or other high energy starting aids on machines equipped with glow plugs.
Fire Hazard
Tie-down instructions
Explosion / Burn Hazard
Have re
extinguisher near.
Tie-down instructions
Keep all open
ames and
sparks away.
Replace tires with same tire.
Replace extension cylinder cover before opeating machine.
No Step
Voltage rating for power to platform
4 S-100 • S-105 • S-120 • S-125 Part No. T111108
Pressure rating for air line to platform
Read service manual.
Page 7
Operator's ManualFifth Edition • Third Printing
General Safety
Part No. T111108 S-100 • S-105 • S-120 • S-125 5
Page 8
Operator's Manual Fifth Edition • Third Printing
General Safety
6 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 9
Operator's ManualFifth Edition • Third Printing
General Safety
Part No. T111108 S-100 • S-105 • S-120 • S-125 7
Page 10
Operator's Manual Fifth Edition • Third Printing
General Safety
8 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 11
Operator's ManualFifth Edition • Third Printing
General Safety
Part No. T111108 S-100 • S-105 • S-120 • S-125 9
Page 12
Operator's Manual Fifth Edition • Third Printing
General Safety
10 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 13
Fall Protection
Personal fall protection equipment (PFPE) is required when operating this machine.
Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.
All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions.
Operator's ManualFifth Edition • Third Printing
Personal Safety
Part No. T111108 S-100 • S-105 • S-120 • S-125 11
Page 14
Operator's Manual Fifth Edition • Third Printing
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.
Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.0 m
50KV to 200KV 15 ft 4.6 m
200KV to 350KV 20 ft 6.1 m
350KV to 500KV 25 ft 7.6 m
500KV to 750KV 35 ft 10.6 m
750KV to 1000KV 45 ft 13.7 m
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, equipment and materials shall not exceed the maximum platform capacity.
Maximum platform capacity S-100 750 lbs 340 kg S-105 500 lbs 227 kg S-120 750 lbs 340 kg S-125 500 lbs 227 kg
Maximum occupants 2
12 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 15
Operator's ManualFifth Edition • Third Printing
Work Area Safety
The weight of options and accessories, such as pipe cradles, panel cradles and welders, will reduce the rated platform capacity and must be factored into the total platform load. See the decals with the options and accessories.
If using accessories, read, understand and obey the decals and instructions with the accessory.
Do not raise or extend the boom unless the
machine is on a rm,
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.
If the tilt alarm sounds while the boom is lowered: Do not extend, rotate or raise the boom above
horizontal. Move the machine to a rm, level
surface before raising the platform.
If the tilt alarm sounds while the boom is raised: Use extreme caution. Identify the condition of the boom on the slope as shown below. Follow the steps to lower the boom before moving to a
rm, level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the platform uphill: First lower the boom, then retract the boom.
If the tilt alarm sounds with the platform downhill: First retract the boom, then lower the boom.
Do not raise the boom when wind speeds may exceed 28 mph / 12.5 m/s. If wind speeds exceed 28 mph / 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine.
Part No. T111108 S-100 • S-105 • S-120 • S-125 13
Page 16
Operator's Manual Fifth Edition • Third Printing
Work Area Safety
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.
Use extreme care and slow speeds while driving the machine in the 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.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent structures.
Do not place loads outside the platform perimeter.
Do not alter or disable the limit switches.
Do not push off or pull toward any object outside of the platform.
Maximum allowable side force - 150 lb / 667 N ANSI & CSA
Maximum allowable manual force - 90 lbs / 400 N Australia
Do not alter or disable machine components that in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specication.
Do not use the machine as a crane.
Do not push the machine or other objects with the boom.
14 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 17
Operator's ManualFifth Edition • Third Printing
Work Area Safety
Do not modify or alter an aerial work platform without prior written permission from the manufacturer. 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 the platform or the load.
Do not place or attach overhanging loads to any part of this machine.
Do not place ladders or scaffolds in the platform or against any part of this machine.
Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform.
Be sure all tires are in good condition, and lug nuts are properly tightened.
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.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds the maximum uphill, downhill or side slope rating of the machine. Slope rating applies to machines in the stowed position.
Maximum slope rating, stowed position
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction.
Do not use the machine on a moving or mobile surface or vehicle.
Do not use air-lled tires. These machines are equipped with foam-lled tires. Wheel weight is
critical to stability.
Part No. T111108 S-100 • S-105 • S-120 • S-125 15
Page 18
Operator's Manual Fifth Edition • Third Printing
Work Area Safety
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.
Do not sit, stand or climb on the platform guard rails. Maintain
a rm footing on the platform oor at all
times.
Do not climb down from the platform when raised.
Keep the platform oor
clear of debris.
Lower the platform entry mid-rail or close the entry gate before operating.
Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level.
Collision Hazards
Be aware of limited sight distance and blind spots when driving or operating.
Be aware of the boom position and tailswing when rotating the turntable.
Check the work area for overhead obstructions or other possible hazards.
Be aware of crushing hazards when grasping the platform guard rail.
Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.
Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.
16 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 19
Operator's ManualFifth Edition • Third Printing
Work Area Safety
Do not lower the boom unless the area below is clear of personnel and obstructions.
Limit travel speed according to the condition of the 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.
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.
Do not operate the machine unless the secondary extend cylinder cover is properly installed.
Improper contact with components under any cover will cause serious injury. Only trained maintenance personnel should access compartments. Access by the operator is only advised when performing a pre-operation inspection. All compartments must remain closed and secured during operation.
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,
ames and lighted tobacco.
Do not operate the machine in hazardous locations
or locations where potentially ammable or
explosive gases or particles may be present.
Do not spray ether into engines equipped with glow plugs.
Part No. T111108 S-100 • S-105 • S-120 • S-125 17
Page 20
Operator's Manual Fifth Edition • Third Printing
Work Area Safety
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough 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
specied in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the platform.
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.
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective clothing and eye wear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, ames
and lighted tobacco away from batteries. Batteries emit explosive gas.
The battery tray should remain open during the entire cycle.
Do not contact the battery terminals or the cable clamps with tools that may cause sparks.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.
18 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 21
Operator's ManualFifth Edition • Third Printing
Work Area Safety
Welder Safety
Read, understand and obey all warnings and instructions provided with the welding power unit.
Do not connect weld leads or cables unless the welding power unit is turned off at the platform controls.
Do not operate unless the weld cables are properly connected and the welder is properly grounded.
The weight of the welder will reduce the rated platform capacity and must be factored into the total platform load. The welder power supply weighs 75 lbs / 34 kg.
Do not operate the welder unless a re
extinguisher is immediately available for instant use, per OSHA regulation 1926.352(d).
Weld Line to Platform Safety
Read, understand and obey all warnings and instructions provided with the welding power unit.
Do not connect weld leads or cables unless the welding power unit is turned off at the platform controls.
Do not operate unless the weld cables are properly connected.
Connect the positive lead to the twist-lock connector at the turntable and platform.
Clamp the negative lead to the ground post at the turntable and platform.
Part No. T111108 S-100 • S-105 • S-120 • S-125 19
Page 22
Operator's Manual Fifth Edition • Third Printing
Work Area Safety
Pipe Cradle Safety
Read, understand and obey all warnings and instructions provided with the pipe cradles.
Do not exceed the rated platform capacity. The pipe cradle assembly and the weight in the pipe cradles will reduce rated platform capacity and must be factored into total platform load.
The pipe cradle assembly weighs 21 lbs / 9.5 kg.
The maximum capacity of the pipe cradle assembly is 200 lbs / 90.7 kg.
The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in platform.
Center the load within the perimeter of the platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the platform.
Do not obstruct the ability to operate the platform controls or the red Emergency Stop button.
Do not operate unless you are adequately instructed and are aware of all of the hazards associated with movement of the platform with an overhanging load.
Do not cause a horizontal force or side load to
the machine by raising or lowering a xed or
overhanging load.
Panel Cradle Safety
Read, understand and obey all warnings and instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The combined weight of the cradles, panels, occupants, tools and any other equipment must not exceed rated capacity.
The panel cradle assembly weighs 30 lbs / 13.6 kg.
The maximum capacity of the panel cradles is 250 lbs / 113 kg.
The weight of the panel cradles and the load in the panel cradles may limit the maximum number of occupants in platform to one person.
Secure the cradles to the platform. Secure the panel(s) to the platform railing using the straps provided.
Do not operate unless you are adequately instructed and are aware of all hazards associated with lifting panels.
Do not cause a horizontal force or side load
to machine by raising or lowering a xed or
overhanging load.
Maximum vertical height of panels: 4 ft / 1.2 m
Maximum wind speed: 15 mph / 6.7 m/sec
Maximum panel area: 32 sq. ft / 3 m
2
Electrocution Hazard: Keep pipes away from all energized electrical conductors.
20 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 23
Lockout After Each Use
1 Select a safe parking location—rm level
surface, clear of obstruction and trafc.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is
between the wheels at the circle end of the machine.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized use.
5 Chock the wheels.
Operator's ManualFifth Edition • Third Printing
Work Area Safety
Part No. T111108 S-100 • S-105 • S-120 • S-125 21
Page 24
Operator's Manual Fifth Edition • Third Printing
S-105 & S-125
S-100 & S-120
Legend
1 Circle-end tire (yellow arrow)
2 Square-end tire (blue arrow)
3 Ground controls
4 Boom
5 Platform controls
6 Platform
7 Jib boom (S-105 and S-125)
22 S-100 • S-105 • S-120 • S-125 Part No. T111108
8 Lanyard anchorage point
9 Sliding mid-rail
10 Manual storage container
11 Foot switch
Page 25
Operator's ManualFifth Edition • Third Printing
Controls
Ground Control Panel
1 Boom down button
2 Boom extend/retract buttons
3 Boom up button
4 Engine speed select button
5 LCD screen control buttons
6 Gasoline/LPG select button
7 LCD readout screen
8 Diesel models: Glow plug button
Gasoline/LPG models: Choke button
9 Red Emergency Stop button
10 Key switch for off/platform/ground selection
Part No. T111108 S-100 • S-105 • S-120 • S-125 23
11 Engine start button
12 Emergency power button
13 High speed function enable button
14 Low speed function enable button
15 Alarm
16 Platform level up/down buttons
17 S-105 and S-125 models: Jib boom up/down
buttons
18 Platform rotate left/right buttons
19 Turntable rotate left/right buttons
Page 26
Operator's Manual Fifth Edition • Third Printing
Controls
1 Boom down button
Push the boom down
button and the boom will lower.
2 Boom extend/retract buttons
Push the boom extend
button and the boom will extend. Push the boom retract button and the boom will retract.
3 Boom up button
Push the boom up
button and the boom will raise.
4 Engine speed select button
Push the engine speed select button to select
the engine speed. When the arrow above the rabbit is lit, the engine is in high idle speed. When the arrow above the turtle is lit, the engine is in low idle speed.
5 LCD screen control buttons
6 Gasoline/LPG select button
Push the fuel select button to select the engine
fuel source. When the arrow above the LPG tank is lit, the engine will run on LPG. When the arrow above the gas tank is lit, the engine will run on gasoline.
7 LCD readout screen
a b c d e f
a low fuel indicator
b engine oil pressure indicator
c water temperature indicator
d emergency power indicator
e high engine rpm indicator
f hour meter
8 Glow plug button (if equipped with manual glow
plugs)
Push the glow plug button and hold for 3 to 5
seconds.
9 Red Emergency Stop button
Push in red Emergency Stop button to the off
position to stop all functions and turn the engine off. Pull out the red Emergency Stop button to the on position to operate the machine.
10 Key switch for off/ground/platform selection
Turn the key switch to the off position and the
machine will be off. Turn the key switch to the ground position and the ground controls will operate. Turn the key switch to the platform position and the platform controls will operate.
24 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 27
Operator's ManualFifth Edition • Third Printing
Controls
11 Engine start button
Push the engine start button and the engine will
start.
12 Emergency power button
Use emergency power if the primary power
source (engine) fails. Simultaneously push the emergency power button and activate the desired function.
13 High speed function enable button
Push the high speed function enable switch
to enable the functions on the ground control panel to operate at high speed.
14 Low speed function enable button
Push the low speed function enable switch
to enable the functions on the ground control panel to operate at low speed.
15 Alarm
16 Platform level up/down buttons
Push the platform level
up button and the level of the platform will raise. Push the platform level down button and the level of the platform will lower.
18 Platform rotate left/right buttons
Push the platform rotate
left button and the platform will rotate to the left. Push the platform rotate right button and the platform will rotate to the right.
19 Turntable rotate left/right buttons
Push the turntable
rotate left button and the turntable will rotate to the left. Push the turntable rotate right button and the turntable will rotate to the right.
17 S-105 and S-125
models: Jib boom up/down buttons
Push the jib boom up
button and the jib boom will raise. Push the jib boom down button and the jib boom will lower.
Part No. T111108 S-100 • S-105 • S-120 • S-125 25
Page 28
Operator's Manual Fifth Edition • Third Printing
1 2
65 7 8
9
10
2425262728
29
43
Controls
Platform Control Panel
1 Platform rotate switch
2 Platform level switch
3 Platform not level indicator
light
4 Machine not level indicator
light
5 Retract boom indicator light
6 Raise boom indicator light
7 Horn button
8 Generator button with
indicator light (option)
9 Emergency power button
with indicator light
10 Diesel models: Glow plug
button with indicator light Gasoline/LPG models: Choke button with indicator light
11 Engine start button with
indicator light
12 Engine idle (rpm) select
button with indicator lights:
· Rabbit & Foot Switch: foot switch activated high idle
· Turtle: low idle
· Rabbit: high idle
13 Gasoline/LPG models:
Fuel select button with indicator lights
14 Fault indicator light
15 Low fuel indicator light
16 Check engine indicator light
26 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 29
Operator's ManualFifth Edition • Third Printing
11 12 13 1514 17
1819
16
20212223
Controls
17 Red Emergency Stop button
18 Dual axis proportional control
handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function
19 Power indicator light
20 Not used
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
24 Axle extend button with
indicator light
25 Axle retract button with
indicator light
26 Used for optional equipment
27 Drive enable button with
indicator light
28 Dual axis proportional control
handle for boom up/down and turntable rotate left/right functions
29 S-105 and S-125 models only:
Jib boom up/down toggle switch
Part No. T111108 S-100 • S-105 • S-120 • S-125 27
Page 30
Operator's Manual Fifth Edition • Third Printing
Controls
Platform Control Panel
1 Platform rotate switch
Move the platform rotate
switch to the right and the platform will rotate to the right. Move the platform rotate switch to the left and the platform will rotate to the left.
2 Platform level switch
Move the platform level switch up and the level
of the platform will raise. Move the platform level switch down and the level of the platform will lower.
3 Platform not level
indicator light
Light is on when the platform is not level. The
tilt alarm will be sounding. The Platform Level switch will only work in the direction that will level the platform. Level the platform until the light goes off.
4 Machine not level indicator light
6 Raise boom indicator light
To continue extending, raise the boom until the
indicator light goes out.
7 Horn button
Push the horn button and the horn will sound.
Release the horn button and the horn will stop.
8 Generator button with indicator light (option)
Push the generator button to activate the
generator. The light will be on. Push the button again to turn off the light and restore machine functions.
9 Emergency power button with indicator light
Use emergency power if the primary power
source (engine) fails. Simultaneously push the emergency power button and step on the foot switch. Activate the desired function. The indicator light will be on when emergency power is being used.
10 Diesel models: Glow plug button with indicator
light
Push the glow plug button and hold for 3 to 5
seconds. The glow plug indicator light will be on when the glow plugs are being used.
Light is on when the tilt alarm is sounding.
Move the machine to level ground.
5 Retract boom indicator light
To continue lowering, retract boom until the
indicator light goes out.
28 S-100 • S-105 • S-120 • S-125 Part No. T111108
Diesel models: Automatic glow plug indicator
light
Amber light indicates glow plugs are on.
Gasoline/LPG models:Choke button with
indicator light
Press the choke button and hold for 3 to 5
seconds. The choke indicator light will be on when the choke is being used.
Page 31
Operator's ManualFifth Edition • Third Printing
Controls
11 Engine start button with indicator light
Push the engine start button and the engine will
start. The engine start button indicator light will be on when the button is being pushed.
12 Engine idle (rpm) select button with indicator
lights
Push the engine idle select button to choose
engine rpm setting. The indicator light next to the current setting will be on.
13 Gasoline/LPG models: Fuel select button with
indicator lights
When the indicator light next to the LPG tank
is lit, the engine will run on LPG. When the indicator light next to the gas tank is lit, the engine will run on gasoline.
14 Fault indicator light
Light on indicates the machine has one or more
faults. Faults are abnormal conditions that exist due to component failure or system misuse. See the appropriate service manual.
15 Low fuel indicator light
Light on indicates the machine is low on fuel.
16 Check engine indicator light
Light on indicates an engine fault.
17 Red Emergency Stop button
Push in red Emergency Stop button to the off
position to stop all functions and turn the engine off. Pull out the red Emergency Stop button to the on position to operate the machine.
18 Dual axis proportional control handle for drive
and steer functions OR Proportional control handle for drive function and thumb rocker switch for steer function
Move the control handle in the direction
indicated by the blue arrow on the control panel and the machine will drive forward. Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards. Move the control handle in the direction indicated by the blue triangle and the machine will steer to the left. Move the control handle in the direction indicated by the yellow triangle and the machine will steer to the right. OR Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward. Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards. Press the left side of the rocker switch and the machine will steer to the left. Press the right side of the rocker switch and the machine will steer to the right.
19 Power indicator light
Light is on when the red Emergency Stop
button is pulled out to the on position.
Part No. T111108 S-100 • S-105 • S-120 • S-125 29
Page 32
Operator's Manual Fifth Edition • Third Printing
Controls
20 Not used
21 Steer mode select buttons with indicator lights
Push the steer mode select button to choose
steer mode. The indicator light next to the current steer mode will be on.
22 Drive select button with
indicator lights
Push the drive select
button to choose drive setting. The indicator light next to the current setting will be on.
23 Single axis proportional control handle for boom
extend/retract function
Move the control handle up and the boom will
retract.
Move the control handle down and the boom
will extend.
24 Axle extend button with indicator light
Push the axle extend button to extend the
axles. The indicator light will ash while the
axles are extending and stay on when the axles are fully extended.
25 Axle retract button with indicator light
26 Used for optional equipment.
27 Drive enable button with indicator light
Light on indicates that
the primary boom has moved past either circle-end wheel and the drive function is turned off. To drive, push the drive enable button and slowly move the drive/steer control handle off center.
28 Dual axis proportional
control handle for boom up/down and turntable rotate left/right functions
Move the control handle
up and the boom will raise. Move the control handle down and the boom will lower.
Move the control handle to the left and the turntable will rotate to the left. Move the control handle to the right and the
Push the axle retract button to retract the axles.
The indicator light will ash while the axles are
retracting and stay on when the axles are fully retracted.
30 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 33
Operator's ManualFifth Edition • Third Printing
Inspections
Pre-operation Inspection Fundamentals
It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance.
Do Not Operate Unless:
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 pre-operation
inspection before going on to the next section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
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 specied in this manual may be performed by the operator.
Refer to the list on the next page and check each of the items.
If damage or any unauthorized 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 qualied service technician, according to the manufacturer's specications. 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 qualied service technicians, according to the manufacturer's specications
and the requirements listed in the responsibilities manual.
Part No. T111108 S-100 • S-105 • S-120 • S-125 31
Page 34
Operator's Manual Fifth Edition • Third Printing
Secondary Extend Cylinder Cover
Inspections
Pre-operation Inspection
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 Inspections section.
Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
Tires and wheels
Engine and related components
Limit switches and horn
Alarms and beacons (if equipped)
Nuts, bolts and other fasteners
Platform entry mid-rail or gate
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 uid leaks and proper uid
level. Add distilled water if needed. See Maintenance section.
Check the following components or areas for damage, improperly installed or missing parts and
unauthorized modications:
Electrical components, wiring and
electrical cables
Hydraulic hoses, ttings, cylinders and
manifolds
Fuel and hydraulic tanks
Drive and turntable motors and drive hubs
Boom and axle wear pads
Check the entire machine for:
Cracks in welds or structural components
Dents or damage to machine
Excessive rust, corrosion or oxidation
Be sure that all structural and other critical
components are present and all associated fasteners and pins are in place and properly tightened.
Be sure the secondary extend cylinder cover is
properly installed.
After you complete your inspection, be sure
that all compartment covers are in place and latched.
32 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 35
Operator's ManualFifth Edition • Third Printing
Inspections
Function Test 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.
Do Not Operate Unless:
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 function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
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 qualied
service technician, according to the manufacturer's
specications.
After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service.
1 Select a test area that is rm, level and free of
obstruction.
At the Ground Controls
2 Turn the key switch to ground 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 ash.
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).
Part No. T111108 S-100 • S-105 • S-120 • S-125 33
Page 36
Operator's Manual Fifth Edition • Third Printing
Inspections
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 Hydraulic Oil Return Filter
7 Press the engine idle speed select button
until the indicator light next to high idle (rabbit symbol) is on.
8 Lift the tank side turntable cover to locate and
check the hydraulic lter condition indicator.
Result: The indicator should be in the green
area.
9 Close and secure the tank side turntable cover.
10 Press the engine idle speed select button until
the indicator light next to low idle (turtle symbol) is on.
Test the Extendable Axles
Note: Start this test with the axles retracted.
11 At the 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.
12 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.
13 Push and hold a function enable/speed select
button and press the boom extend button.
Result: The boom should not extend.
14 Turn the key switch to platform
control. At the platform controls, step on the foot switch and 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 ash
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.
34 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 37
Operator's ManualFifth Edition • Third Printing
Inspections
15 Return to the ground controls. Turn the key
switch to ground control. Push and hold a function enable/speed select button and push the boom up button and then the boom down button.
Result: The boom should raise and lower
normally.
16 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
17 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.
18 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. The descent alarm (if equipped) should sound while the boom is lowering.
Test Emergency Controls
19 Turn the key switch to ground control and shut
the engine off.
20 Pull out the red Emergency Stop button to the
on position.
21 Simultaneously push and hold
the emergency 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.
Test the Tilt Sensor
22 Push one of the LCD screen buttons until
TURNTABLE LEVEL SENSOR X-DIRECTION appears.
Result: The LCD screen should display the
angle in degrees.
23 Push one of the LCD screen buttons until
TURNTABLE LEVEL SENSOR Y-DIRECTION appears.
Result: The LCD screen should display the
angle in degrees.
24 Push one of the LCD screen buttons until
PLATFORM LEVEL SENSOR DEGREES appears.
Result: The LCD screen should display the
angle in degrees.
Part No. T111108 S-100 • S-105 • S-120 • S-125 35
Page 38
Operator's Manual Fifth Edition • Third Printing
Inspections
Test the Operating Envelope
25 Simultaneously push and
then release the LCD screen buttons shown to activate status mode.
26 Push one of the LCD screen
buttons shown until BOOM ANGLE is displayed.
27 Raise the boom and observe the LCD screen.
Result: The LCD screen should display:
< 10 >= 10 >= 53
> 68
28 Push one of the LCD
screen buttons shown until BOOM LENGTH is displayed.
29 Extend the boom and observe the LCD screen.
Result: The LCD screen should display:
at 0 > 0 > 75 = 100
> 100
At the Platform Controls
Test Emergency Stop
31 Turn the key switch to platform control.
32 Push in the platform red Emergency Stop
button to the off position.
Result: The engine should turn off and no
functions should operate.
33 Pull out the red Emergency Stop button and
restart the engine.
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.
30 Retract the boom.
36 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 39
Operator's ManualFifth Edition • Third Printing
Inspections
Test the Foot Switch
36 Push in the platform red Emergency Stop
button to the off position.
37 Pull out the red Emergency Stop button to
the on position but do not 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
mode select button for crab steer.
50 Press down the foot switch.
Part No. T111108 S-100 • S-105 • S-120 • S-125 37
Page 40
Operator's Manual Fifth Edition • Third Printing
Inspections
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 triangle.
Result: All wheels should turn in the direction
that the blue triangles point on the drive chassis.
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 triangle.
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 the yellow 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 yellow arrow points on the 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.
38 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 41
Operator's ManualFifth Edition • Third Printing
Blue
Yellow
Inspections
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 controls and the drive chassis to identify the direction of travel.
Test Limited Drive Speed
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 / 30 cm per second.
Note: The machine will travel 40 feet / 12.2 m 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 / 30 cm per second.
Note: The machine will travel 40 feet / 12.2 m in 40 seconds.
If the drive speed with the boom raised or extended exceeds 1 foot / 30 cm per second, immediately tag and remove the machine from service.
If the drive/steer control handle is not moved within
68 Raise the boom to horizontal. Extend the boom
as far as it will go.
two seconds of pushing the drive enable button, the drive function will not operate.
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 / 18 cm per second.
Note: The machine will travel 40 feet / 12.2 meters in 70 seconds.
Part No. T111108 S-100 • S-105 • S-120 • S-125 39
Page 42
Operator's Manual Fifth Edition • Third Printing
Inspections
Test Emergency 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 emergency power button and 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.
40 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 43
Operator's ManualFifth Edition • Third Printing
Inspections
Workplace Inspection
Be aware of and avoid the following hazardous situations:
• drop-offs or holes
Do Not Operate Unless:
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 workplace.
Know and understand the workplace
inspection before going on to the next section.
5 Only use the machine as it was intended.
Fundamentals
The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace.
• bumps, oor obstructions or debris
• sloped surfaces
• unstable or slippery surfaces
• overhead obstructions and high voltage conductors
• hazardous locations
• inadequate surface support to withstand all load forces imposed by the machine
• wind and weather conditions
• the presence of unauthorized personnel
• other possible unsafe conditions
It is the operator's responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine.
Part No. T111108 S-100 • S-105 • S-120 • S-125 41
Page 44
Operator's Manual Fifth Edition • Third Printing
Inspections
Inspection for Decals with Words
Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place.
Part No. Description Quantity
25994 Notice - Component Damage Hazard 1
27204 Arrow - Blue 1
27205 Arrow - Yellow 1
27206 Triangle - Blue 4
27207 Triangle - Yellow 4
28159 Label - Diesel Only 1
28161 Warning - Crushing Hazard 6
28165 Instructions - Foot Switch Operation 1
28174 Label - Power to Platform, 230V 2
28175 Warning - Compartment Access 1
28176 Label - Manual Missing 1
28177 Warning - Crushing Hazard Platform 2
28181 Warning - No Step or Ride 1
28235 Label - Power to Platform, 115V 2
28236 Warning - Read The Manual 1
30080 Instructions - Max. Capacity, 500 lbs/227 kg, S-105 and S-125 1
31788 Danger - Battery Safety 1
38149 Label - Patents 1
40434 Label - Lanyard Anchorage Point 3
43594 Instructions - Max. Capacity, 750 lbs/340 kg, S-100 and S-120 1
44981 Label - Air Line to Platform (option) 2
44986 Instructions - Max. Manual Force, 1 90 lbs/400 N (AUS)
Part No. Description Quantity
52865 Warning - Annual Inspection, U.S. Only 1
61227 Ground Control Panel 1
65182 Platform Control Panel 1
65187 Danger - Do Not Alter or Disable Limit Switches 1
65264 Cosmetic - Genie S-125 1
65265 Cosmetic - S-125 1
65266 Cosmetic - 4 x 4 1
65267 Cosmetic - Genie S-120 1
65268 Cosmetic - S-120 1
65273 Label - Tire Specications, S-120 and S-125 4
65278 Label - No Step 4
65428 Danger - Tip-over Hazard, Tires 4
72119 Label - Range of Motion, S-120 and S-125 1
72131 Label - Cylinder Cover 4
72147 Cosmetic - Genie S-100 1
72148 Cosmetic - Genie S-105 1
72149 Cosmetic - S-100 1
72150 Cosmetic - S-105 1
72151 Label - Tire Specications, S-100 and S-105 4
72152 Label - Range of Motion, S-100 and S-105 1
This inspection continues on the next page.
42 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 45
Operator's ManualFifth Edition • Third Printing
Shading indicates decal is hidden from view, i.e. under covers
Inspections
Part No. T111108 S-100 • S-105 • S-120 • S-125 43
Page 46
Operator's Manual Fifth Edition • Third Printing
Inspections
Inspection for Decals with Words
Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place.
This inspection is a continuation from the previous page.
Part No. Description Quantity
72168 Label - Starter Battery 1
72169 Label - Battery Controls 1
72875 Warning - Pipe Cradle (option) 2
72968 Label - 25 amp Circuit Breaker 1
82237 Danger - High Voltage, Welder (option) 2
82289 Danger - Tip-over Hazard ­ Do not alter limit switch 1
82366 Label - Chevron Rando 1
82410 Warning - Panel Cradle (option) 2
82422 Label - Work Lights or Driving Lights (option) 1
82862 Danger - Fire Extinguisher, Welder (option) 1
82902 Danger - Tip-over Hazard ­ Do not alter limit switch 1
97579 Danger - Tip-Over, Welder (option) 1
97602 Warning - Explosion Hazard 1
97815 Label - Mid-rail 1
97875 Warning - Weld Line to Platform (option) 2
97887 Instructions - Max. Side Force, 150 lbs/667 N (ANSI & CSA) 1
114112 Label - Transport Diagram 2
114258 Danger - Explosion Hazard 1
114389 Danger - General Safety Rules 2
114390 Danger - Electrocution Hazard 4
Part No. Description Quantity
114416 Danger - Tip-over Hazard, Tilt Alarm 1
122043 Instructions - Engine Specs, Cummins 1
128953 Instructions - Engine Specs, Deutz 1
128974 Instructions - Engine Specs, Perkins 1
133278 Label - Ultra Low or Low Sulfur, US Only 1
146097 Danger- Tire Specications, Solid Rubber S-100 and S-105 4
146098 Danger- Tire Specications, Solid Rubber S-120 and S-125 4
146418 Label - Wheel Load, S-100 4
146419 Label - Wheel Load, S-105 4
146420 Label - Wheel Load, S-120 4
146421 Label - Wheel Load, S-125 4
146423 Danger - Do Not Alter or Disable Limit Switches 1
229356 Danger - Tip-over Hazard, Low Prole, S-120 and S-125 4
230977 Danger- Tire Specications, Solid Rubber S-120 and S-125 4
230978 Danger- Tire Specications, Solid Rubber S-100 and S-105 4
233581 Danger - Tip-over Hazard, Low Prole, S-100 and S-105 4
1000256 Instructions - Operating Instructions 2
1257237 Instructions - Perkins Tier 4 1
T110549 Label - Fault Code Chart 1
T114285 Warning - Install Cover/Read the Manual 4
44 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 47
Operator's ManualFifth Edition • Third Printing
Shading indicates decal is hidden from view, i.e. under covers
Inspections
Part No. T111108 S-100 • S-105 • S-120 • S-125 45
Page 48
Operator's Manual Fifth Edition • Third Printing
Inspections
Inspection for Decals with Symbols
Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place.
Part No. Description Quantity
27204 Arrow - Blue 1
27205 Arrow - Yellow 1
27206 Triangle - Blue 4
27207 Triangle - Yellow 4
28159 Label - Diesel 1
28174 Label - Power to Platform, 230V 2
28235 Label - Power to Platform, 115V 2
40434 Label - Lanyard Anchorage Point 3
44981 Label - Air Line to Platform (option) 2
61227 Ground Control Panel 1
65182 Platform Control Panel 1
65264 Cosmetic - Genie S-125 1
65265 Cosmetic - S-125 1
65266 Cosmetic - 4 x 4 1
65267 Cosmetic - Genie S-120 1
65268 Cosmetic - S-120 1
65278 Label - No Step 4
72119 Label - Range of Motion,
S-120 and S-125 1
Part No. Description Quantity
72147 Cosmetic - Genie S-100 1
72148 Cosmetic - Genie S-105 1
72149 Cosmetic - S-100 1
72150 Cosmetic - S-105 1
72152 Label - Range of Motion,
S-100 and S-105 1
82422 Label - Work Lights or
Driving Lights (option) 1
82472 Label - Crushing Hazard 6
82473 Label - Compartment Access 1
82481 Label - Battery Safety 1
82487 Label - Read the Manual 2
82487 Label - Read the Manual,
Panel Cradle (option) 2
82487 Label - Read the Manual,
Pipe Cradle (option) 2
82547 Label - Maximum Capacity, 340 kg,
S-100/S-120 1
82548 Label - Crushing Hazard, Platform 2
82601 Label - Maximum Capacity, 227 kg,
S-105 and S-125 1
This inspection continues on the next page.
46 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 49
Operator's ManualFifth Edition • Third Printing
Shading indicates decal is hidden from view, i.e. under covers
Inspections
Part No. T111108 S-100 • S-105 • S-120 • S-125 47
Page 50
Operator's Manual Fifth Edition • Third Printing
Inspections
Inspection for Decals with Symbols
Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place.
This inspection is a continuation from the previous page.
Part No. Description Quantity
82602 Label - Max Side Force, 667 N 1
82603 Label - Drive Enable Patch 1
82671 Label - Weld Line to Platform (option) 2
97757 Label - Hydraulic Oil Level 1
97815 Label - Lower Mid-rail 1
114112 Label - Transport Diagram 2
114247 Label - No Step or Ride 1
114249 Label - Tip-Over Hazard, Tires 4
114251 Label - Explosion Hazard 1
114252 Label - Tip-Over Hazard, Limit Switch 4
114473 Label - Tip-Over Hazard, Tilt Alarm 1
133067 Label - Electrocution Hazard 4
133205 Label - Electrocution Hazard, Battery 1
146418 Label - Wheel Load, S-100 4
146419 Label - Wheel Load, S-105 4
146420 Label - Wheel Load, S-120 4
146421 Label - Wheel Load, S-125 4
T114286 Label - Install Cover/Read the Manual 8
48 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 51
Operator's ManualFifth Edition • Third Printing
Shading indicates decal is hidden from view, i.e. under covers
Inspections
Part No. T111108 S-100 • S-105 • S-120 • S-125 49
Page 52
Operator's Manual Fifth Edition • Third Printing
Operating Instructions
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.
Do Not Operate Unless:
Using the machine for anything other than lifting
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 workplace.
5 Only use the machine as it was intended.
personnel, along with their tools and materials, 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
qualied 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 workplace inspection before using the machine.
50 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 53
Operator's ManualFifth Edition • Third Printing
Operating Instructions
Starting the Engine
1 At the ground controls, turn the key switch to
the desired position.
2 Be sure both ground and platform control red
Emergency Stop buttons are pulled out to the on position.
Deutz models
1 Diesel models with glow plug button: Push the
glow plug button.
Diesel models with automatic glow plugs:
Amber light will be on when glow plugs are on.
2 Move the engine start toggle switch
to either side. The engine start switch can be moved at any time while the glow plugs are on. If the engine fails to start or dies, the restart delay will disable the start switch for 3 seconds.
Perkins models
1 Move the glow plug switch to either side and
hold.
2 Move the engine start toggle switch to either
side. If the engine fails to start or dies, the restart delay will disable the start switch for 3 seconds.
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.
In cold conditions, 20°F / -6°C and below, warm the engine for 5 minutes before operating to prevent hydraulic system damage.
In extreme cold conditions, 0°F / -18°C and below, machines should be equipped with optional cold start kits. Attempting to start the engine when temperatures are below 0°F / -18°C may require the use of a booster battery.
Part No. T111108 S-100 • S-105 • S-120 • S-125 51
Page 54
Operator's Manual Fifth Edition • Third Printing
Operating Instructions
Emergency Stop
Push in either the ground or platform red Emergency Stop button to the off position to stop all functions and turn the engine off.
Repair any function that operates when the red Emergency Stop button is pushed in.
Selecting and operating the ground controls will override the platform red Emergency Stop button.
Emergency Controls
Use emergency power if the primary power source (engine) fails.
1 Turn the key switch to ground or platform
control.
2 Pull out the red Emergency Stop button to the
on position.
3 Press down the foot switch when operating the
emergency controls from the platform.
4 Simultaneously hold the emergency
power button and activate the desired function.
The drive function will not operate with emergency power.
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.
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.
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.
52 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 55
Operator's ManualFifth Edition • Third Printing
Operating Instructions
To Steer
1 Press down the foot switch.
2 Select the steer mode by pressing 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 direction of the blue or yellow triangle OR press the thumb rocker switch located on top of the drive control handle.
Use the color-coded direction triangles on the platform controls and the drive chassis to identify the direction the wheels will turn.
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.
Driving on a slope
Determine the uphill, downhill and side slope ratings for the machine and determine the slope grade.
Maximum slope rating, platform downhill (gradeability): 40% (22°)
Maximum slope rating, platform uphill: 40% (22°)
Maximum side slope rating: 25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction. The term gradeability
applies to the platform downhill conguration only.
Be sure the boom is below horizontal and the platform is between the non-steer wheels.
To determine the slope grade:
Measure the slope with a digital inclinometer OR use the following procedure.
You will need:
carpenter’s level
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.
Part No. T111108 S-100 • S-105 • S-120 • S-125 53
straight piece of wood, at least 3 feet / 1 m long
tape measure
Page 56
Operator's Manual Fifth Edition • Third Printing
Operating Instructions
Lay the piece of wood on the slope.
At the downhill end, lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level.
While holding the piece of wood level, measure the distance from the bottom of the piece of wood to the ground.
Divide the tape measure distance (rise) by the length of the piece of wood (run) and multiply by
100.
Example:
run
rise
Piece of wood = 144 inches (3.6 m)
Run = 144 inches (3.6 m)
Rise = 12 inches (0.3 m)
12 in ÷ 144 in = 0.083 x 100 = 8.3% grade
Drive Enable
Light on indicates that the boom has moved past either circle­end wheel and drive function has been interrupted.
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 that 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.
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.
0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade
If the slope exceeds the maximum uphill, downhill or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting Instructions section.
54 S-100 • S-105 • S-120 • S-125 Part No. T111108
· Rabbit and foot switch symbol: foot switch activated high idle
· Turtle symbol: low idle
· Rabbit symbol: high idle
Page 57
Operator's ManualFifth Edition • Third Printing
Operating Instructions
Check Engine Light
Light on and engine stopped: Tag the machine and remove from service.
Light on and engine still running: Contact service personnel within 24 hours.
Operating Envelope Indicator Lights
The operating envelope indicator lights will come on to notify the operator that a function has been interrupted and/or an action is required by the operator.
Raise Boom indicator light
ashing: To continue extending
the boom, raise the boom until the indicator light is off.
Retract Boom indicator light
ashing: To continue lowering
the boom, retract the boom until the indicator light is off.
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.
Machine Not Level indicator
light ashing: The tilt alarm will
be sounding when this light is
ashing. Move the machine to a rm level surface.
Platform Not Level indicator
light ashing: The tilt alarm will
be sounding when this light is
ashing. The Platform Level
toggle switch will only work in the direction that will level the platform. Level the platform until the indicator light is off.
Part No. T111108 S-100 • S-105 • S-120 • S-125 55
Page 58
Operator's Manual Fifth Edition • Third Printing
Operating Instructions
Machine Not Level Indicator Light (if equipped)
If the tilt alarm sounds when the platform is raised, the Machine Not Level indicator light will come on and the drive function in one or both directions will not operate. Identify the condition of the boom on the slope as shown below. Follow the steps to lower the boom before moving to a
rm, level surface. Do not rotate
the boom while lowering.
If the tilt alarm sounds with the platform uphill:
1 Lower the boom.
2 Retract the boom.
If the tilt alarm sounds with the platform downhill:
1 Retract the boom.
2 Lower the boom.
LCD Screen (if equipped)
The LCD screen displays hour meter, voltage, oil pressure and coolant temperature. The screen also displays fault codes and other service information.
Perkins Engine
Machines equipped with Perkins 854F-34T Diesel engines have a regeneration mode that should run automatically when needed.
LCD will display REGEN FORCED and WARNING HIGH EXHAUST SYSTEM TEMP when the regeneration mode is runnung. No service required.
After Each Use
1 Select a safe parking location—rm level
surface, clear of obstruction and trafc.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is
between the circle-end wheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized use.
56 S-100 • S-105 • S-120 • S-125 Part No. T111108
5 Chock the wheels.
Page 59
Operator's ManualFifth Edition • Third Printing
Operating Instructions
Pipe Cradle Instructions
The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform and mounted to the guardrails with U-bolts.
Observe and Obey:
Pipe cradles must be installed on the inside of
the platform.
Pipe cradles must not obstruct the platform
controls or the platform entrance.
The bottom of the pipe cradle tube must rest on
the platform oor.
Be sure the platform is level before installing a
pipe cradle.
Pipe Cradle Installation
1 Install a pipe cradle on each side of the
platform. Refer to the illustration on the left. Make sure the bottom of the pipe cradle tube
rests on the platform oor.
2 Install two U-bolts from the outside of the
platform rails through each pipe cradle mount.
3 Secure each U-bolt with 2 washers and 2 nuts.
a strap
b U-bolts
c pipe cradle mount
d upper platform
railing
Part No. T111108 S-100 • S-105 • S-120 • S-125 57
e pipe cradle
weldment
f middle platform railing
g at washers
3
/8-inch nylock nuts
h
Page 60
Operator's Manual Fifth Edition • Third Printing
Operating Instructions
Pipe Cradle Operation
1 Be sure the pipe cradle assembly and
installation instructions have been followed properly and that the pipe cradles are secured to the platform railings.
2 Place the load so that it rests in both pipe
cradles. The length of the load should be parallel with the length of the platform.
3 Center the load in the pipe cradles.
4 Secure the load to each pipe cradle. Pass the
nylon strap over the load. Depress the buckle and slide the strap through. Tighten the strap.
5 Gently push and pull on the load to make sure
the pipe cradles and load are secure.
6 Keep the load secured when the machine is
moving.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles will reduce the rated platform capacity of the machine and must be factored into the total platform load.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles may limit the maximum number of occupants in the platform.
Maximum Pipe Cradle Capacity
All models 200 lbs
90.7 kg
Pipe Cradle Assembly Weight 21 lbs
9.5 kg
58 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 61
Operator's ManualFifth Edition • Third Printing
Operating Instructions
Panel Cradle Assembly
1 Apply the warning decal to the front of each
panel cradle (if needed).
2 Install rubber bumper 1 in the panel cradle
base. See the illustration.
3 Secure the bumper with 2 high prole lock nuts
and 2 washers.
Panel Cradle Installation
1 Insert the hook piece through the slots in the
panel cradle base.
2 Hook the panel cradle to the bottom platform
tube in the desired location.
3 Install rubber bumper 2 through the panel cradle
base and the hook piece. See the illustration.
4 Secure with 2 low prole lock nuts.
5 If the panel cradle is installed at a platform oor
support tube, insert the U-bolt through the oor,
around the tube and into the panel cradle base.
Installation of Padding
1 Install the 2 pieces of padding on the platform
rails. Position the padding to protect the panels from contact with the platform rails.
Installation of Strap
1 Open the clamp and install it around a vertical
platform rail tube.
2 Insert a bolt with a washer through one side of
the clamp.
3 Install the strap assembly end plate onto the
bolt.
4 Insert the bolt through the other side of the
clamp.
5 Secure with a washer and a nut. Do not
over-tighten. The strap assembly end plate should be able to slide on the platform rail.
6 Secure the U-bolt with 2 nuts and 2 washers.
Proceed to step 9.
7 If the panel cradle is not installed at a platform
oor support tube, use the aluminum tube
provided.
8 Place the tube between the panel cradle and
the platform oor. Insert the U-bolt through the oor, around the tube and into the panel cradle
base.
9 Repeat above for the second set of parts.
Part No. T111108 S-100 • S-105 • S-120 • S-125 59
Page 62
Operator's Manual Fifth Edition • Third Printing
Operating Instructions
Panel Cradle Operation
1 Secure both panel cradles to the platform.
2 Place the load so that it rests in both panel
cradles.
3 Center the load on the platform.
4 Secure the load to the platform using the strap.
Tighten the strap.
rubber bumper 1
decal
hook piece
rubber
bumper 2
U-bolt
mounting
slots
panel
cradle
base
padding
clamp
hook
60 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 63
Transport Instructions
Disengage
Engage
Observe and Obey:
Genie Industries provides this securement
information as a recommendation. Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations, other localized regulations, and their company policy.
Genie customers needing to containerize any
lift or Genie product should source a qualied
freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment.
Only qualied aerial lift operators should move
the machine on or off the truck.
Transport vehicle must be parked on a level
surface.
Transport vehicle must be secured to prevent
rolling while machine is being loaded.
Be sure vehicle capacity, loading surfaces and
chains or straps are sufcient to withstand the
machine weight. Genie lifts are very heavy relative to their size. See the serial label for the machine weight. See the Decals section for the serial label location.
Operator's ManualFifth Edition • Third Printing
Transport and Lifting Instructions
Be sure the turntable is secured with the
turntable rotation lock before transporting. Be sure to unlock the turntable for operation.
Do not drive the machine on a slope that
exceeds the slope or side slope rating. See Driving on a Slope in the Operating Instructions section.
If the slope of the transport vehicle bed exceeds
the uphill or downhill maximum slope rating, the machine must be loaded and unloaded using a winch as described.
Free-wheelCongurationfor
Winching
Chock the wheels to prevent the machine from rolling.
Release the wheel brakes by turning over all four torque hub disconnect caps.
Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions.
Reverse the procedures described to re-engage the brakes.
Part No. T111108 S-100 • S-105 • S-120 • S-125 61
Page 64
Operator's Manual Fifth Edition • Third Printing
Truck bed
Truck bed
Truck bed
turntable rotation
lock pin
Transport and Lifting Instructions
Securing to Truck or Trailer
for Transit
Always use the turntable rotation lock pin each time the machine is transported.
Turn the key switch to the off position and remove the key before transporting.
Inspect the entire machine for loose or unsecured items.
Securing the Chassis
Use chains of ample load capacity.
Use a minimum of 5 chains.
Securing the Platform - S-100 and S-120
Lower the boom to the stowed position.
Raise the platform as far as it will go (see below).
Run a strap through the platform support between the plates next to the rotator.
Anchor the strap to each corner of the truck bed.
The platform will hang over the end of the truck.
Securing the Platform - S-105 and S-125
Lower the jib to the stowed position.
Adjust the rigging to prevent damage to the chains.
Lower the platform as far as it will go, so that the jib and platform are tucked underneath the boom.
Run a strap through the platform support between the plates next to the rotator.
Anchor the strap to each corner of the truck bed.
The platform will hang over the end of the truck.
62 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 65
Observe and Obey:
Only qualied riggers should rig and lift the
machine.
Be sure the crane capacity, loading surfaces
and straps or lines are sufcient to withstand
the machine weight. See the serial plate for the machine weight.
Operator's ManualFifth Edition • Third Printing
Transport and Lifting Instructions
Lifting Instructions
Fully lower and retract the boom. Move the jib boom (if equipped) parallel with the ground. Remove all loose items on the machine.
Use the turntable rotation lock to secure the turntable.
Determine the center of gravity of your machine using the table and the picture on this page.
Attach the rigging only to the designated lifting points on the machine. There are two lifting points on the chassis and two on the turntable.
Adjust the rigging to prevent damage to the machine and to keep the machine level.
Turntable lifting points (2)
Use a spreader bar to keep the rigging from damaging the machine.
Center of Gravity Location
X Axis Y Axis
S-100 6.81 ft 4.26 ft
2.08 m 1.30 m
S-105 6.62 ft 4.95 ft
2.02 m 1.51 m
S-120 6.55 ft 4.40 ft
2.0 m 1.34 m
S-125 6.32 ft 5.10 ft
1.93 m 1.55 m
Y Axis
Chassis lifting points (2) -
X Axis
Part No. T111108 S-100 • S-105 • S-120 • S-125 63
behind tires
Page 66
Operator's Manual Fifth Edition • Third Printing
Maintenance
Check the Engine Oil Level
Maintaining the proper engine oil level is essential to good engine performance and service life.
Observe and Obey:
Only routine maintenance items specied in this
manual shall be performed by the operator.
Operating the machine with an improper oil level can damage engine components.
Note: Check the oil level with the engine off.
Scheduled maintenance inspections shall be
completed by qualied service technicians, according to the manufacturer's specications and the requirements specied 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 symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.
Indicates that tools will be required to perform this procedure.
Indicates that new parts will be required to perform this procedure.
1 Check the engine oil dipstick. Add oil as needed.
Cummins B3.3C80 Engine
Oil type 15W-40 Oil type - cold conditions 10W-30
Deutz TD2011L04i Engine
Oil type 15W-40 Oil type - cold conditions 5W-30
Perkins 804D-33T Engine
Oil type 15W-40 Oil type - cold conditions 5W-40
Perkins 1104D-44T Engine
Oil type 15W-40 Oil type - cold conditions 10W-30
Perkins 854D-34T Engine
Oil type 15W-40 Oil type - cold conditions 5W-30
Deutz TD2.9L Engine
Oil type 15W-40 Oil type - cold conditions 5W-0
Indicates that a cold engine is required before performing this procedure.
64 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 67
Operator's ManualFifth Edition • Third Printing
Maintenance
Diesel Fuel Requirements
Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following result: long engine life and acceptable exhaust emissions levels.
Minimum diesel fuel requirements for each engine are listed below.
1 Check the engine oil dipstick. Add oil as needed.
Perkins 1104D-44T Engine
Fuel Type Low Sulfur Diesel (LSD)
Perkins 854D-34T Engine
Fuel Type Ultra Low Sulfur Diesel (ULSD)
Deutz TD2011L04i Engine
Fuel Type Low Sulfur Diesel (LSD)
Deutz TD2.9L Engine
Fuel Type Ultra Low Sulfur Diesel (ULSD)
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. Add oil as needed.
Result: The hydraulic oil level should be within
the top 2 inches / 5 cm of the sight gauge.
Hydraulicoilspecications
Hydraulic oil type Chevron Rando equivalent
Part No. T111108 S-100 • S-105 • S-120 • S-125 65
Page 68
Operator's Manual Fifth Edition • Third Printing
Maintenance
Check the Batteries
Proper battery condition is essential to good engine performance and operational safety.
Improper uid levels or damaged cables and
connections can result in engine component damage and hazardous conditions.
Electrocution hazard. Contact with hot or live
circuits may result in death or serious injury. Remove all rings, watches and other jewelry.
Bodily injury hazard. Batteries contain acid.
Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
Note: The controls battery is below the start battery.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Be sure that the battery hold-down bar is
secure.
4 Remove the battery vent caps.
5 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery ll tube. Do not overll.
6 Install the vent caps.
Check the Engine Coolant Level
- Liquid Cooled Models
Maintaining the engine coolant at the proper level is essential to engine service life. Improper coolant level will affect the engine's cooling capability and damage engine components. Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems.
Burn hazard. Beware of hot engine parts and
coolant. Contact with hot engine parts and/or coolant may cause severe burns.
1 Check the uid level in the coolant recovery
tank. Add uid as needed.
Result: The uid level should be at the
full mark.
Note: Do not remove the radiator cap.
Scheduled Maintenance
Maintenance performed quarterly, annually and every two years must be completed by a person
trained and qualied to perform maintenance on
this machine according to the procedures found in the service manual for this machine.
Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.
Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.
66 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 69
Operator's ManualFifth Edition • Third Printing
Specications
S-100
Height, working maximum 106 ft 32.5 m
Height, platform maximum 100 ft 30.5 m
Height, stowed maximum 10 ft 1 in 3.1 m
Horizontal reach maximum 75 ft 22.9 m
Width, axles retracted 8 ft 2 in 2.5 m
Width, axles extended 11 ft 3.35 m
Length, stowed 42 ft 8 in 13 m
Maximum load capacity 750 lbs 340 kg
Maximum wind speed 28 mph 12.5 m/s
Wheelbase 12 ft 3.7 m
Turning radius, inside, 9 ft 2.74 m axles extended
Turning radius, outside, 19 ft 10 in 6.05 m axles extended
Turning radius, inside, 13 ft 7 in 4.14 m axles retracted
Turning radius, outside, 21 ft 7 in 6.58 m axles retracted
Turntable rotation (degrees) 360
o
, continuous
Turntable tailswing, 5 ft 6 in 1.68 m axles retracted
Turntable tailswing 4 ft 1.22 m axles extended
Controls 12V DC proportional
Platform dimensions, 96 x 36 in length x width 2.4 m x 91 cm
Platform leveling self-leveling
Platform rotation 160°
AC outlet in platform standard
Tire size, foam-lled tires 385/65 D22.5 16 ply
Tire size, solid rubber tires 385/65 D24
Ground clearance 14 in 35.6 cm
Fuel tank capacity 40 gallons 151 liters
Weight 39,700 lbs 18,008 kg
(Machine weights vary with option congurations)
Drive speeds
Drive speed, stowed 3.0 mph 4.8 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
Maximum slope rating, stowed position
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction.
Floor loading information
Tire load, maximum 18,650 lbs 8460 kg
Tire contact pressure 105 psi 7.4 kg/cm
Occupied oor pressure 240 psf 1172 kg/m
axles extended 11.5 kPa
Occupied oor pressure 318 psf 1552 kg/m
axles retracted 15.2 kPa
Note: Floor loading information is approximate and does
not incorporate different option congurations. It should
be used only with adequate safety factors.
Hydraulic pressure, maximum 4250 psi 293 bar (drive functions)
System voltage 12V
Vibration value does not exceed 2.5 m/s
2
724 kPa
2
2
2
Continuous improvement of our products is a Genie
policy.Productspecicationsaresubjecttochange
without notice or obligation.
Part No. T111108 S-100 • S-105 • S-120 • S-125 67
Page 70
Operator's Manual Fifth Edition • Third Printing
Specications
S-105
Height, working maximum 111 ft 34 m
Height, platform maximum 105 ft 32 m
Height, stowed maximum 10 ft 1 in 3.1 m
Horizontal reach maximum 81 ft 24.7 m
Width, axles retracted 8 ft 2 in 2.5 m
Width, axles extended 11 ft 3.35 m
Length, stowed 46 ft 14 m
Maximum load capacity 500 lbs 227 kg
Maximum wind speed 28 mph 12.5 m/s
Wheelbase 12 ft 3.7 m
Turning radius, inside, 9 ft 2.74 m axles extended
Turning radius, outside, 19 ft 10 in 6.05 m axles extended
Turning radius, inside, 13 ft 7 in 4.14 m axles retracted
Turning radius, outside, 21 ft 7 in 6.58 m axles retracted
Turntable rotation (degrees) 360
o
, continuous
Turntable tailswing, 5 ft 6 in 1.68 m axles retracted
Turntable tailswing 4 ft 1.22 m axles extended
Controls 12V DC proportional
Platform dimensions, 96 x 36 in length x width 2.4 m x 91 cm
Platform leveling self-leveling
Platform rotation 160°
Tire size, foam-lled tires 385/65 D22.5 16 ply
Tire size, solid rubber tires 385/65 D24
Ground clearance 14 in 35.6 cm
Fuel tank capacity 40 gallons 151 liters
Weight 40,000 lbs 18,144 kg
(Machine weights vary with option congurations)
Drive speed, stowed 3.0 mph 4.8 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
Maximum slope rating, stowed position
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction.
Floor loading information
Tire load, maximum 21,200 lbs 9617 kg
Tire contact pressure 105 psi 7.4 kg/cm
Occupied oor pressure 240 psf 1172 kg/m
axles extended 11.5 kPa
Occupied oor pressure 318 psf 1552 kg/m
axles retracted 15.2 kPa
Note: Floor loading information is approximate and does
not incorporate different option congurations. It should
be used only with adequate safety factors.
AC outlet in platform standard
Hydraulic pressure, maximum 4250 psi 293 bar (drive functions)
System voltage 12V
Vibration value does not exceed 2.5 m/s
2
724 kPa
2
2
2
Continuous improvement of our products is a Genie
policy.Productspecicationsaresubjecttochange
without notice or obligation.
68 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 71
Operator's ManualFifth Edition • Third Printing
Specications
S-120
Height, working maximum 126 ft 38.6 m
Height, platform maximum 120 ft 36.6 m
Height, stowed maximum 10 ft 1 in 3.1 m
Horizontal reach maximum 75 ft 22.9 m
Width, axles retracted 8 ft 2 in 2.5 m
Width, axles extended 11 ft 3.35 m
Length, stowed 42 ft 8 in 13 m
Maximum load capacity 750 lb 340 kg
Maximum wind speed 28 mph 12.5 m/s
Wheelbase 12 ft 3.7 m
Turning radius, inside, 8 ft 6 in 2.6 m axles extended
Turning radius, outside, 18 ft 10 in 5.7 m axles extended
Turning radius, inside, 13 ft 2 in 4.01 m axles retracted
Turning radius, outside, 22 ft 1 in 6.7 m axles retracted
Turntable rotation (degrees) 360
o
, continuous
Turntable tailswing, 5 ft 6 in 1.68 m axles retracted
Turntable tailswing 4 ft 1 in 1.24 m axles extended
Controls 12V DC proportional
Platform dimensions, 96 x 36 in length x width 2.4 m x 91 cm
Platform leveling self-leveling
Platform rotation 160°
AC outlet in platform standard
Tire size, foam-lled tires 445/65 D22.5 18 ply
Tire size, solid rubber tires 445/65 D24
Ground clearance 14 in 35.6 cm
Fuel tank capacity 40 gallons 151 liters
Weight 44,340 lbs 20,112 kg
(Machine weights vary with option congurations)
Drive speeds
Drive speed, stowed 3.0 mph 4.8 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
Maximum slope rating, stowed position
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction.
Floor loading information
Tire load, maximum 21,250 lbs 9639 kg
Tire contact pressure 105 psi 7.4 kg/cm
Occupied oor pressure 266 psf 1299 kg/m
axles extended
Occupied oor pressure 353 psf 1723 kg/m
axles retracted 16.9 kPa
Note: Floor loading information is approximate and does
not incorporate different option congurations. It should
be used only with adequate safety factors.
Hydraulic pressure, maximum 4250 psi 293 bar (drive functions)
System voltage 12V
Vibration value does not exceed 2.5 m/s
2
2
724 kPa
2
12.7 kPa
2
Continuous improvement of our products is a Genie
policy.Productspecicationsaresubjecttochange
without notice or obligation.
Part No. T111108 S-100 • S-105 • S-120 • S-125 69
Page 72
Operator's Manual Fifth Edition • Third Printing
Specications
S-125
Height, working maximum 131 ft 40.1 m
Height, platform maximum 125 ft 38.1 m
Height, stowed maximum 10 ft 1 in 3.1 m
Horizontal reach maximum 80 ft 24.4 m
Width, axles retracted 8 ft 2 in 2.5 m
Width, axles extended 11 ft 3.35 m
Length, stowed 46 ft 9 in 14.2 m
Maximum load capacity 500 lb 227 kg
Maximum wind speed 28 mph 12.5 m/s
Wheelbase 12 ft 3.7 m
Turning radius, inside, 8 ft 6 in 2.6 m axles extended
Turning radius, outside, 18 ft 10 in 5.7 m axles extended
Turning radius, inside, 13 ft 2 in 4.01 m axles retracted
Turning radius, outside, 22 ft 1 in 6.7 m axles retracted
Turntable rotation (degrees) 360
o
, continuous
Turntable tailswing, 5 ft 6 in 1.68 m axles retracted
Turntable tailswing 4 ft 1 in 1.24 m axles extended
Controls 12V DC proportional
Platform dimensions, 96 x 36 in length x width 2.4 m x 91 cm
Platform leveling self-leveling
Platform rotation 160°
AC outlet in platform standard
Tire size, foam-lled tires 445/65 D22.5 18 ply
Tire size, solid rubber tires 445/65 D24
Ground clearance 14 in 35.6 cm
Fuel tank capacity 40 gallons 151 liters
Weight 44,640 lbs 20,248 kg
(Machine weights vary with option congurations)
Drive speeds
Drive speed, stowed 3.0 mph 4.8 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
Maximum slope rating, stowed position
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction.
Floor loading information
Tire load, maximum 23,750 lbs 10,773 kg
Tire contact pressure 105 psi 7.4 kg/cm
Occupied oor pressure 265 psf 1294 kg/m
axles extended
Occupied oor pressure 353 psf 1723 kg/m
axles retracted 16.9 kPa
Note: Floor loading information is approximate and does
not incorporate different option congurations. It should
be used only with adequate safety factors.
Hydraulic pressure, maximum 4250 psi 293 bar (drive functions)
System voltage 12V
Vibration value does not exceed 2.5 m/s
2
2
724 kPa
2
12.7 kPa
2
Continuous improvement of our products is a Genie
policy.Productspecicationsaresubjecttochange
without notice or obligation.
70 S-100 • S-105 • S-120 • S-125 Part No. T111108
Page 73
Operator's ManualFifth Edition • Third Printing
Specications
S-105 Range of Motion ChartS-100 Range of Motion Chart
S-125 Range of Motion ChartS-120 Range of Motion Chart
Part No. T111108 S-100 • S-105 • S-120 • S-125 71
Page 74
Loading...