Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you have
any questions, call Genie Industries.
Sixth Edition:Second Printing, January 2012
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "S" is a trademark of Genie Industries.
These machines comply with AUS 1418.10
Printed on recycled paper
Printed in U.S.A.
S-100 • S-105 • S-120 • S-125Part No . 226484
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 ManualSixth Edition • Second 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/certified 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.
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 . 226484S-100 • S-105 • S-120 • S-1251
Page 4
Operator's ManualSixth Edition • Second Printing
Introduction
Hazard Classification
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.
2S-100 • S-105 • S-120 • S-125Part No . 226484
Page 5
Operator's ManualSixth Edition • Second Printing
Symbol and Hazard Pictorials Definitions
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 flame.
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 . 226484S-100 • S-105 • S-120 • S-1253
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 ManualSixth Edition • Second Printing
Symbol and Hazard Pictorials Definitions
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 fire
extinguisher near.
Tie-down
instructions
Keep all open
flames and
sparks away.
Replace tires with
same tire.
Replace
extension cylinder
cover before
opeating machine.
No Step
Voltage rating for
power to platform
4S-100 • S-105 • S-120 • S-125Part No . 226484
Pressure rating for
air line to platform
Read service
manual.
Page 7
Operator's ManualSixth Edition • Second Printing
General Safety
Part No . 226484S-100 • S-105 • S-120 • S-1255
Page 8
Operator's ManualSixth Edition • Second Printing
General Safety
6S-100 • S-105 • S-120 • S-125Part No . 226484
Page 9
Operator's ManualSixth Edition • Second Printing
General Safety
Part No . 226484S-100 • S-105 • S-120 • S-1257
Page 10
Operator's ManualSixth Edition • Second Printing
Personal Safety
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.
8S-100 • S-105 • S-120 • S-125Part No . 226484
Page 11
Operator's ManualSixth Edition • Second 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 VoltageRequired Clearance
0 to 50KV3.0 m
50KV to 200KV4.6 m
200KV to 350KV6.1 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.
350KV to 500KV7.6 m
500KV to 750KV10.6 m
750KV to 1000KV13.7 m
Maximum platform capacity
S-100340 kg
S-105227 kg
S-120340 kg
S-125227 kg
Maximum occupants 2
Part No . 226484S-100 • S-105 • S-120 • S-1259
Page 12
Operator's ManualSixth Edition • Second 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 firm,
level surface.
Do not depend on the
tilt alarm as a level
indicator. The tilt alarm
sounds in the platform
only when the machine
is on a severe slope.
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 firm, 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 firm,
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 12.5 m/s. If wind speeds exceed 12.5 m/s
when the boom is raised, lower the boom and do
not continue to operate the machine.
10S-100 • S-105 • S-120 • S-125Part No . 226484
Page 13
Operator's ManualSixth Edition • Second 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 dropoffs.
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 manual force - 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 specification.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Part No . 226484S-100 • S-105 • S-120 • S-12511
Page 14
Operator's ManualSixth Edition • Second 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.
Do not use the
machine on a moving
or mobile surface or
vehicle.
Be sure all tires are in good condition, and lug nuts
are properly tightened.
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 downhill40% (22°)
Platform uphill40% (22°)
Side slope25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction.
Do not use air-filled tires. These machines are
equipped with foam-filled tires. Wheel weight is
critical to stability.
12S-100 • S-105 • S-120 • S-125Part No . 226484
Page 15
Operator's ManualSixth Edition • Second 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
firm footing on the
platform floor at all
times.
Do not climb down from
the platform when
raised.
Keep the platform floor
clear of debris.
Lower the platform
entry mid-rail or close
the entry gate before
operating.
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.
Part No . 226484S-100 • S-105 • S-120 • S-12513
Page 16
Operator's ManualSixth Edition • Second 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,
flames and lighted tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.
Do not spray ether into engines equipped with glow
plugs.
14S-100 • S-105 • S-120 • S-125Part No . 226484
Page 17
Operator's ManualSixth Edition • Second 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
specified 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, flames
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.
Part No . 226484S-100 • S-105 • S-120 • S-12515
Page 18
Operator's ManualSixth Edition • Second 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
34 kg.
Do not operate the welder unless a fire extinguisher
is immediately available for instant use.
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.
16S-100 • S-105 • S-120 • S-125Part No . 226484
Page 19
Operator's ManualSixth Edition • Second 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 9.5 kg.
The maximum capacity of the pipe cradle assembly
is 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.
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
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.
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 fixed or
overhanging load.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.
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 bc 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 Diesel models: Glow plug button
Gasoline/LPG models: Choke button
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.
1 0 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.
20S-100 • S-105 • S-120 • S-125Part No . 226484
Page 23
Operator's ManualSixth Edition • Second Printing
Controls
1 1 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.
indicator light
2 6 Used for optional equipment
2 7 Drive enable button with
indicator light
2 8 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
1 7 Red Emergency Stop button
1 8 Dual axis proportional control
handle for drive and steer
functions
OR Proportional control
handle for drive function and
thumb rocker for steer
function
1 9 Power indicator light
2 0 Platform overload indicator
light
21 Steer mode select buttons
with indicator lights
20212223
2 2 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
2 3 Single axis proportional
control handle for boom
extend/retract function
2 4 Axle extend button with
indicator light
Part No . 226484S-100 • S-105 • S-120 • S-12523
Page 26
Operator's ManualSixth Edition • Second 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
Light is on when the tilt alarm is sounding. Move
the machine to level ground.
5 Retract boom 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.
Gasoline/LPG models: Choke button with
indicator light
Push the choke button and hold for 3 to 5
seconds. The choke indicator light will be on
when the choke is being used.
To continue lowering, retract boom until the
indicator light goes out.
24S-100 • S-105 • S-120 • S-125Part No . 226484
1 1 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.
Page 27
Operator's ManualSixth Edition • Second Printing
Controls
1 2 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.
1 3 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.
1 4 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.
1 5 Low fuel indicator light
Light on indicates the machine is low on fuel.
1 6 Check engine indicator light
Light on indicates an engine fault.
1 7 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.
1 8 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.
1 9 Power indicator light
Light is on when the red Emergency Stop button
is pulled out to the on position.
2 0 Platform overload indicator light
Flashing light indicates the platform is
overloaded. The engine will stop and no
functions will operate.
Remove the weight from the platform until the
light goes off and then restart the engine.
Part No . 226484S-100 • S-105 • S-120 • S-12525
Page 28
Operator's ManualSixth Edition • Second Printing
Controls
2 1 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.
2 2 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.
2 3 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.
2 4 Axle extend button with indicator light
Push the axle extend button to extend the axles.
The indicator light will flash while the axles are
extending and stay on when the axles are fully
extended.
2 5 Axle retract button with indicator light
Push the axle retract button to retract the axles.
The indicator light will flash while the axles are
retracting and stay on when the axles are fully
retracted.
2 6 Used for optional equipment.
2 7 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.
2 8 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
turntable will rotate to
the right.
2 9 S-105 and S-125 models: Jib boom up/down
toggle switch
Move the jib boom
switch up and the jib will
raise.
Move the jib boom
switch down and the jib
will lower.
26S-100 • S-105 • S-120 • S-125Part No . 226484
Page 29
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.
Operator's ManualSixth Edition • Second Printing
Inspections
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
5 Only use the machine as it was intended.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Part No . 226484S-100 • S-105 • S-120 • S-12527
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Operator's ManualSixth Edition • Second Printing
Inspections
Pre-operation Inspection
R
R
Be sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
R
Be sure that all decals are legible and in place.
See Inspectionssection.
R
Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
R
Check for hydraulic oil leaks and proper oil
level. Add oil if needed. See Maintenance
section.
R
Check for engine coolant leaks and proper
level of coolant. Add coolant if needed. See
Maintenance section.
R
Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
R
Electrical components, wiring and
electrical cables
Boom and axle wear pads
R
Tires and wheels
R
Engine and related components
R
Limit switches and horn
R
Alarms and beacons (if equipped)
R
Nuts, bolts and other fasteners
R
Platform entry mid-rail or gate
Check the entire machine for:
R
Cracks in welds or structural components
R
Dents or damage to machine
R
Excessive rust, corrosion or oxidation
R
Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
Secondary Extend
Cylinder Cover
R
Hydraulic hoses, fittings, cylinders and
manifolds
R
Fuel and hydraulic tanks
R
Drive and turntable motors and drive hubs
28S-100 • S-105 • S-120 • S-125Part No . 226484
R
Be sure the secondary extend cylinder cover
is properly installed.
R
After you complete your inspection, be sure
that all compartment covers are in place and
latched.
Page 31
Operator's ManualSixth Edition • Second 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 qualified service
technician, according to the manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.
1 Select a test area that is firm, 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 flash.
Note: In cold climates, the LCD readout screen will
need to warm up before the display appears.
4 Start the engine (see Operating Instructions
section).
Part No . 226484S-100 • S-105 • S-120 • S-12529
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Operator's ManualSixth Edition • Second 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 filter condition indicator.
Result: The indicator should be in the green
area.
9 Close and secure the tank side turntable cover.
1 0 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.
1 1 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
flash while the axles are moving and stay on
when the axles are fully extended.
Note: The extend axle function will only work
while the machine is moving.
30S-100 • S-105 • S-120 • S-125Part No . 226484
Page 33
Operator's ManualSixth Edition • Second 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.
1 6 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
1 7 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.
1 8 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
1 9 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 . 226484S-100 • S-105 • S-120 • S-12531
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Operator's ManualSixth Edition • Second Printing
Inspections
Test the Operating Envelope
2 5 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.
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.
3 3 Pull out the red Emergency Stop button and
restart the engine.
Test the Horn
3 4 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.
Result: The LCD screen should display:
at 0
> 0
> 75
= 100
> 100
30 Retract the boom.
32S-100 • S-105 • S-120 • S-125Part No . 226484
Page 35
Operator's ManualSixth Edition • Second 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.
4 0 Do not press down the foot switch and test each
machine function.
Result: No machine functions should operate.
Test Machine Functions
4 1 Press down the foot switch.
4 2 Activate each machine function control handle,
toggle switch or button.
Result: All functions should operate through a
full cycle.
Test the Steering
4 3 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.
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.
Part No . 226484S-100 • S-105 • S-120 • S-12533
Page 36
Operator's ManualSixth Edition • Second Printing
Inspections
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
5 5 Press down the foot switch.
5 6 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.
34S-100 • S-105 • S-120 • S-125Part No . 226484
Page 37
Operator's ManualSixth Edition • Second Printing
Inspections
Test the Drive Enable System
5 8 Press down the foot switch and lower the boom
to the stowed position.
5 9 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
Blue
drive chassis to identify the
direction of travel.
Test Limited Drive Speed
6 2 Press down the foot switch.
6 3 Raise the boom to 10° above horizontal.
6 4 Slowly move the drive control handle to the full
drive position.
Result: The maximum achievable drive speed
with the boom raised should not exceed 30 cm
per second.
Note: The machine will travel 12.2 m in 40
seconds.
6 5 Lower the boom to the stowed position.
6 6 Extend the boom 1.2 m.
6 7 Slowly move the drive control handle to the full
drive position.
Result: The maximum achievable drive speed
with the boom extended should not exceed 30
cm per second.
Note: The machine will travel 12.2 m in 40
seconds.
If the drive speed with the boom raised or extended
exceeds 30 cm per second, immediately tag and
remove the machine from service.
If the drive/steer control
handle is not moved within
Yellow
6 8 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.
6 9 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 18 cm per second.
Note: The machine will travel 12.2 meters in 70
seconds.
Part No . 226484S-100 • S-105 • S-120 • S-12535
Page 38
Operator's ManualSixth Edition • Second Printing
Inspections
Test Emergency Controls
7 0 Shut off the engine.
7 1 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.
36S-100 • S-105 • S-120 • S-125Part No . 226484
Page 39
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.
Operator's ManualSixth Edition •Second Printing
Inspections
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
• drop-offs or holes
• bumps, floor 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
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.
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 . 226484S-100 • S-105 • S-120 • S-12537
Page 40
Operator's ManualSixth Edition • Second Printing
Inspections
Decal Inspection
Use the pictures on the next page to verify that all
decals are legible and in place.
Below is a numerical list with quantities and
descriptions.
97815Label - Mid-rail1
97875Warning - Weld Line to Platform (option)2
114112 Label - Transport Diagram2
114258 Danger - Explosion Hazard1
114389 Danger - General Safety Rules2
114390 Danger - Electrocution Hazard4
114416 Danger - Tip-over Hazard, Tilt Alarm1
230978 Danger- Tire Specifications, Solid Rubber
S-100 and S-1054
230977 Danger- Tire Specifications, Solid Rubber
S-120 and S-1254
233581 Danger - Tip-over Hazard, Low Profile,
S-100 and S-1054
T110549 Label - Fault Code Chart1
T114285 Warning - Install Cover/Read the Manual4
40S-100 • S-105 • S-120 • S-125Part No . 226484
Page 43
Shading indicates decal is
hidden from view,
i.e. under covers
Operator's ManualSixth Edition • Second Printing
Inspections
Part No . 226484S-100 • S-105 • S-120 • S-12541
Page 44
Operator's ManualSixth Edition • Second 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:
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.
Using the machine for anything other than lifting
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
qualified operators and are all expected to follow all
safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
every new operator should perform a pre-operation
inspection, function tests, and a workplace
inspection before using the machine.
42S-100 • S-105 • S-120 • S-125Part No . 226484
Page 45
Operator's ManualSixth Edition • Second 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.
Diesel models
3 Press the engine start button.
Note: In cold conditions, 10°C and
below, push and hold the glow plug
button for 10 to 20 seconds before
starting the engine.
Gasoline/LPG models
3 Choose fuel by pressing the fuel select button.
4 Push the engine start button.
Note: In cold conditions, -6°C and below, the
machine should be started on gasoline and warmed
for 2 minutes, then switched to LPG. Warm engines
can be started on LPG.
All models
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.
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, -6°C and below, warm the engine
for 5 minutes before operating to prevent hydraulic
system damage.
In extreme cold conditions, -18°C and below,
machines should be equipped with optional cold
start kits. Attempting to start the engine when
temperatures are below -18°C may require the use
of a booster battery.
Part No . 226484S-100 • S-105 • S-120 • S-12543
The drive function will not operate with emergency
power.
Page 46
Operator's ManualSixth Edition • Second Printing
Operating Instructions
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.
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.
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.
44S-100 • S-105 • S-120 • S-125Part No . 226484
Page 47
Operator's ManualSixth Edition • Second Printing
Operating Instructions
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 configuration 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.
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 = 3.6 m
Run = 3.6 m
Rise = 0.3 m
0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade
You will need:
carpenter’s level
straight piece of wood, at least 3 feet / 1 m
long
tape measure
Part No . 226484S-100 • S-105 • S-120 • S-12545
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.
Page 48
Operator's ManualSixth Edition • Second Printing
Operating Instructions
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.
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
flashing: To continue extending
the boom, raise the boom until
the indicator light is off.
Retract Boom indicator light
flashing: To continue lowering
the boom, retract the boom until
the indicator light is off.
Machine Not Level indicator
light flashing: The tilt alarm will
be sounding when this light is
flashing. Move the machine to a
firm level surface.
·Rabbit and foot switch symbol:
foot switch activated high idle
·Turtle symbol: low idle
·Rabbit symbol: high idle
46S-100 • S-105 • S-120 • S-125Part No . 226484
Platform Not Level indicator
light flashing: The tilt alarm will
be sounding when this light is
flashing. 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.
Page 49
Operator's ManualSixth Edition • Second Printing
Operating Instructions
Platform Overload
Flashing light indicates the platform is
overloaded. The engine will stop and
no functions will operate.
Remove the weight from the platform
until the light goes off and then restart
the engine.
Out of Operational Envelope
Recovery
If all functions stop operating, you may have
exceeded the operational envelope.
Retract Boom indicator light is flashing: Use the
Auxiliary Power Unit at the platform to retract the
boom until the indicator light is off. Restart the
engine to continue operation.
Raise Boom indicator light is flashing: Use the
Auxiliary Power Unit at the platform to raise the
boom until the indicator light is off. Restart the
engine to continue operation.
If the Auxiliary Power Unit at the platform
does not function, a trained operator on the ground
will need to lower the platform from
the ground controls. Please see the Service
Bypass / Recovery Key Switch section in the
service manual.
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.
After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
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.
5 Chock the wheels.
Part No . 226484S-100 • S-105 • S-120 • S-12547
Page 50
Operator's ManualSixth Edition • Second 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 floor.
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 floor.
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
48S-100 • S-105 • S-120 • S-125Part No . 226484
e pipe cradle
weldment
fmiddle platform
railing
g flat washers
3
h
/8-inch nylock nuts
Page 51
Transport Instructions
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 qualified
freight forwarder with expertise in preparing,
loading and securing construction and lifting
equipment for international shipment.
Only qualified 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.
Operator's ManualSixth Edition • Second 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 Configuration 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.
Disengage
Engage
Be sure vehicle capacity, loading surfaces and
chains or straps are sufficient 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.
Part No . 226484S-100 • S-105 • S-120 • S-12549
Page 52
Operator's ManualSixth Edition • Second Printing
Transport and Lifting Instructions
Securing to Truck or Trailer
for Transit
Always use the turntable rotation lock pin each time
the machine is transported.
turntable rotation
lock pin
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.
Truck bed
Securing the Platform - S-105 and S-125
Lower the jib to the stowed position.
Adjust the rigging to prevent damage to the chains.
Truck bed
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.
Truck bed
50S-100 • S-105 • S-120 • S-125Part No . 226484
Page 53
Observe and Obey:
Only qualified riggers should rig and lift the
machine.
Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial plate for the
machine weight.
Operator's ManualSixth Edition • Second 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 AxisY Axis
S-1002.08 m1.30 m
S-1052.02 m1.51 m
S-1202.0 m1.34 m
S-1251.93 m1.55 m
Y Axis
Chassis lifting
points (2) -
X Axis
Part No . 226484S-100 • S-105 • S-120 • S-12551
behind tires
Page 54
Operator's ManualSixth Edition • Second 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 specified 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 qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
Maintenance Symbols Legend
The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the 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 type15W-40
Oil type - cold conditions10W-30
Deutz TD2011L04i Engine
Oil type15W-40
Oil type - cold conditions5W-30
Perkins 804D-33T Engine
Oil type15W-40
Oil type - cold conditions5W-40
Indicates that a cold engine is required
before performing this procedure.
52S-100 • S-105 • S-120 • S-125Part No . 226484
Page 55
Operator's ManualSixth Edition • Second Printing
Maintenance
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 5 cm of the sight gauge.
Hydraulic oil specifications
Hydraulic oil typeChevron Rando equivalent
Check the Batteries
Proper battery condition is essential to good engine
performance and operational safety. Improper fluid
levels or damaged cables and connections can
result in engine component damage and hazardous
conditions.
Electrocution hazard. 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 fill tube. Do not overfill.
6 Install the vent caps.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
Part No . 226484S-100 • S-105 • S-120 • S-12553
Page 56
Operator's ManualSixth Edition • Second Printing
Maintenance
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 fluid level in the coolant recovery
tank. Add fluid as needed.
Result: The fluid 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 qualified 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.
54S-100 • S-105 • S-120 • S-125Part No . 226484
Page 57
Operator's ManualSixth Edition • Second Printing
Specifications
S-100
Height, working maximum32.5 m
Height, platform maximum30.5 m
Height, stowed maximum3.1 m
Horizontal reach maximum22.9 m
Width, axles retracted2.5 m
Width, axles extended3.35 m
Length, stowed13 m
Maximum load capacity340 kg
Maximum wind speed12.5 m/s
Wheelbase3.7 m
Turning radius, inside,2.74 m
axles extended
Turning radius, outside,6.05 m
axles extended
Turning radius, inside,4.14 m
axles retracted
Turning radius, outside, 6.58 m
axles retracted
System voltage12V
Vibration value does not exceed 2.5 m/s
2
Tire size, foam-filled tires385/65 D22.5 16 ply
Tire size, solid rubber tires385/65 D24
Ground clearance35.6 cm
Fuel tank capacity151 liters
Weight18,008 kg
(Machine weights vary with option configurations)
Drive speeds
Drive speed, stowed4.8 km/h
12.2 m/9.1 sec
Drive speed,1.1 km/h
raised or extended12.2 m/40 sec
Drive speed,0.6 km/h
fully extended12.2 m/70 sec
Maximum slope rating, stowed position
Platform downhill40% (22°)
Platform uphill40% (22°)
Side slope25% (14°)
Turntable rotation (degrees)360o, continuous
Turntable tailswing,1.68 m
axles retracted
Turntable tailswing1.22 m
axles extended
Controls12V DC proportional
Platform dimensions,
length x width2.4 m x 91 cm
Platform levelingself-leveling
Platform rotation160°
AC outlet in platformstandard
Note: Slope rating is subject to ground conditions and
adequate traction.
Floor loading information
Tire load, maximum8460 kg
Tire contact pressure7.4 kg/cm
Note: Floor loading information is approximate and
does not incorporate different option configurations. It
Hydraulic pressure, maximum293 bar
should be used only with adequate safety factors.
(drive functions)
Part No . 226484S-100 • S-105 • S-120 • S-12555
2
2
2
Page 58
Operator's ManualSixth Edition • Second Printing
Specifications
S-105
Height, working maximum34 m
Height, platform maximum32 m
Height, stowed maximum3.1 m
Horizontal reach maximum24.7 m
Width, axles retracted2.5 m
Width, axles extended3.35 m
Length, stowed14 m
Maximum load capacity227 kg
Maximum wind speed12.5 m/s
Wheelbase3.7 m
Turning radius, inside,2.74 m
axles extended
Turning radius, outside,6.05 m
axles extended
Turning radius, inside,4.14 m
axles retracted
Turning radius, outside, 6.58 m
axles retracted
Turntable rotation (degrees)360o, continuous
Turntable tailswing,1.68 m
axles retracted
Turntable tailswing1.22 m
axles extended
Controls12V DC proportional
Platform dimensions,
length x width2.4 m x 91 cm
Platform levelingself-leveling
Platform rotation160°
AC outlet in platformstandard
System voltage12V
Vibration value does not exceed 2.5 m/s
2
Tire size, foam-filled tires385/65 D22.5 16 ply
Tire size, solid rubber tires385/65 D24
Ground clearance35.6 cm
Fuel tank capacity151 liters
Weight18,144 kg
(Machine weights vary with option configurations)
Drive speed, stowed4.8 km/h
12.2 m/9.1 sec
Drive speed,1.1 km/h
raised or extended12.2 m/40 sec
Drive speed,0.6 km/h
fully extended12.2 m/70 sec
Maximum slope rating, stowed position
Platform downhill40% (22°)
Platform uphill40% (22°)
Side slope25% (14°)
Note: Slope rating is subject to ground conditions and
adequate traction.
Floor loading information
Tire load, maximum9617 kg
Tire contact pressure7.4 kg/cm
Note: Floor loading information is approximate and
does not incorporate different option configurations. It
should be used only with adequate safety factors.
2
2
2
Hydraulic pressure, maximum293 bar
(drive functions)
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
56S-100 • S-105 • S-120 • S-125Part No . 226484
Page 59
Operator's ManualSixth Edition • Second Printing
Specifications
S-120
Height, working maximum38.6 m
Height, platform maximum36.6 m
Height, stowed maximum3.1 m
Horizontal reach maximum22.9 m
Width, axles retracted2.5 m
Width, axles extended3.35 m
Length, stowed13 m
Maximum load capacity340 kg
Maximum wind speed12.5 m/s
Wheelbase3.7 m
Turning radius, inside,2.6 m
axles extended
Turning radius, outside,5.7 m
axles extended
Turning radius, inside,4.01 m
axles retracted
Turning radius, outside, 6.7 m
axles retracted
System voltage12V
Vibration value does not exceed 2.5 m/s
2
Tire size, foam-filled tires445/65 D22.5 18 ply
Tire size, solid rubber tires445/65 D24
Ground clearance35.6 cm
Fuel tank capacity151 liters
Weight20,112 kg
(Machine weights vary with option configurations)
Drive speeds
Drive speed, stowed4.8 km/h
12.2 m/9.1 sec
Drive speed,1.1 km/h
raised or extended12.2 m/40 sec
Drive speed,0.6 km/h
fully extended12.2 m/70 sec
Maximum slope rating, stowed position
Platform downhill40% (22°)
Platform uphill40% (22°)
Side slope25% (14°)
Turntable rotation (degrees)360o, continuous
Turntable tailswing,1.68 m
axles retracted
Turntable tailswing1.24 m
Note: Slope rating is subject to ground conditions and
adequate traction.
Floor loading information
Tire load, maximum9639 kg
axles extended
Controls12V DC proportional
Platform dimensions,
length x width2.4 m x 91 cm
Platform levelingself-leveling
Platform rotation160°
AC outlet in platformstandard
Note: Floor loading information is approximate and
does not incorporate different option configurations. It
Hydraulic pressure, maximum293 bar
should be used only with adequate safety factors.
(drive functions)
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
Part No . 226484S-100 • S-105 • S-120 • S-12557
2
2
2
Page 60
Operator's ManualSixth Edition • Second Printing
Specifications
S-125
Height, working maximum40.1 m
Height, platform maximum38.1 m
Height, stowed maximum3.1 m
Horizontal reach maximum24.4 m
Width, axles retracted2.5 m
Width, axles extended3.35 m
Length, stowed14.2 m
Maximum load capacity227 kg
Maximum wind speed12.5 m/s
Wheelbase3.7 m
Turning radius, inside,2.6 m
axles extended
Turning radius, outside,5.7 m
axles extended
Turning radius, inside,4.01 m
axles retracted
Turning radius, outside, 6.7 m
axles retracted
System voltage12V
Vibration value does not exceed 2.5 m/s
2
Tire size, foam-filled tires445/65 D22.5 18 ply
Tire size, solid rubber tires445/65 D24
Ground clearance35.6 cm
Fuel tank capacity151 liters
Weight20,248 kg
(Machine weights vary with option configurations)
Drive speeds
Drive speed, stowed4.8 km/h
12.2 m/9.1 sec
Drive speed,1.1 km/h
raised or extended12.2 m/40 sec
Drive speed,0.6 km/h
fully extended12.2 m/70 sec
Maximum slope rating, stowed position
Platform downhill40% (22°)
Platform uphill40% (22°)
Side slope25% (14°)
Turntable rotation (degrees)360o, continuous
Turntable tailswing,1.68 m
axles retracted
Turntable tailswing1.24 m
Note: Slope rating is subject to ground conditions and
adequate traction.
Floor loading information
Tire load, maximum10,773 kg
axles extended
Controls12V DC proportional
Platform dimensions,
length x width2.4 m x 91 cm
Platform levelingself-leveling
Platform rotation160°
AC outlet in platformstandard