Page 1
Operator's Manual
S
-100HD
from S100HD15D-212
CE
S
-120HD
from S120HD15D-208
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 1261387
Page 2
Operator's Manual Second Edition First Printing
S-100HD • S-120HD Part No. 1261387
Front Matter
Important
Read, understand and obey these safety rules and
operating instructions before operating this
machine. Only trained and authorized personnel
shall be permitted to operate this machine. This
manual should be considered a permanent part of
your machine and should remain with the machine
at all times. If you have any questions, contact us.
Contact Us:
Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions ............. 3
General Safety ...................................................... 5
Personal Safety ..................................................... 8
Work Area Safety .................................................. 9
Legend ................................................................ 16
Controls ............................................................... 17
Inspections .......................................................... 25
Operating Instructions ......................................... 39
Transport and Lifting Instructions ....................... 45
Maintenance ....................................................... 48
Specifications ...................................................... 51
Copyright © 2014 by Terex Corporation
Second Edition: First Printing, October 2014
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Page 3
Second Edition First Printing Operator's Manual
Introduction
Part No. 1261387 S-100HD • S-120HD 1
Introduction
Owners, Users and Operators:
Thank you for choosing 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:
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.
Danger
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 safety rules
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.
Page 4
Operator's Manual Second Edition First Printing
Introduction
2 S-100HD • S-120HD Part No. 1261387
Hazard Classification
Decals on this machine use 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
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.
DANGER
WARNING
CAUTION
NOTICE
Page 5
Second Edition First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1261387 S-100HD • S-120HD 3
Symbol and Hazar d Pi ctor ial s De finit ions
Crush hazard
Keep away from
moving parts
Explosion hazard
No smoking.
No flame.
Stop engine.
Electrocution hazard
Maintain required
clearance
Crush hazard
Keep away from path
of moving platform
Fall hazard Keep off this surface.
Only trained
maintenance
personnel should
access compartments
Read the operator’s
manual
Replace tires with
tires of same
specification.
Replace extension
cylinder cover before
operating machine.
Tip-over hazard
Recovery procedure if tilt alarm sounds while
elevated.
Tip-over hazard Platform downhill:
1 Retract boom.
2 Lower boom.
Platform uphill:
1 Lower boom.
2 Retract boom.
Tip-over hazard Fall hazard
Page 6
Operator's Manual Second Edition First Printing
Symbol and Hazard Pictorials Definitions
4 S-100HD • S-120HD Part No. 1261387
Lanyard anchorage
points
Wheel load Fire hazard
Have fire extinguisher
near.
Voltage rating for
power to platform
Electrocution hazard Avoid contact Tie-down instructions Tie-down instructions
Pressure rating for air
line to platform
Explosion hazard
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs
Explosion / Burn
hazard
Keep open flames
away.
Read the service
manual
No step
Page 7
Second Edition First Printing Operator's Manual
General Safety
Part No. 1261387 S-100HD • S-120HD 5
General Safety
82472
82487
133067
114249 114249
133067
T114286
82472
T114286
114252
82487
82548
82472
133067
133067 A
114249
T114286
114252
82548
Page 8
Operator's Manual Second Edition First Printing
General Safety
6 S-100HD • S-120HD Part No. 1261387
114473 A
12.5 m/sec
82604 C
82547 B
340 kg
+
<=
340 kg
82487 C
82487
114473
82547
82604
Page 9
Second Edition First Printing Operator's Manual
General Safety
Part No. 1261387 S-100HD • S-120HD 7
82472 114251
82473
133067
82472
82548
T110471
114252
133205
114249
114249
82548
133067
82472
133205
T110471
82473
114251
133067
114252
T114286
T114286
T114286
82481
82481
114252
82472
114249
T110471 A
Page 10
Operator's Manual Second Edition First Printing
Personal Safety
8 S-100HD • S-120HD Part No. 1261387
Personal Safety
Personal 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 anchorage points 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.
Page 11
Second Edition First Printing Operator's Manual
Work Area Safety
Part No. 1261387 S-100HD • S-120HD 9
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or proximity
to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 13.72 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 operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity
340 kg
Maximum occupants
2
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will reduce
the rated platform capacity and must be subtracted
from the platform capacity. See the decals with the
options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals 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.
Page 12
Operator's Manual Second Edition First Printing
Work Area Safety
10 S-100HD • S-120HD Part No. 1261387
If the tilt alarm sounds when the platform is raised,
use extreme caution. 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 firm, 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.
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.
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 o
r
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 use the machine as a crane.
Do not push the machine or other objects with the
boom.
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 push off or pull
toward any object outside
of the platform.
Maximum allowable
manual force – 400 N
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 alter or disable the limit switches.
Page 13
Second Edition First Printing Operator's Manual
Work Area Safety
Part No. 1261387 S-100HD • S-120HD 11
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
fixed or overhanging loads
to any part of this machine.
Do not place ladders or
scaffolds in the platform o
r
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.
Do not use air-filled tires. These machines are
equipped with solid tires. Wheel weight is critical to
stability.
Be sure the tires are in good condition and the lug
nuts 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 only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 25% (14°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Page 14
Operator's Manual Second Edition First Printing
Work Area Safety
12 S-100HD • S-120HD Part No. 1261387
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor 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 use of personal
protective equipment.
Page 15
Second Edition First Printing Operator's Manual
Work Area Safety
Part No. 1261387 S-100HD • S-120HD 13
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any othe
r
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 or charge the battery 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.
Page 16
Operator's Manual Second Edition First Printing
Work Area Safety
14 S-100HD • S-120HD Part No. 1261387
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 machine.
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.
Do not operate the machine in locations where
extremely high magnetic fields may be present.
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 Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
The battery tray should
remain open during the entire
charging 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.
Page 17
Second Edition First Printing Operator's Manual
Work Area Safety
Part No. 1261387 S-100HD • S-120HD 15
Overhead Platform Protection
Safety
The maximum weight for overhead platform
protection is 11.5 kg and does not have to be
subtracted from the total capacity of the platform.
Do not exceed the rated platform capacity. If the
weight of overhead platform protection exceeds
11.5 kg, it will reduce the rated platform capacity of
the machine and must be factored into the total
platform load.
The weight of the overhead platform protection may
limit the maximum number of occupants in the
platform.
Secure overhead platform protection to the
provided platform attachment points.
Do not obstruct the entrance or 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 the hazards
associated with movement with platform overhead
protection.
Lower Platform Protection
Safety
The maximum weight for lower platform protection
is 13 kg and does not have to be subtracted from
the total capacity of the platform.
Do not exceed the rated platform capacity. If the
weight of lower platform protection exceeds 13 kg, it
will reduce the rated platform capacity of the
machine and must be factored into the total
platform load.
The weight of the lower platform protection may
limit the maximum number of occupants in the
platform.
Secure lower platform protection to the provided
platform attachment points.
Do not obstruct the entrance or 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 the hazards
associated with movement with platform overhead
protection.
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 non-steer wheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
Page 18
Operator's Manual Second Edition First Printing
Legend
16 S-100HD • S-120HD Part No. 1261387
Legend
1 Non-steer tire
2 Steer tire
3 Ground controls
4 Boom
5 Platform controls
6 Platform
7 Platform bumpers
8 Lanyard anchorage points
9 Sliding mid-rail
10 Manual storage container
11 Foot switch
12 Overhead protection (optional)
13 Lower Protection (optional)
Page 19
Second Edition First Printing Operator's Manual
Controls
Part No. 1261387 S-100HD • S-120HD 17
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 Not used
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
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 Not used
18 Platform rotate left/right buttons
19 Turntable rotate left/right buttons
STOP
19
2
4
5
6
3
15
14
11
10
8
9
7
13
12
1
18 17 16
Page 20
Operator's Manual Second Edition First Printing
Controls
18 S-100HD • S-120HD Part No. 1261387
Ground Control Panel
1 Boom down button
Press the boom down button and the
boom will lower.
2 Boom extend/retract buttons
Press the boom
extend button and the
boom will extend.
Press the boom retract
button and the boom
will retract.
3 Boom up button
Press the boom up button and the
boom will raise.
4 Engine speed select button
Press 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 Not used
7 LCD readout screen
a low fuel indicator
b engine oil pressure indicator
c water temperature indicator
d auxiliary power indicator
e high engine rpm indicator
f hour meter
8 Diesel models:Glow plug button
Gasoline/LPG models:Choke button
Press the glow plug button and hold for 3 to 5
seconds.
9 Red Emergency Stop button
Push in the 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/platform/ground selection
Turn the key switch to the off position and the
machine will be off. Turn the key switch to the
platform position and the platform controls will
operate. Turn the key switch to the ground
position and the ground controls will operate.
11 Engine start button
Press the engine start button to start the
engine.
abc de
f
Page 21
Second Edition First Printing Operator's Manual
Controls
Part No. 1261387 S-100HD • S-120HD 19
12 Emergency power button
Use emergency power if the primary power
source (engine) fails.
Simultaneously hold the emergency power
button and activate the desired function.
13 High speed function enable button
Press the high speed function enable button to
enable the functions on the ground control
panel to operate at high speed.
14 Low speed function enable button
Press the low speed function enable button to
enable the functions on the ground control
panel to operate at low speed.
15 Alarm
16 Platform level up/down buttons
Press the platform
level up button and
the level of the
platform will raise.
Press the platform
level down button
and the level of the
platform will lower.
17 Not used
18 Platform rotate left/right buttons
Press the platform rotate left
button and the platform will
rotate left.
Press the platform rotate
right button and the platform
will rotate right.
19 Turntable rotate left/right buttons
Press the turntable rotate
left button and the turntable
will rotate to the left.
Press the turntable rotate
right button and the
turntable will rotate to the
right.
Page 22
Operator's Manual Second Edition First Printing
Controls
20 S-100HD • S-120HD Part No. 1261387
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 Not used
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 Not used
14 Fault indicator light
15 Low fuel indicator light
16 Check engine indicator light
17 Red Emergency Stop button
1 2
65 7 8
9
10
2425262728
29
43
Page 23
Second Edition First Printing Operator's Manual
Controls
Part No. 1261387 S-100HD • S-120HD 21
1 Dual axis proportional control
handle for drive and steer
functions
OR Proportional control
handle for drive function and
thumb rocker for steer
function
2 Power indicator light
3 Platform overload indicator
light
4 Steer mode select buttons
with indicator lights
5 Drive speed 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
6 Single axis proportional
control handle for boom
extend/retract function
7 Axle extend button with
indicator light
8 Axle retract button with
indicator light
9 Used for optional equipment
10 Drive enable button with
indicator light
11 Dual axis proportional control
handle for boom up/down and
turntable rotate left/right
functions
12 Not used
11 12 13 1514 17
1819
16
20
21
2223
Page 24
Operator's Manual Second Edition First Printing
Controls
22 S-100HD • S-120HD Part No. 1261387
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 platform is raised and the
machine is on a severe slope. The drive
function in one or both directions will not
operate.
5 Retract boom indicator light
To continue lowering, retract boom until the
indicator light goes out.
6 Raise boom indicator light
To continue extending, raise the boom until the
indicator light goes out.
7 Horn button
Press this button and the horn will sound.
Release the button and the horn will stop.
8 Not used
9 Emergency power button with indicator light
Use emergency power if the primary power
source (engine) fails.
Simultaneously press 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
Press 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
Press the choke button and hold for 3 to 5
seconds. The choke indicator light will be on
when the choke is being used.
11 Engine start button with indicator light
Press the engine start button to start the engine.
The engine start button indicator light will be on
when the button is being pressed.
Page 25
Second Edition First Printing Operator's Manual
Controls
Part No. 1261387 S-100HD • S-120HD 23
12 Engine idle (rpm) select button with indicator
lights
Press this button to select the engine idle rpm
setting. The indicator light next to the current
setting will be on.
13 Not used
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 the 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 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 thumb
rocker and the machine will steer to the left.
Press the right side of the thumb rocker 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.
20 Platform overload indicator light
Light flashing indicates the platform is
overloaded. The engine will stop and no
functions will operate. Remove weight until the
light goes off and then restart the engine.
Page 26
Operator's Manual Second Edition First Printing
Controls
24 S-100HD • S-120HD Part No. 1261387
21 Steer mode select buttons with indicator lights
Press the steer mode select button to choose
steer mode. The indicator light next to the
current steer mode will be on.
22 Drive speed select button with indicator lights:
Press 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
Press the axle select button to extend the axles.
The indicator light will flash while the axles are
extending and stay on when the axles are fully
extended.
25 Axle retract button with indicator light
Press 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.
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, press the
drive enable button and slowly move the drive
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 right and the turntable will
rotate to the right. Move the
control handle to the left and
the turntable will rotate to the
left.
29 Not used
Page 27
Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 25
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.
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.
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.
Page 28
Operator's Manual Second Edition First Printing
Inspections
26 S-100HD • S-120HD Part No. 1261387
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 hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
Check for engine 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 the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
Electrical components, wiring and electrical
cables
Hydraulic hoses, fittings, cylinders and
manifolds
Fuel and hydraulic tanks
Drive and turntable motors and drive hubs
Wear pads
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
Lanyard anchorage points
Check 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.
Secondary Extend
Cylinder Cover
Page 29
Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 27
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.
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.
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.
Page 30
Operator's Manual Second Edition First Printing
Inspections
28 S-100HD • S-120HD Part No. 1261387
At the Ground Controls
1 Select a test area that is firm, level and free of
obstruction.
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.
Test Emergency Stop
5 Push in the red Emergency Stop button to the
off position.
Result: The engine should shut 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 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 light should be green.
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, press and
hold a function enable/speed select
button and press 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 Press and hold a function enable/speed select
button and press the boom down button.
Result: The boom should lower and return to
the stowed position.
13 Press 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 press 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.
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Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 29
15 Return to the ground controls. Turn the key
switch to ground control. Press and hold a
function enable/speed select button and press
the boom up button and then the boom down
button.
Result: The boom should raise and lower
normally.
16 At the ground controls, press and hold a
function enable/speed select button and press
the boom extend button and then the boom
retract button.
Result: The boom should extend and retract
normally.
Test 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
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 press and hold the
emergency power button and press
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 Press one of the LCD
screen control buttons until
TURNTABLE LEVEL
SENSOR X-DIRECTION
appears.
Result: The LCD screen should display the
angle in degrees.
23 Press the LCD screen control buttons until
TURNTABLE LEVEL SENSOR Y-DIRECTION
appears.
Result: The LCD screen should display the
angle in degrees.
24 Press the LCD screen control buttons until
PLATFORM LEVEL SENSOR DEGREES
appears.
Result: The LCD screen should display the
angle in degrees.
Page 32
Operator's Manual Second Edition First Printing
Inspections
30 S-100HD • S-120HD Part No. 1261387
Test the Operating Envelope
25 Simultaneously press and
then release the LCD
screen control buttons
shown to activate status
mode.
26 Press one of the LCD screen
control 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 Press one of the LCD
screen control 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
30 Retract the boom.
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 shut off and no
functions should operate.
33 Pull out the red Emergency Stop button and
restart the engine.
Test the Horn
34 Press the horn button.
35 Result: The horn should sound.
Test the Tilt Sensor Alarm
36 Press a button, such as the engine RPM button
or he fuel select button.
Result: The alarm should sound at the platform
controls.
Page 33
Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 31
Test the Foot Switch
37 Push in the platform red Emergency Stop
button to the off position.
38 Pull out the red Emergency Stop button to the
on position and do not start the engine.
39 Press down the foot switch and attempt to start
the engine by pressing the engine start button.
Result: The engine should not start.
40 Do not press down the foot switch and restart
the engine.
41 Do not press down the foot switch and test
each machine function.
Result: No functions should operate.
Test Machine Functions
42 Press down the foot switch.
43 Activate each function control handle, toggle
switch or thumb rocker switch.
Result: All functions should operate through a
full cycle.
Test the Steering
44 Press the steer
mode select button
for square-end
(blue arrow) steer.
45 Press down the foot switch.
46 Slowly move the drive 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.
47 Slowly move the 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 square-end wheels should turn in
the direction that the yellow triangles point on
the drive chassis.
48 Press the steer
mode select button
for circle-end
(yellow arrow)
steer.
49 Press down the foot switch.
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Operator's Manual Second Edition First Printing
Inspections
32 S-100HD • S-120HD Part No. 1261387
50 Slowly move the 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 blue triangles point on the
drive chassis.
51 Slowly move the drive 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 circle-end wheels should turn in the
direction that the yellow triangles point on the
drive chassis.
52 Press the steer
mode select button
for crab steer.
53 Press down the foot switch.
54 Slowly move the drive 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.
55 Slowly move the 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: All wheels should turn in the direction
that the yellow triangles point on the drive
chassis.
56 Press the steer
mode select switch
for coordinated
steer.
57 Press down the foot switch.
58 Slowly move the drive 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.
Page 35
Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 33
Test Drive and Braking
59 Press down the foot switch.
60 Slowly move the drive 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.
61 Slowly move the 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.
Test the Drive Enable System
62 Press down the foot switch and lower the boom
to the stowed position.
63 Rotate the turntable until the boom moves past
one of the circle-end tires.
Result: The drive enable
indicator light should come on
and remain on while the boom
is anywhere in the range
shown.
64 Move the drive control handle off center.
Result: The drive function should not operate.
65 Press the drive enable button and slowly move
the drive 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.
If the drive control handle is not moved within two
seconds of pressing the drive enable button, the
drive function will not operate.
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Operator's Manual Second Edition First Printing
Inspections
34 S-100HD • S-120HD Part No. 1261387
Test Limited Drive Speed
66 Press down the foot switch.
67 Raise the boom to 10° above horizontal.
68 Slowly move the drive control handle to the full
drive position.
Result: The maximum achievable drive speed
with the primary boom raised should not
exceed 30 cm/s.
Note: The machine will travel 12 m in 40 seconds.
69 Lower the boom to the stowed position.
70 Extend the boom 1.2 m.
71 Slowly move the drive control handle to the full
drive position.
Result: The maximum achievable drive speed
with the primary boom extended should not
exceed 30 cm/s.
Note: The machine will travel 12 m in 40 seconds.
If the drive speed with the boom raised or extended
exceeds 30 cm/s, immediately tag and remove the
machine from service.
72 Raise the boom to horizontal. Extend the boom
as far as it will go.
73 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
4.5 cm per second.
Note: The machine will travel 12 m in 270 seconds.
Test Emergency Controls
74 Shut the engine off.
75 Pull out the red Emergency Stop button to the
on position.
76 Press down the foot switch.
77 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 functions should operate.
Drive functions should not operate with
auxiliary power.
Test the Lift/Drive Select Function
78 Press down the foot switch.
79 Move the drive control handle off center and
activate a boom function toggle switch.
Result: No boom functions should operate. The
machine will in the direction indicated on the
control panel.
Page 37
Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 35
Test Drive Tilt Cutout
80 Press down the foot switch.
81 With the boom fully stowed, drive the machine
onto a slope where the chassis angle is greater
than 4.5° along the Y-Axis (front to back).
Result: The machine should continue to drive.
82 Return the machine to level ground and extend
the boom approximately 110 cm.
83 Drive the machine onto a slope where the
chassis angle is greater than 4.5° along the
Y-Axis (front to back).
Result: The machine should stop once the
machine reaches 4.5° of chassis tilt.
84 Retract the boom to the stowed position or
drive in the opposite direction.
Result: The machine should drive.
85 Return to level ground and raise the boom to
approximately 15° above horizontal.
86 Drive the machine onto a slope where the
chassis angle is greater than 4.5° along the
Y-Axis (front to back).
Result: The machine should stop once the
machine reaches 4.5° of chassis tilt.
87 Lower the boom to the stowed position or drive
in the opposite direction.
Result: The machine should drive.
88 Return to level ground and stow the boom.
89 Press down the foot switch.
90 With the boom fully stowed, drive the machine
onto a slope where the chassis angle is greater
than 4.5° along the X-Axis (side to side).
Result: The machine should continue to drive.
91 Return the machine to level ground and extend
the boom approximately 110 cm.
92 Drive the machine onto a slope where the
chassis angle is greater than 4.5° along the
X-Axis (side to side).
Result: The machine should stop once the
machine reaches 4.5° of chassis tilt.
93 Retract the boom to the stowed position or
drive in the opposite direction.
Result: The machine should drive.
94 Return to level ground and raise the boom to
approximately 15° above horizontal.
95 Drive the machine onto a slope where the
chassis angle is greater than 4.5° along the
X-Axis (side to side).
Result: The machine should stop once the
machine reaches 4.5° of chassis tilt.
96 Lower the boom to the stowed position or drive
in the opposite direction.
Result: The machine should drive.
97 Return to level ground and stow the boom.
Page 38
Operator's Manual Second Edition First Printing
Inspections
36 S-100HD • S-120HD Part No. 1261387
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.
Workplace Inspection
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.
Workplace Inspection Checklist
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
Page 39
Second Edition First Printing Operator's Manual
Inspections
Part No. 1261387 S-100HD • S-120HD 37
Inspection for Decals with
Symbols
Use the pictures on the next page to verify that all
decals are legible and in place.
Below is a numerical list with quantities and
descriptions.
Part No. Decal Description Qty
27204 Arrow – Blue 1
27205 Arrow – Yellow 1
27206 Triangle – Blue 4
27207 Triangle – Yellow 4
28159 Label – Diesel 1
40434 Label – Lanyard Anchorage Points 4
52966 Cosmetic – 4 x 2 1
61227 Ground Control Panel 1
65266 Cosmetic – 4 x 4 1
65278 Caution – No Step 4
82240 Label – Noise Level 1
82472 Label – Crushing Hazard 6
82473 Label – Compartment Access 1
82481 Label – Battery/Charger Safety 1
82487 Label – Read the Manual 2
82547 Label – Maximum Capacity, 340 kg 1
82548 Label – Platform Rotate 2
82577 Label – Platform Overload Patch 1
82604 Label – Max Manual Force, 400 N 1
97757 Label – Hydraulic Oil Level 1
97815 Label – Lower Mid-rail 1
114112 Label – Transport Diagram 2
114249 Label – Tip-over Hazard, Tires 4
114251 Label – Explosion Hazard 1
114252 Label – Tip-over Hazard, Limit Switches 4
114473 Label – Tilt Alarm 1
133067 Label – Electrocution Hazard 4
133205 Label – Electrocution/Burn Hazard 1
215005 Label – Lifting Point 4
226144 Label – Emergency Stop, Platform
Controls
1
Part No. Decal Description Qty
226145 Label – Boom Up/Down, Platform
Controls
1
226146 Label – Boom Extend/Retract & Swing
Rotate, Platform Controls
1
226147 Label – Steer/Drive, Platform Controls 1
1256293 Label – CG and Lifting Capacity
(S-100HD)
2
1256294 Label – CG and Lifting Capacity
(S-120HD)
2
1256298 Label – Wheel Load, S-100HD 4
1256299 Label – Wheel Load, S-120HD 4
1256300 Label – Range of Motion, S-100HD and
S-120HD
1
1256301 Cosmetic – Genie S-100HD 1
1256303 Cosmetic – Genie S-120HD 1
1256302 Cosmetic – S-100HD 1
1256304 Cosmetic – S-120HD 1
T110470 Label – Close Cover When Not Using
Platform Cotrols
1
T110549CS Label – Fault Code Chart (China
Only)
1
T114286 Label – Install Cover/Read the Manual 8
T114471 Label – No Step or Ride 1
Page 40
Operator's Manual First Edition • First Printing
Inspections
38 S-100HD • S-120HD Part No. 1256222
Page 41
First Edition • First Printing Operator's Manual
Operating Instructions
Part No. 1256222 S-100HD • S-120HD 39
Operating Instruct ions
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.
Fundamentals
The Operating Instructions section provides
instructions for each aspect of machine operation. It
is the operator’s responsibility to follow all the safety
rules and instructions in the operator’s, safety and
responsibilities manuals.
Using the machine for anything other than lifting
personnel, 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.
Page 42
Operator's Manual Second Edition First Printing
Operating Instructions
40 S-100HD • S-120HD Part No. 1261387
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.
3 Press the engine start button.
Note: In cold conditions, 10°C and
below, press and hold the glow plug
button for 10 to 20 seconds before
starting the engine.
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.
Emergency Stop
Push in the red Emergency Stop button to the off
position at the ground controls or the platform
controls to stop all machine functions and turn the
engine off.
Repair any function that operates when either 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 using the
controls from the platform.
4 Simultaneously press and hold the
emergency power button and
activate the desired function.
The drive function will not operate with emergency
power.
Page 43
Second Edition First Printing Operator's Manual
Operating Instructions
Part No. 1261387 S-100HD • S-120HD 41
Operation from Ground
1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to the
on position.
3 Start the engine.
To Position Platform
1 Press and hold a function
enable/speed select button.
2 Press the appropriate function
button according to the marking 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 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 above the
current steer mode will be on.
3 Slowly move the drive control handle in the
direction indicated by blue or yellow triangles
OR press the thumb rocker switch located on
top of the drive control handle.
4 Use the color-coded direction
arrows 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
control handle in the direction indicated
by the blue or yellow arrows.
Decrease speed: Slowly move the
drive control handle toward center.
Stop: Return the drive 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.
Page 44
Operator's Manual Second Edition First Printing
Operating Instructions
42 S-100HD • S-120HD Part No. 1261387
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):
2WD: 25% (14°)
4WD: 40% (22°)
Maximum slope rating, platform
uphill:
2WD: 25% (14°)
4WD: 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 counterweight downhill configuration
only.
Be sure the boom is below horizontal and the
platform is between the circle-end wheels.
Press the drive speed select button until the light
next to the machine on incline symbol is on.
To determine the slope grade:
Measure the slope with a digital inclinometer OR
use the following procedure.
You will need:
carpenter’s level
straight piece of wood, at least 1 m long
tape measure
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
vertical 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:
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
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 section.
Page 45
Second Edition First Printing Operator's Manual
Operating Instructions
Part No. 1261387 S-100HD • S-120HD 43
Drive Enable
Light on indicates that the boom
has moved past either circle-end
wheel and the drive function has
been interrupted.
To drive, hold the drive enable switch to either side
and slowly move the drive control handle off center.
If the drive control handle is not moved within two
seconds of pushing the drive enable button, the
drive function will not operate. Release and press
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 engine idle (rpm) by pressing the select
button. The indicator light next to the current setting
will be on.
Rabbit and foot switch symbol: foot switch
activated high idle
Turtle symbol: low idle
Rabbit symbol: high idle
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 if off.
Retract Boom indicator light
flashing: To continue lowering the
boom, retract the boom until the
indicator light is off.
Machine Not Level indicator light
flashing: The tilt alarm will be
sounding when this light is
flashing. Move the machine to a
firm, level surface.
Platform Not Level indicator light
flashing: The tilt alarm will be
sounding when this light is
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 46
Operator's Manual Second Edition First Printing
Operating Instructions
44 S-100HD • S-120HD Part No. 1261387
Platform Overload Indicator Light
Light flashing indicates the
platform is overloaded and no
functions will operate.
Remove weight from the
platform until the light goes off.
Overload Recovery
If the ground controls LCD screen displays
OVERLOAD RECOVERY, the emergency lowering
system has been used while the platform was
overloaded. For information on how to reset this
message, please consult the appropriate Genie
Service Manual.
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
Emergency Power Unit at the platform to raise the
boom until the indicator light is off. Restart the
engine to continue operation.
If the Emergency 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.
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 non-steer wheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
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 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
firm, 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 Lower the boom.
2 Retract the boom.
Page 47
First Edition • First Printing Operator's Manual
Transport and Lifting Instructions
Part No. 1256222 S-100HD • S-120HD 45
Transport and Lift ing In stru cti ons
Observe and Obey:
Genie 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.
The transport vehicle must be parked on a level
surface.
The transport vehicle must be secured to
prevent rolling while the machine is being
loaded.
Be sure the 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.
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 uphill, downhill or side slope rating.
See Driving on a Slope in the Operating
Instructions section.
If the slope of the transport vehicle bed
exceeds the maximum slope rating, the
machine must be loaded and unloaded using a
winch as described in the brake release
operation.
Free-wheel Configuration for
Winching
Chock the wheels to prevent the machine from
rolling.
Release the wheel brakes by
turning over all four drive 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.
Page 48
Operator's Manual First Edition • First Printing
Transport and Lifting Instructions
46 S-100HD • S-120HD Part No. 1256222
Securing to Truck or Trailer for
Transit
Always use the turntable rotation lock pin each time
the machine is transported.
1 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.
Adjust the rigging to prevent damage to the chains.
Securing the Platform
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.
Page 49
First Edition • First Printing Operator's Manual
Transport and Lifting Instructions
Part No. 1256222 S-100HD • S-120HD 47
Observe and Obey:
Only qualified riggers should rig the machine.
Only certified crane operators should lift the
machine and only in accordance with the
applicable crane regulations.
Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial label for the
machine weight.
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.
Use a spreader bar to keep the rigging from
damaging the machine.
Center of gravity X Axis Y Axis
S-100HD
1.96 m 1.23 m
S-120HD
1.89 m1.68 m
Page 50
Operator's Manual First Edition • First Printing
Maintenance
48 S-100HD • S-120HD Part No. 1256222
Maintenance
Observe and Obey:
Only routine maintenance items specified in
this manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer’s specifications
and the requirements specified in the
responsibilities manual.
Dispose of material in accordance with
governmental regulations.
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.
Indicates that a cold engine is required
before performing this procedure.
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Note: Check the oil level with the engine off.
1 Check the oil level dipstick. Add oil as needed.
Cummins B3.3C80 Engine
Oil type 15W-40
Oil type - cold conditions 10W-30
Deutz TD2011 L04i Engine
Oil type 15W-40
Oil type - cold conditions 5W-30
Page 51
Second Edition First Printing Operator's Manual
Maintenance
Part No. 1261387 S-100HD • S-120HD 49
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.
2 Visually inspect the sight gauge located on the
side of the hydraulic oil tank.
Result: The hydraulic oil level should be within
the top 5 cm of the sight gauge.
3 Add oil as needed. Do not overfill.
Hydraulic oil specifications
Hydraulic oil type Chevron Rando HD equivalent
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.
Page 52
Operator's Manual Second Edition First Printing
Maintenance
50 S-100HD • S-120HD Part No. 1261387
Check the Batteries
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in 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.
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 brackets are
in place and secure.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.
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.
Page 53
First Edition • First Printing Operator's Manual
Specifications
Part No. 1256222 S-100HD • S-120HD 51
Specifications
S-100HD
Height, working maximum 32.5 m
Height, platform maximum 30.5 m
Height, stowed maximum 3.1 m
Horizontal reach, maximum 22.3 m
Width, axles retracted 2.5 m
Width, axles extended 3.35 m
Length, stowed 13 m
Maximum load capacity 340 kg
Maximum wind speed 12.5 m/s
Wheelbase 3.7 m
Ground clearance 35.68 cm
Turning radius, axles extended
2WD Inside
Outside
5.13 m
9.3 m
4WD Inside
Outside
2.74 m
6.05 m
Turning radius, axles retracted
2WD Inside
Outside
11.13 m
14.15 m
4WD Inside
Outside
4.14 m
6.58 m
Turntable rotation (degrees) 360° continuous
Turntable tailswing, axles extended 1.22 m
Turntable tailswing, axles retracted 1.68 m
Controls 12V DC proportional
Platform dimensions (length x width) 152 x 76 cm
Platform leveling self-leveling
Platform rotation 160°
Hydraulic pressure, maximum (drive
functions)
293 bar
System voltage 12V
Tire size, solid rubber tires 385/65 D22.5
Total vibration value to which the hand/arm system is
Subjected does not exceed 2.5 m/s
2
.
Highest root mean square value of weighted
acceleration to which the whole body is subjected
doesn’t exceed 0.5 m/s
2
.
Ground clearance 35.6 cm
Fuel tank capacity 240 liters
Weight 18,035 kg
(Machine weights vary with option configurations. See
serial label for specific machine weight.)
Drive speeds
Drive speed, stowed – all models 4.8 km/h
12.2 m/9.1 sec
Drive speed, raised or extended – all
models
1.1 km/h
12.2 m/40 sec
Drive speed, fully extended – all
models
0.6 km/h
12.2 m/70 sec
Maximum slope rating, stowed position, 2WD
Counterweight uphill 25% 14°
Counterweight downhill 25% 14°
Side slope 25% 14°
Maximum slope rating, stowed position, 4WD
Counterweight uphill 40% 22°
Counterweight downhill 40% 22°
Side slope 25% 14°
Note: Slope rating is subject to ground conditions and
adequate traction.
Airborne noise emissions
Sound pressure level at ground workstation 99 dBA
Sound pressure level at platform workstation 87 dBA
Guaranteed sound power level 105 dBA
Floor loading information
Tire load maximum 9885 kg
Tire contact pressure 7.4 kg / cm
2
724 kPa
Occupied floor pressure, axles
extended
1162 kg / m
2
11.4 kPa
Occupied floor pressure, axles
retracted
1542 kg / m
2
15.1 kPa
Note: Floor loading information is approximate and does
not incorporate different option configurations. It should
be used only with adequate safety factors.
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
Page 54
Second Edition First Printing Operator's Manual
Specifications
52 S-100HD • S-120HD Part No. 1261387
S-120HD
Height, working maximum 38.6 m
Height, platform maximum 36.6 m
Height, stowed maximum 3.2 m
Horizontal reach, maximum 22.3 m
Width, axles retracted 2.5 m
Width, axles extended 3.35 m
Length, stowed 13 m
Maximum load capacity 340 kg
Maximum wind speed 12.5 m/s
Wheelbase 3.7 m
Ground clearance 35.6 cm
Turning radius, axles extended
2WD Inside
Outside
5.62 m
9.78 m
4WD Inside
Outside
2.74 m
6.05 m
Turning radius, axles retracted
2WD Inside
Outside
12.90 m
18.98 m
4WD Inside
Outside
4.14 m
6.58 m
Turntable rotation (degrees) 360° continuous
Turntable tailswing, axles extended 1.22 m
Turntable tailswing, axles retracted 1.68 m
Controls 12V DC proportional
Platform dimensions (length x width) 152 x 76 cm
Platform leveling self-leveling
Platform rotation 160°
Hydraulic pressure, maximum (drive
functions)
293 bar
System voltage 12V
Tire size, solid rubber tires 445/65 D22.5
Total vibration value to which the hand/arm system is
Subjected does not exceed 2.5 m/s
2
.
Highest root mean square value of weighted
acceleration to which the whole body is subjected
doesn’t exceed 0.5 m/s
2
.
Ground clearance 35.6 cm
Fuel tank capacity 240 liters
Weight 20,548 kg
(Machine weights vary with option configurations. See
serial label for specific machine weight.)
Drive speeds
Drive speed, stowed – all models 4.8 km/h
12.2 m/9.1 sec
Drive speed, raised or extended – all
models
1.1 km/h
12.2 m/40 sec
Drive speed, fully extended – all
models
0.6 km/h
12.2 m/70 sec
Maximum slope rating, stowed position, 2WD
Counterweight uphill 25% 14°
Counterweight downhill 25% 14°
Side slope 25% 14°
Maximum slope rating, stowed position, 4WD
Counterweight uphill 40% 22°
Counterweight downhill 40% 22°
Side slope 25% 14°
Note: Slope rating is subject to ground conditions and
adequate traction.
Airborne noise emissions
Sound pressure level at ground workstation 99 dBA
Sound pressure level at platform workstation 87 dBA
Guaranteed sound power level 105 dBA
Floor loading information
Tire load maximum 11302kg
Tire contact pressure 7.4 kg / cm
2
724 kPa
Occupied floor pressure, axles
extended
1303 kg / m
2
12.8 kPa
Occupied floor pressure, axles
retracted
1729 kg / m
2
17 kPa
Note: Floor loading information is approximate and does
not incorporate different option configurations. It should
be used only with adequate safety factors.
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
Page 55
Second Edition First Printing Operator's Manual
Specifications
53 S-100HD • S-120HD Part No. 1261387
S-100HD Range of Motion Chart
S-120HD Range of Motion Chart
S-100HD • S-120HD Part No. 1256222 Operator's Manual First Edition • First Printing
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