Genie S-105 User manual

Serial Number Range
from GR10-20000
Original Instructions
Sixth Edition
Second Printing
Part No. 1261388
with
Maintenance
Information
CE
from S10016D-1382
from S10516D-1356
from S12016D-1399
from S12516D-1334

Operator's Manual Sixth Edition • Second Printing
S-100 • S-105 • S-120 • S-125 Part No. 1261388
Copyright © 2000 by Terex Corporation
Sixth Edition: Second Printing, September 2015
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
Contents
Introduction ..............................................................1
Symbol and Hazard Pictorials Denitions..................3
General Safety..........................................................5
Personal Safety.........................................................8
Work Area Safety......................................................9
Legend....................................................................20
Controls..................................................................21
Inspections..............................................................29
Operating Instructions.............................................45
Transport and Lifting Instructions.............................57
Maintenance...........................................................60
Specications..........................................................63

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 1
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 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.
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:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Onlyhavetrained/certiedoperators,
directed by informed and knowledgeable
supervision, running the machine.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet: www.genielift.com
E-mail: [email protected]
Introduction

Operator's Manual Sixth Edition • Second Printing
2 S-100 • S-105 • S-120 • S-125 Part No. 1261388
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Introduction
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.
HazardClassication
Genie uses symbols, color coding and signal
words to identify the following:
Safety alert symbol—used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
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.
Red
Orange
Yellow
Blue

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 3
SymbolandHazardPictorialsDenitions
Crush Hazard Explosion Hazard
Fall Hazard
Crush Hazard
Tip-over Hazard
Electrocution
Hazard
Keep off this
surface.
Keep away from
moving parts.
Maintain required
clearance.
Keep away from
path of moving
platform.
No smoking.
No ame.
Stop engine.
Do not overload
platform. Welder
power supply
weighs
75 lbs / 34 kg
Tip-over Hazard
Only trained
maintenance
personnel
should access
compartments.
Read the
operator’s
manual.
Platform downhill:
1. Retract boom.
2. Lower boom.
Platform uphill:
1. Lower boom.
2. Retract boom.
Tip-over Hazard
Recovery procedure if tilt alarm
sounds while elevated.
No Step
Fall Hazard

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4 S-100 • S-105 • S-120 • S-125 Part No. 1261388
Lanyard
anchorage points
SymbolandHazardPictorialsDenitions
Wheel load
Avoid contact.
Have re
extinguisher near.
Tie-down
instructions
Tie-down
instructions
Electrocution
Hazard
Explosion Hazard Do not use ether
or other high
energy starting
aids on machines
equipped with
glow plugs.
Fire Hazard
Explosion / Burn
Hazard Keep all open
ames and
sparks away.
Pressure rating for
air line to platform
Read service
manual.
Voltage rating for
power to platform
Replace tires with
same tire.
Replace extension
cylinder cover
before operating
machine.

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 5
General Safety

Operator's Manual Sixth Edition • Second Printing
6 S-100 • S-105 • S-120 • S-125 Part No. 1261388
General Safety

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 7
General Safety

Operator's Manual Sixth Edition • Second Printing
8 S-100 • S-105 • S-120 • S-125 Part No. 1261388
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 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.

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 9
Electrocution Hazards
This machine is not
electrically insulated
and will not provide
protection from contact
with or proximity to
electrical current.
Maintain safe
distances from
electrical power
lines and apparatus
in accordance
with applicable
governmental
regulations and the
following chart.
Line Voltage Required Clearance
0 to 50KV 3.0 m
50KV to 200KV 4.6 m
200KV to 350KV 6.1 m
350KV to 500KV 7.6 m
500KV to 750KV 10.6 m
750KV to 1000KV 13.7 m
Allow for platform movement, electrical line sway
or sag and beware of strong or gusty winds.
Keep away from the
machine if it contacts
energized power
lines. Personnel
on the ground or in
the platform must
not touch or operate
the machine until
energized power lines
are shut off.
Do not use the
machine as a ground
for welding unless the
machine is equipped
with the weld line to
platform option and it is
properly connected.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity
S-100 340 kg
S-105 227 kg
S-120 340 kg
S-125 227 kg
Maximum occupants 2
Work Area Safety

Operator's Manual Sixth Edition • Second Printing
10 S-100 • S-105 • S-120 • S-125 Part No. 1261388
Work Area Safety
The weight of options and accessories, such as
pipe cradles, panel cradles, welders and overhead
protection will reduce the rated platform capacity
and must be factored into the total platform load.
See the decals with the options and accessories.
If using accessories,
read, understand and
obey the decals and
instructions with the
accessory.
Do not raise or extend
the boom unless the
machine is on a rm,
level surface.
Do not depend on the
tilt alarm as a level
indicator. The tilt alarm
sounds in the platform
only when the machine
is on a severe slope.
If the tilt alarm sounds while the boom is 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 rm, level surface. Do not rotate the
boom while lowering.
If the tilt alarm sounds with
the platform uphill:
First lower the boom, then
retract the boom.
If the tilt alarm sounds with
the platform downhill:
First retract the boom, then
lower the boom.
Do not raise the boom when wind speeds may
exceed 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.

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 11
Do not operate the
machine in strong
or gusty winds. Do
not increase the
surface area of
the platform or the
load. Increasing
the area exposed
to the wind will
decrease machine
stability.
Use extreme care
and slow speeds
while driving the
machine in the
stowed position
across uneven
terrain, debris,
unstable or
slippery surfaces
and near holes
and drop-offs.
Do not drive the machine on or near uneven
terrain, unstable surfaces or other hazardous
conditions with the boom raised or extended.
Do not 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 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
Do not alter or disable machine components that
in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specication.
Work Area Safety

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12 S-100 • S-105 • S-120 • S-125 Part No. 1261388
Work Area Safety
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating
of the machine. Slope rating applies to machines
in the stowed position.
Maximum slope rating, stowed position
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction.
Do not 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.
Do not use air-lled tires. These machines are
equipped with foam-lled tires. Wheel weight is
critical to stability.
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.

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 13
Fall Hazards
Occupants must
wear a safety belt or
harness in accordance
with governmental
regulations. Attach
the lanyard to the
anchorage points
provided in the
platform.
Do not sit, stand or
climb on the platform
guard rails. Maintain
a rm footing on the
platform oor at all
times.
Do not climb down
from the platform when
raised.
Keep the platform oor
clear of debris.
Lower the platform
entry mid-rail or close
the entry gate before
operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited
sight distance and blind
spots when driving or
operating.
Be aware of the boom
position and tailswing
when rotating the
turntable.
Check the work
area for overhead
obstructions or other
possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply
with employer, job
site and governmental
rules regarding the use
of personal protective
equipment.
Observe and use
the color-coded direction arrows on the platform
controls and drive chassis for drive and steer
functions.
Work Area Safety

Operator's Manual Sixth Edition • Second Printing
14 S-100 • S-105 • S-120 • S-125 Part No. 1261388
Work Area Safety
Do not lower the boom
unless the area below
is clear of personnel
and obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any
other factors which
may cause collision.
Do not operate a
boom in the path of
any crane unless the
controls of the crane
have been locked out
and/or precautions
have been taken to
prevent any potential
collision.
No stunt driving or horseplay while operating a
machine.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not operate the machine unless the secondary
extend cylinder cover is properly installed.
Improper contact with components under any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operation inspection. All compartments must
remain closed and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine
running.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
ames and lighted tobacco.
Do not operate the machine in hazardous
locations or locations where potentially
ammable or explosive gases or particles may be
present.
Do not spray ether into engines equipped with
glow plugs.

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 15
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of
the machine and test all functions before each
work shift. Immediately tag and remove from
service a damaged or malfunctioning machine.
Be sure all maintenance has been performed
as specied in this manual and the appropriate
Genie service manual.
Be sure all decals are in place and legible.
Be sure the operator's, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Component Damage Hazards
Do not use any battery or charger greater than
12V to jump-start the engine.
Do not use the machine as a ground for welding.
Work Area Safety
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear
when working with
batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, ames
and lighted tobacco
away from batteries.
Batteries emit explosive
gas.
The battery tray should
remain open during the
entire cycle.
Do not contact the
battery terminals or the
cable clamps with tools
that may cause sparks.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.

Operator's Manual Sixth Edition • Second Printing
16 S-100 • S-105 • S-120 • S-125 Part No. 1261388
Work Area Safety
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.

Operator's ManualSixth Edition • Second Printing
Part No. 1261388 S-100 • S-105 • S-120 • S-125 17
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 re
extinguisher is immediately available for instant
use, per OSHA regulation 1926.352(d).
Weld Line to Platform Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are
properly connected.
Connect the positive lead to the twist-lock
connector at the turntable and platform.
Clamp the negative lead to the ground post at
the turntable and platform.
Work Area Safety

Operator's Manual Sixth Edition • Second Printing
18 S-100 • S-105 • S-120 • S-125 Part No. 1261388
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.
Do not operate unless you are adequately
instructed and are aware of all of the hazards
associated with movement of the platform with
an overhanging load.
Do not cause a horizontal force or side load to
the machine by raising or lowering a xed or
overhanging load.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.
Panel Cradle Safety
Read, understand and obey all warnings and
instructions provided with the panel cradles.
Do not exceed the rated platform capacity.
The combined weight of the cradles, panels,
occupants, tools and any other equipment must
not exceed rated capacity.
The panel cradle assembly weighs 13.6 kg.
The maximum capacity of the panel cradles is
113 kg.
The weight of the panel cradles and the load in
the panel cradles may limit the maximum number
of occupants in platform to one person.
Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.
Do not operate unless you are adequately
instructed and are aware of all hazards associated
with lifting panels.
Do not cause a horizontal force or side load
to machine by raising or lowering a xed or
overhanging load.
Maximum vertical height of panels: 1.2 m
Maximum wind speed: 6.7 m/sec
Maximum panel area: 3 m2
Work Area Safety