Terex Genie S-100 Operator's Manual
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Terex Genie S-100 Operator's Manual

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Summary of Contents for Terex Genie S-100

  • Page 2: Table Of Contents

    Operator's Manual Fifth Edition • Second Printing 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.

  • Page 3: Introduction

    Fifth Edition • Second Printing Operator's Manual Introduction 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 Danger operators:...
  • Page 4 Operator's Manual Fifth Edition • Second Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal This machine is intended to be used only to lift words to identify the following: personnel, along with their tools and materials to an aerial work site.

  • Page 5: Symbol And Hazard Pictorials Definitions

    Fifth Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Keep away from No smoking. Crush Hazard Explosion Hazard Electrocution moving parts. No flame. Hazard Stop engine. Keep off this Keep away from Maintain required Fall Hazard Crush Hazard surface.
  • Page 6 Operator's Manual Fifth Edition • Second Printing Symbol and Hazard Pictorials Definitions Voltage rating for Lanyard Wheel load Have fire Fire Hazard power to platform attachment point extinguisher near. Avoid contact. Tie-down Tie-down Electrocution Pressure rating for instructions instructions Hazard air line to platform Do not use ether Explosion Hazard...

  • Page 7: General Safety

    Fifth Edition • Second Printing Operator's Manual General Safety Part No. T113597 S-100 • S-105 • S-120 • S-125...
  • Page 8 Operator's Manual Fifth Edition • Second Printing General Safety S-100 • S-105 • S-120 • S-125 Part No. T113597...
  • Page 9 Fifth Edition • Second Printing Operator's Manual General Safety Part No. T113597 S-100 • S-105 • S-120 • S-125...

  • Page 10: Personal Safety

    Operator's Manual Fifth Edition • Second Printing Personal Safety Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 11: Work Area Safety

    Fifth Edition • Second Printing Operator's Manual Work Area Safety Allow for platform movement, electrical line sway Electrocution Hazards or sag and beware of strong or gusty winds. This machine is not Keep away from the electrically insulated machine if it contacts and will not provide energized power lines.
  • Page 12 Operator's Manual Fifth Edition • Second Printing Work Area Safety The weight of options and accessories, such as If the tilt alarm sounds while the boom is lowered: pipe cradles, panel cradles, and welders, will Do not extend, rotate or raise the boom above reduce the rated platform capacity and must be horizontal.
  • Page 13 Fifth Edition • Second Printing Operator's Manual Work Area Safety Do not operate the Do not contact adjacent machine in strong or structures with the gusty winds. Do not boom. increase the surface Do not tie the boom or area of the platform or platform to adjacent the load.
  • Page 14 Operator's Manual Fifth Edition • Second Printing Work Area Safety Do not modify or alter an aerial work platform Operation on Slopes Hazards without prior written permission from the manufacturer. Mounting attachments for holding Do not drive the machine on a slope that exceeds tools or other materials onto the platform, the maximum uphill, downhill or side slope rating toeboards or guard rail system can increase the...
  • Page 15 Fifth Edition • Second Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited safety belt or harness sight distance and in accordance with blind spots when governmental driving or operating. regulations. Attach the Be aware of the boom lanyard to the position and tailswing...
  • Page 16 Operator's Manual Fifth Edition • Second Printing Work Area Safety Do not lower the boom Bodily Injury Hazard unless the area below is clear of personnel Do not operate the machine with a hydraulic oil or and obstructions. air leak. An air leak or hydraulic leak can penetrate and/or burn skin.
  • Page 17 Fifth Edition • Second Printing Operator's Manual Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear work shift.
  • Page 18 Operator's Manual Fifth Edition • Second Printing Work Area Safety Welder Safety Weld Line to Platform Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the welding power unit. instructions provided with the welding power unit. Do not connect weld leads or cables unless the Do not connect weld leads or cables unless the welding power unit is turned off at the platform...
  • Page 19 Fifth Edition • Second Printing Operator's Manual Work Area Safety Pipe Cradle Safety Panel Cradle Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
  • Page 20 Operator's Manual Fifth Edition • Second Printing Work Area Safety Lockout After Each Use 1 Select a safe parking location—firm level surface, clear of obstruction and traffic. 2 Retract and lower the boom to the stowed position. 3 Rotate the turntable so that the boom is between the wheels at the circle end of the machine.

  • Page 21: Legend

    Fifth Edition • Second Printing Operator's Manual Legend S-100 & S-120 S-105 & S-125 1 Circle-end tire (yellow arrow) 8 Lanyard anchorage point 2 Square-end tire (blue arrow) 9 Sliding mid-rail 3 Ground controls 10 Manual storage container 4 Boom 11 Foot switch 5 Platform controls 6 Platform...

  • Page 22: Controls

    Operator's Manual Fifth Edition • Second Printing Controls Ground Control Panel 1 Boom down button 11 Engine start button 2 Boom extend/retract buttons 12 Emergency power button 3 Boom up button 13 High speed function enable button 4 Engine speed select button 14 Low speed function enable button 5 LCD screen control buttons 15 Alarm...
  • Page 23 Fifth Edition • Second Printing Operator's Manual Controls 1 Boom down button 7 LCD readout screen Push the boom down button and the boom will lower. 2 Boom extend/retract buttons a low fuel indicator Push the boom extend b engine oil pressure indicator button and the boom will extend.
  • Page 24 Operator's Manual Fifth Edition • Second Printing Controls 11 Engine start button 18 Platform rotate left/right buttons Push the engine start button and the engine Push the platform rotate will start. left button and the platform will rotate to 12 Emergency power button the left.
  • Page 25 Fifth Edition • Second Printing Operator's Manual Controls Platform Control Panel 9 Emergency power button 12 Engine idle (rpm) select with indicator light button with indicator lights: 1 Platform rotate switch · Rabbit & Foot Switch: foot 10 Diesel models: Glow plug 2 Platform level switch switch activated high idle button with indicator light...
  • Page 26 Operator's Manual Fifth Edition • Second Printing Controls 17 Red Emergency Stop button 22 Drive select button with 25 Axle retract button with indicator lights: indicator light 18 Dual axis proportional Machine on incline symbol: control handle for drive and 26 Used for optional equipment Low range operation for steer functions...
  • Page 27 Fifth Edition • Second Printing Operator's Manual Controls Platform Control Panel 6 Raise boom indicator light To continue extending, raise the boom until the 1 Platform rotate switch indicator light goes out. Move the platform 7 Horn button rotate switch to the right and the platform Push the horn button and the horn will sound.
  • Page 28 Operator's Manual Fifth Edition • Second Printing Controls 12 Engine idle (rpm) select button with indicator 18 Dual axis proportional control handle for drive lights and steer functions OR Proportional control handle for drive function Push the engine idle select button to choose and thumb rocker switch for steer function engine rpm setting.
  • Page 29 Fifth Edition • Second Printing Operator's Manual Controls 22 Drive select button with indicator lights 28 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions Push the drive select button to choose drive setting. The indicator light next to the current Move the control handle setting will be on.

  • Page 30: Inspections

    Operator's Manual Fifth Edition • Second Printing Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Do Not Operate Unless: 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 You learn and practice the principles of safe...
  • Page 31 Fifth Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection Boom and axle wear pads Be sure that the operator’s, safety and responsibilities manuals are complete, legible Tires and wheels and in the storage container located in the Engine and related components platform.
  • Page 32 Operator's Manual Fifth Edition • Second Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 33 Fifth Edition • Second Printing Operator's Manual Inspections Test Emergency Stop Test the Extendable Axles 5 Push in the red Emergency Stop button to the Note: Start this test with the axles retracted. off position. 11 At the ground controls, push Result: The engine should turn off and no and hold a function enable/ functions should operate.
  • Page 34 Operator's Manual Fifth Edition • Second Printing Inspections 15 Return to the ground controls. Turn the key Test Emergency Controls switch to ground control. Push and hold a 19 Turn the key switch to ground control and shut function enable/speed select button and push the engine off.
  • Page 35 Fifth Edition • Second Printing Operator's Manual Inspections Test the Operating Envelope At the Platform Controls 25 Simultaneously push and Test Emergency Stop then release the LCD 31 Turn the key switch to platform control. screen buttons shown to activate status mode. 32 Push in the platform red Emergency Stop button to the off position.
  • Page 36 Operator's Manual Fifth Edition • Second Printing Inspections Test the Foot Switch 46 Push the steer mode select button 36 Push in the platform red Emergency Stop button to the off position. circle-end (yellow arrow) 37 Pull out the red Emergency Stop button to steer.
  • Page 37 Fifth Edition • Second Printing Operator's Manual Inspections 54 Slowly move the drive/steer control handle in the Test the Drive Enable System direction indicated by the blue triangle on the 58 Press down the foot switch and lower the boom control panel OR press the thumb rocker switch to the stowed position.
  • Page 38 Operator's Manual Fifth Edition • Second Printing Inspections Test Limited Drive Speed Test Emergency Controls 62 Press down the foot switch. 70 Shut off the engine. 63 Raise the boom to 10° above horizontal. 71 Pull out the red Emergency Stop button to the on position.
  • Page 39 Fifth Edition • Second Printing Operator's Manual Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: • drop-offs or holes • bumps, floor obstructions or debris Do Not Operate Unless: • sloped surfaces You learn and practice the principles of safe •...
  • Page 40 Part No. Description Quantity Part No. Description Quantity 27204 Arrow - Blue 72147 Cosmetic - Genie S-100 27205 Arrow - Yellow 72148 Cosmetic - Genie S-105 27206 Triangle - Blue 72149 Cosmetic - S-100 27207 Triangle - Yellow...
  • Page 41 Fifth Edition • Second Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers Part No. T113597 S-100 • S-105 • S-120 • S-125...
  • Page 42 Operator's Manual Fifth Edition • Second Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. This inspection is a continuation from the previous page.
  • Page 43 Fifth Edition • Second Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers Part No. T113597 S-100 • S-105 • S-120 • S-125...

  • Page 44: Operating Instructions

    Operator's Manual Fifth Edition • Second Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: Using the machine for anything other than lifting personnel, along with their tools and materials, to...
  • Page 45 Fifth Edition • Second Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop 1 At the ground controls, turn the key switch to Push in either the ground or platform red the desired position. Emergency Stop button to the off position to stop all functions and turn the engine off.
  • Page 46 Operator's Manual Fifth Edition • Second Printing Operating Instructions Operation from Ground To Steer 1 Press down the foot switch. 1 Turn the key switch to ground control. 2 Select the steer mode by pressing a steer 2 Pull out the red Emergency Stop button to mode button.
  • Page 47 Fifth Edition • Second Printing Operator's Manual Operating Instructions Driving on a slope Lay the piece of wood on the slope. Determine the uphill, downhill and side slope At the downhill end, lay the level on the top edge ratings for the machine and determine the slope of the piece of wood and lift the end until the piece grade.
  • Page 48 Operator's Manual Fifth Edition • Second Printing Operating Instructions Drive Enable Check Engine Light Light on indicates that the Light on and engine stopped: boom has moved past either Tag the machine and remove circle-end wheel and drive from service. function has been interrupted.
  • Page 49 Fifth Edition • Second Printing Operator's Manual Operating Instructions Platform Overload Generator (if equipped) Flashing light indicates the platform is To operate the generator, press the generator overloaded. The engine will stop and button. The indicator light will come on and the no functions will operate.
  • Page 50 Operator's Manual Fifth Edition • Second Printing Operating Instructions Fault Code Indicator Readout Fault Type Description Value at 5V If the ground controls LCD readout displays Value too High a fault code, the fault source will display as No Response Fault XXX and fault type as xx Source.
  • Page 51 Fifth Edition • Second Printing Operator's Manual Operating Instructions After Each Use 1 Select a safe parking location—firm level surface, clear of obstruction and traffic. 2 Retract and lower the boom to the stowed position. 3 Rotate the turntable so that the boom is between the circle-end wheels.
  • Page 52 Operator's Manual Fifth Edition • Second Printing Operating Instructions Pipe Cradle Instructions Observe and Obey: The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of cradles positioned at either side of the platform and the platform.
  • Page 53 Fifth Edition • Second Printing Operator's Manual Operating Instructions Pipe Cradle Operation 1 Be sure the pipe cradle assembly and installation instructions have been followed properly and that the pipe cradles are secured to the platform railings. 2 Place the load so that it rests in both pipe cradles.
  • Page 54 Operator's Manual Fifth Edition • Second Printing Operating Instructions Panel Cradle Assembly Installation of Padding 1 Apply the warning decal to the front of each 1 Install the 2 pieces of padding on the platform panel cradle (if needed). rails. Position the padding to protect the panels from contact with the platform rails.
  • Page 55 Fifth Edition • Second Printing Operator's Manual Operating Instructions Panel Cradle Operation rubber 1 Secure both panel cradles to the platform. bumper 2 2 Place the load so that it rests in both panel cradles. U-bolt mounting 3 Center the load on the platform. rubber slots bumper 1...

  • Page 56: Transport And Lifting Instructions

    Operator's Manual Fifth Edition • Second Printing Transport and Lifting Instructions Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. Do not drive the machine on a slope that exceeds the slope or side slope rating.
  • Page 57 Fifth Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing the Platform - S-100 and S-120 Securing to Truck or Trailer for Transit Lower the boom to the stowed position. Always use the turntable rotation lock pin each time Raise the platform as far as it will go (see below).
  • Page 58 Operator's Manual Fifth Edition • Second Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Move the jib boom (if equipped) parallel with the ground. Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable.

  • Page 59: Maintenance

    Fifth Edition • Second Printing Operator's Manual Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components. Only routine maintenance items specified in this Note: Check the oil level with the engine off.
  • Page 60 Operator's Manual Fifth Edition • Second Printing Maintenance Check the Hydraulic Oil Level Check the Batteries Proper battery condition is essential to good engine Maintaining the hydraulic oil at the proper level is performance and operational safety. Improper fluid essential to machine operation. Improper hydraulic levels or damaged cables and connections can oil levels can damage hydraulic components.
  • Page 61 Fifth Edition • Second Printing Operator's Manual Maintenance Check the Engine Coolant Level Scheduled Maintenance - Liquid Cooled Models 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 Maintaining the engine coolant at the proper level is the service manual for this machine.

  • Page 62: Specifications

    Operator's Manual Fifth Edition • Second Printing Specifications S-100 Tire size, foam-filled tires 385/65 D22.5 16 ply Tire size, solid rubber tires 385/65 D24 Height, working maximum 32.5 m Ground clearance 35.6 cm Height, platform maximum 30.5 m Height, stowed maximum 3.1 m Fuel tank capacity 151 liters...
  • Page 63 Fifth Edition • Second Printing Operator's Manual Specifications S-105 Tire size, foam-filled tires 385/65 D22.5 16 ply Tire size, solid rubber tires 385/65 D24 Height, working maximum 34 m Ground clearance 35.6 cm Height, platform maximum 32 m Fuel tank capacity 151 liters Height, stowed maximum 3.1 m...
  • Page 64 Operator's Manual Fifth Edition • Second Printing Specifications S-120 Tire size, foam-filled tires 445/65 D22.5 18 ply Tire size, solid rubber tires 445/65 D24 Height, working maximum 38.6 m Ground clearance 35.6 cm Height, platform maximum 36.6 m Fuel tank capacity 151 liters Height, stowed maximum 3.1 m...
  • Page 65 Fifth Edition • Second Printing Operator's Manual Specifications S-125 Tire size, foam-filled tires 445/65 D22.5 18 ply Tire size, solid rubber tires 445/65 D24 Height, working maximum 40.1 m Ground clearance 35.6 cm Height, platform maximum 38.1 m Fuel tank capacity 151 liters Height, stowed maximum 3.1 m...
  • Page 66 Operator's Manual Fifth Edition • Second Printing Specifications Airborne noise emissions Sound pressure level at ground workstation 83 dBA Sound pressure level at platform workstation 71 dBA Guaranteed sound power level 105 dBA S-100 • S-105 • S-120 • S-125 Part No.
  • Page 67 Fifth Edition • Second Printing Operator's Manual Specifications S-100 Range of Motion Chart S-105 Range of Motion Chart S-120 Range of Motion Chart S-125 Range of Motion Chart Part No. T113597 S-100 • S-105 • S-120 • S-125...

This manual is also suitable for:

Genie s-105Genie s-120Genie s-125

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