Terex S10515D-983 Operator's Manual
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Terex S10515D-983 Operator's Manual

Terex S10515D-983 Operator's Manual

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from S10015D-1001
from S10515D-983
from S12015D-1012
from S12515D-984
CE
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Maintenance
Information
Original Instructions
Sixth Edition
Second Printing
Part No. 1261388

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Summary of Contents for Terex S10515D-983

  • Page 1 S10015D-1001 from S10515D-983 from S12015D-1012 from S12515D-984 with Maintenance Information Original Instructions Sixth Edition Second Printing Part No. 1261388...

  • Page 2: Table Of Contents

    Specifications............63 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 S-100 •...

  • Page 3: Introduction

    2 Always perform a pre-operation inspection. Internet: www.genielift.com 3 Always perform function tests prior to use. E-mail: awp.techpub@terex.com 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—...
  • Page 4 Operator's Manual Sixth 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

    Sixth 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. path of moving clearance.
  • Page 6 Operator's Manual Sixth Edition • Second Printing Symbol and Hazard Pictorials Definitions Lanyard Wheel load Have fire Voltage rating for Fire Hazard power to platform anchorage points 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 or other high...

  • Page 7: General Safety

    Sixth Edition • Second Printing Operator's Manual General Safety Part No. 1261388 S-100 • S-105 • S-120 • S-125...
  • Page 8 Operator's Manual Sixth Edition • Second Printing General Safety S-100 • S-105 • S-120 • S-125 Part No. 1261388...
  • Page 9 Sixth Edition • Second Printing Operator's Manual General Safety Part No. 1261388 S-100 • S-105 • S-120 • S-125...

  • Page 10: Personal Safety

    Operator's Manual Sixth 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 anchorage points provided in the platform.

  • Page 11: Work Area Safety

    Sixth Edition • Second Printing Operator's Manual Work Area Safety Electrocution Hazards Keep away from the machine if it contacts energized power This machine is not electrically insulated lines. Personnel and will not provide on the ground or in the platform must protection from contact with or proximity to not touch or operate...
  • Page 12 Operator's Manual Sixth Edition • Second Printing Work Area Safety The weight of options and accessories, such as If the tilt alarm sounds while the boom is raised, pipe cradles, panel cradles, welders and overhead use extreme caution. The Machine Not Level protection will reduce the rated platform capacity indicator light will come on and the drive function and must be factored into the total platform load.
  • Page 13 Sixth Edition • Second Printing Operator's Manual Work Area Safety Do not operate the Do not push the machine in strong machine or other or gusty winds. Do objects with the boom. not increase the Do not contact adjacent surface area of structures with the the platform or the boom.
  • Page 14 Operator's Manual Sixth Edition • Second Printing Work Area Safety Operation on Slopes Hazards Do not modify or alter an aerial work platform 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 Sixth Edition • Second Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must Be aware of limited wear a safety belt or sight distance and blind harness in accordance spots when driving or with governmental operating. regulations. Attach Be aware of the boom the lanyard to the position and tailswing...
  • Page 16 Operator's Manual Sixth Edition • Second Printing Work Area Safety Bodily Injury Hazard Do not lower the boom 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 Sixth Edition • Second Printing Operator's Manual Work Area Safety Battery Safety Damaged Machine Hazards Burn Hazards Do not use a damaged or malfunctioning machine. Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 18 Operator's Manual Sixth Edition • Second Printing Work Area Safety Overhead Platform Protection Lower Platform Protection Safety Safety The maximum weight for overhead platform The maximum weight for lower platform protection protection is 11.5 kg and does not have to be is 13 kg and does not have to be subtracted from subtracted from the total capacity of the platform.
  • Page 19 Sixth Edition • Second Printing Operator's Manual 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 20 Operator's Manual Sixth Edition • Second Printing 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 21 Sixth Edition • Second Printing Operator's Manual 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 22: Legend

    Operator's Manual Sixth Edition • Second Printing Legend S-100 & S-105 & S-125 S-120 1 Circle-end tire (yellow arrow) 8 Lanyard anchorage points 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 12 Overhead protection (optional)

  • Page 23: Controls

    Sixth Edition • Second Printing Operator's Manual 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 24 Operator's Manual Sixth Edition • Second Printing 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 25 Sixth Edition • Second Printing Operator's Manual Controls 18 Platform rotate left/right buttons 11 Engine start button Push the engine start button and the engine will Push the platform rotate left button and the start. platform will rotate to 12 Emergency power button the left.
  • Page 26 Operator's Manual Sixth Edition • Second Printing Controls Platform Control Panel 9 Emergency power button 12 Engine idle (rpm) select button with indicator light 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 27 Sixth Edition • Second Printing Operator's Manual 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 28 Operator's Manual Sixth Edition • Second Printing 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 rotate 7 Horn button switch to the right and the platform will rotate Push the horn button and the horn will sound.
  • Page 29 Sixth Edition • Second Printing Operator's Manual 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 Push the engine idle select button to choose function and thumb rocker switch for steer engine rpm setting.
  • Page 30 Operator's Manual Sixth Edition • Second Printing Controls 21 Steer mode select buttons with indicator lights 28 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions Push the steer mode select button to choose steer mode. The indicator light next to the Move the control handle current steer mode will be on.

  • Page 31: Inspections

    Sixth Edition • Second Printing Operator's Manual 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.
  • Page 32 Operator's Manual Sixth Edition • Second Printing Inspections Pre-operation Inspection Boom and axle wear pads Tires and wheels Be sure that the operator’s, safety and responsibilities manuals are complete, legible Engine and related components and in the storage container located in the platform.
  • Page 33 Sixth Edition • Second Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. Do Not Operate Unless: A malfunctioning machine must never be used.
  • Page 34 Operator's Manual Sixth Edition • Second Printing 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 35 Sixth Edition • Second Printing Operator's Manual Inspections Test Emergency Controls 15 Return to the ground controls. Turn the key 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 36 Operator's Manual Sixth Edition • Second Printing 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 37 Sixth Edition • Second Printing Operator's Manual Inspections Test the Foot Switch Test the Steering 36 Push in the platform red Emergency Stop 43 Push the steer button to the off position. mode select button for 37 Pull out the red Emergency Stop button to square-end (blue the on position but do not start the engine.
  • Page 38 Operator's Manual Sixth Edition • Second Printing Inspections Test Drive and Braking 51 Slowly move the drive/steer 55 Press down the foot switch. control handle in the direction 56 Slowly move the drive/steer control handle in indicated by the the direction indicated by the blue arrow on blue triangle on the control panel OR press the the control panel until the machine begins to thumb rocker switch in the direction indicated...
  • Page 39 Sixth Edition • Second Printing Operator's Manual Inspections Test Limited Drive Speed Test the Drive Enable System 62 Press down the foot switch. 58 Press down the foot switch and lower the boom to the stowed position. 63 Raise the boom to 10° above horizontal. 59 Rotate the turntable until the boom moves past 64 Slowly move the drive control handle to the full one of the circle-end tires.
  • Page 40 Operator's Manual Sixth Edition • Second Printing Inspections Test Drive Tilt Cutout 79 Press down the foot switch. 80 With the boom fully stowed, drive the machine 70 Press down the foot switch. onto a slope where the chassis angle is greater 71 With the boom fully stowed, drive the machine than 4.5°...
  • Page 41 Sixth Edition • Second Printing Operator's Manual Inspections Test Emergency Controls 88 Shut off the engine. 89 Pull out the red Emergency Stop button to the on position. 90 Press down the foot switch. 91 Simultaneously press and hold the emergency power button and activate each function control handle, toggle switch or button.
  • Page 42 Operator's Manual Sixth Edition • Second Printing 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 43 Sixth Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
  • Page 44 Operator's Manual Sixth Edition • Second Printing Inspections 114247 T114286 133067 114251 82481 65264 82487 or 65267 114252 82472 28159 133205 133067 or 72147 82487 or 72148 114252 82473 40434 114112 114249 82548 82472 T114286 114249 146418 or 146419 82472 or 146420 Shading indicates decal 65268...
  • Page 45 Sixth Edition • Second Printing Operator's Manual 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 46 Operator's Manual Sixth Edition • Second Printing Inspections 114247 T114286 133067 114251 82481 65264 82487 or 65267 114252 82472 28159 133205 133067 or 72147 82487 or 72148 114252 82473 40434 114112 114249 82548 82472 T114286 114249 146418 or 146419 82472 or 146420 Shading indicates decal 65268...

  • Page 47: Operating Instructions

    Sixth Edition • Second Printing Operator's Manual Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: Using the machine for anything other than lifting You learn and practice the principles of safe...
  • Page 48 Operator's Manual Sixth Edition • Second Printing 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 49 Sixth Edition • Second Printing Operator's Manual 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 mode 2 Pull out the red Emergency Stop button to button.
  • Page 50 Operator's Manual Sixth Edition • Second Printing Operating Instructions Driving on a slope Lay the piece of wood on the slope. At the downhill end, lay the level on the top edge Determine the uphill, downhill and side slope of the piece of wood and lift the end until the ratings for the machine and determine the slope piece of wood is level.
  • Page 51 Sixth Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Check Engine Light Light on indicates that the boom Light on and engine stopped: has moved past either circle- Tag the machine and remove end wheel and drive function from service.
  • Page 52 Operator's Manual Sixth Edition • Second Printing Operating Instructions Platform Overload Machine Not Level Indicator Light (if equipped) Flashing light indicates the platform is overloaded. The engine will stop and If the tilt alarm sounds when the no functions will operate. platform is raised, the Machine Not Level indicator light will Remove the weight from the platform...
  • Page 53 Sixth Edition • Second Printing Operator's Manual Operating Instructions LCD Screen (if equipped) After Each Use The LCD screen displays hour meter, voltage, oil 1 Select a safe parking location—firm level pressure and coolant temperature. The screen also surface, clear of obstruction and traffic. displays fault codes and other service information.
  • Page 54 Operator's Manual Sixth 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 55 Sixth Edition • Second Printing Operator's Manual 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 the platform.
  • Page 56 Operator's Manual Sixth Edition • Second Printing Operating Instructions Pipe Cradle Operation Tip-over hazard. The weight of the pipe cradle 1 Be sure the pipe cradle assembly and assembly and the load in the pipe cradles installation instructions have been followed will reduce the rated platform capacity of the properly and that the pipe cradles are secured machine and must be factored into the total...
  • Page 57 Sixth Edition • Second Printing Operator's Manual 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 58 Operator's Manual Sixth Edition • Second Printing 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 59: Transport And Lifting Instructions

    Sixth Edition • Second Printing Operator's Manual 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 60 Operator's Manual Sixth Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer Lower the boom to the stowed position. for Transit Raise the platform as far as it will go (see below). Run a strap through the platform support between Always use the turntable rotation lock pin each time the machine is transported.
  • Page 61 Sixth Edition • Second Printing Operator's Manual 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 62: Maintenance

    Operator's Manual Sixth Edition • Second Printing Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service Observe and Obey: life. 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 63 Sixth Edition • Second Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Diesel Fuel Requirements Satisfactory engine performance is dependent Maintaining the hydraulic oil at the proper level on the use of a good quality fuel. The use of a is essential to machine operation.
  • Page 64 Operator's Manual Sixth Edition • Second Printing Maintenance Check the Batteries Check the Engine Coolant Level - Liquid Cooled Models Proper battery condition is essential to good engine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.

  • Page 65: Specifications

    Sixth Edition • Second Printing Operator's Manual Specifications S-100 Tire size, solid rubber tires 385/65 D24 Total vibration value to which the hand/arm system Height, working maximum 32.5 m is subjected does not exceed 2.5m/s Height, platform maximum 30.5 m Highest root mean square value of weighted Height, stowed maximum 3.1 m...
  • Page 66 Operator's Manual Sixth Edition • Second Printing Specifications S-105 Tire size, solid rubber tires 385/65 D24 Total vibration value to which the hand/arm system Height, working maximum 34 m is subjected does not exceed 2.5m/s Height, platform maximum 32 m Highest root mean square value of weighted Height, stowed maximum 3.1 m...
  • Page 67 Sixth Edition • Second Printing Operator's Manual Specifications S-120 Tire size, solid rubber tires 445/65 D24 Total vibration value to which the hand/arm system Height, working maximum 38.6 m is subjected does not exceed 2.5m/s Height, platform maximum 36.6 m Highest root mean square value of weighted Height, stowed maximum 3.1 m...
  • Page 68 Operator's Manual Sixth Edition • Second Printing Specifications S-125 Tire size, solid rubber tires 445/65 D24 Total vibration value to which the hand/arm system Height, working maximum 40.1 m is subjected does not exceed 2.5m/s Height, platform maximum 38.1 m Highest root mean square value of weighted Height, stowed maximum 3.1 m...
  • Page 69 Sixth Edition • Second Printing Operator's Manual 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 Part No. 1261388 S-100 • S-105 • S-120 • S-125...
  • Page 70 Operator's Manual Sixth Edition • Second Printing 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 S-100 • S-105 • S-120 • S-125 Part No. 1261388...
  • Page 71 www.genielift.com...

This manual is also suitable for:

Genie s-105Genie s-120Genie s-125Genie s-100S12515d-984S10015d-1001 ... Show all

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