Terex Genie S-80 XC Operator's Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Lifting Systems
  5. Genie S-80 XC Series
  6. Operator's manual

Terex Genie S-80 XC Operator's Manual

Hide thumbs Also See for Genie S-80 XC:
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's Manual
S
-80 XC™
®
S
-85 XC™
®
Serial Number Range
CE
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 1311085GT
 

Advertisement

Table of Contents
loading

Related Manuals for Terex Genie S-80 XC

Summary of Contents for Terex Genie S-80 XC

  • Page 1   Operator's Manual Serial Number Range -80 XC™ ® -85 XC™ ® with Maintenance Information Original Instructions Second Edition First Printing Part No. 1311085GT...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2017 by Terex Corporation Second Edition: First Printing, December 2021 Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" is a trademark of Terex South Dakota, Inc.

  • Page 3: Introduction

    Second Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Second Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level Platform level, jib boom up/down, boom extend/retract,and boom up/down Platform rotate Turntable rotate and platform rotate Jib boom up/down Sequential functions and movement: Drive and steer.
  • Page 5 Second Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual Second Edition • First Printing 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.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 8 Operator's Manual Second Edition • First Printing Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Weight of welder reduces capacity Tie-down point Lifting point Platform tie-down Lifting and tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 9 Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Crush hazard Support the platform Read the service Explosion hazard Relieve all pressure or boom during manual...

  • Page 10: General Safety

    Operator's Manual Second Edition • First Printing General Safety General Safety ® ™ ® ™ -80 XC • S -85 XC Part No. 1311085GT...
  • Page 11 Second Edition • First Printing Operator's Manual General Safety ® ™ ® ™ Part No. 1311085GT -80 XC • S -85 XC...
  • Page 12 Operator's Manual Second Edition • First Printing General Safety ® ™ ® ™ -80 XC • S -85 XC Part No. 1311085GT...

  • Page 13: Personal Safety

    Second Edition • First Printing Operator's Manual Personal Safety 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 anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 14: Work Area Safety

    Operator's Manual Second Edition • First Printing Work Area Safety Work Area Safety Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will Occupants, equipment and materials shall not not provide protection from contact with or exceed the maximum platform capacity for the proximity to electrical current.
  • Page 15 Second Edition • First Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds with the boom unless the machine platform uphill: is on a firm, level surface. Lower the boom. Retract the boom. If the tilt alarm sounds with the platform downhill: Retract the boom.
  • Page 16 Operator's Manual Second Edition • First Printing Work Area Safety Do not drive the machine on or near uneven Do not alter or disable machine components that terrain, unstable surfaces or other hazardous in any way affect safety and stability. conditions with the boom raised or extended.
  • Page 17 Second Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 18 Operator's Manual Second Edition • First Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 19 Second Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 20 Operator's Manual Second Edition • First Printing 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 protective work shift.
  • Page 21 Second Edition • First Printing Operator's Manual Work Area Safety Contact Alarm Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand, and obey all warnings and instructions provided with the contact alarm. instructions provided with the pipe cradles. Do not exceed the rated platform capacity.
  • Page 22 Operator's Manual Second Edition • First Printing Work Area Safety Panel Cradle Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the panel cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 23 Second Edition • First Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 24: Legend

    Operator's Manual Second Edition • First Printing Legend Legend Non-steer tire Swing gate Steer tire Platform Ground controls Lanyard anchorage points Boom 10 Sliding mid-rail Jib boom (if equipped) 11 Manual storage container Platform controls 12 Foot switch ® ™ ®...

  • Page 25: Controls

    Second Edition • First Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 26 Operator's Manual Second Edition • First Printing Controls Ground Control Panel LCD readout screen Screen displays hour meter, voltage, oil Function enable button pressure and coolant temperature. Screen Press and hold the function enable button to also displays fault codes and other service enable the functions on the ground control information.
  • Page 27 Second Edition • First Printing Operator's Manual Controls 11 Key switch for off/ground/platform selection 16 Platform level down button Turn the key switch to the off position and the Press the platform level down button and the machine will be off. Turn the key switch to the level of the platform will lower.
  • Page 28 Operator's Manual Second Edition • First Printing Controls Platform Control Panel ® ™ ® ™ -80 XC • S -85 XC Part No. 1311085GT...
  • Page 29 Second Edition • First Printing Operator's Manual Controls ® ™ ® ™ Part No. 1311085GT -80 XC • S -85 XC...
  • Page 30 Operator's Manual Second Edition • First Printing Controls Platform Control Panel Fault indicator light Light on indicates a system fault. Horn button Restricted range of motion indicator light, Press this button and the horn will sound. Release the button and the horn will stop. weight.
  • Page 31 Second Edition • First Printing Operator's Manual Controls 11 Raise/retract boom indicator light 17 Dual axis proportional control handle for drive and steer functions. Raise/retract the boom until the light is off. Proportional control handle for drive function 12 Lower boom indicator light and thumb rocker for steer function.
  • Page 32 Operator's Manual Second Edition • First Printing Controls 19 Drive enable switch 24 Engine start switch To drive when the drive enable light is Move the engine start switch to either side to flashing, hold the drive enable switch to either start the engine.

  • Page 33: Inspections

    Second Edition • First Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 34 Operator's Manual Second Edition • First Printing Inspections Pre-operation Inspection  Primary boom angle sensor  Turntable level sensor  Be sure that the operator’s, safety, and  String pot length sensor responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 35 Second Edition • First 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. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 36 Operator's Manual Second Edition • First Printing Inspections At the Ground Controls Test Machine Functions Select a test area that is firm, level and free of Do not push the function hazards. enable button. Attempt to activate each boom and Turn the key switch to ground control.
  • Page 37 Second Edition • First Printing Operator's Manual Inspections Test Auxiliary Power Test Emergency Stop 10 Turn the key switch to ground control and shut 15 Start the engine. the engine off. 16 Push in the platform red Emergency Stop 11 Pull out the red Emergency Stop button to the button to the off position.
  • Page 38 Operator's Manual Second Edition • First Printing Inspections Test Machine Functions Test Drive and Braking 24 Press down the foot switch. 29 Press down the foot switch. 25 Activate each machine function control handle 30 Slowly move the drive control handle in the or toggle switch.
  • Page 39 Second Edition • First Printing Operator's Manual Inspections Test Limited Drive Speed Test the Drive Enable System 40 Press down the foot switch. 36 Press down the foot switch and lower the boom to the stowed position. 41 Raise the boom approximately 15° above horizontal.
  • Page 40 Operator's Manual Second Edition • First Printing Inspections 55 Return to level ground and stow the boom. Test Drive Tilt Cutout 56 Press down the foot switch. 46 Press down the foot switch. 57 With the boom fully stowed, drive the machine 47 With the boom fully stowed, drive the machine onto a slope where the roll angle is greater onto a slope where the machine pitch angle is...
  • Page 41 Second Edition • First Printing Operator's Manual Inspections Test Auxiliary Power Test the Contact Alarm (if equipped) 66 Shut the engine off. 70 Do not activate the foot switch and press on the contact alarm cable to release the actuator 67 Pull out the red Emergency Stop button to the from the switch socket.
  • Page 42 Operator's Manual Second Edition • First Printing Inspections 75 Insert the actuator into the switch socket. Test Aircraft Protection Package (if equipped) Result: The lights and horn will turn off. Note: Two people may be required to perform this 76 Operate each machine function. test.
  • Page 43 Second Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 44 Operator's Manual Second Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 82487 Label – Read the Manual 82487 Label – Read the Manual (panel Determine whether the decals on your machine cradle) have words or symbols. Use the appropriate 82487 Label –...
  • Page 45 Second Edition • First Printing Operator's Manual Inspections ® ™ ® ™ Part No. 1311085GT -80 XC • S -85 XC...
  • Page 46 Operator's Manual Second Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 1281184 Label – Runaway Machine Hazard, S-80/85 XC Determine whether the decals on your machine 1281187 Label – Emergency Lowering have words or symbols. Use the appropriate 1281188 Label –...
  • Page 47 Second Edition • First Printing Operator's Manual Inspections ® ™ ® ™ Part No. 1311085GT -80 XC • S -85 XC...

  • Page 48: Operating Instructions

    Operator's Manual Second Edition • First Printing Operating Instructions 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.
  • Page 49 Second Edition • First Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop Push in the red Emergency Stop button to the off Diesel models position at the ground controls or the platform controls to stop all machine functions and turn the At the ground controls, turn the key switch to engine off.
  • Page 50 Operator's Manual Second Edition • First Printing Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 51 Second Edition • First Printing Operator's Manual Operating Instructions To Steer Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Slowly move the drive control handle in the grade.
  • Page 52 Operator's Manual Second Edition • First Printing Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light flashing indicates that the use the following procedure. boom has moved just past either non-steer wheel and the You will need: drive function has been interrupted.
  • Page 53 Second Edition • First Printing Operator's Manual Operating Instructions Engine RPM Select Operating Envelope Indicator Lights Select engine RPM using the symbols on the The operating envelope indicator lights will come control panel. on to notify the operator that a function has been interrupted and/or an action is required by the When the foot switch is not pressed, the engine operator.
  • Page 54 Operator's Manual Second Edition • First Printing Operating Instructions Platform Overload Indicator Light Platform Out of Level (> ±10° error) When the platform level is > +/- 10° off target Light flashing indicates the platform angle, then the machine malfunction indicator light is overloaded.
  • Page 55 Second Edition • First Printing Operator's Manual Operating Instructions Machine Malfunction Indicator Light Platform Capacity Range Range of motion is controlled automatically based Light on indicates a system fault. on platform load. S-80 XC, S-85 XC Unrestricted Range of Motion: When the platform load is less than 661 lbs/300 kg.
  • Page 56 Operator's Manual Second Edition • First Printing Operating Instructions S-80 XC, S-85 XC: The range of Tilt Sensor Activation Settings - S-80 XC, motion light is on when the platform S-85 XC load exceeds 660 lbs/300 kg. Model Tilt/Slope Maximum Boom Angle/ Light on indicates restricted range (front to back) Platform Load...
  • Page 57 Second Edition • First Printing Operator's Manual Operating Instructions LCD Screen Standstill Regeneration The LCD screen at the ground controls displays During the DPF standstill generation process, hour meter, voltage, oil pressure and coolant all boom functions are disabled. temperature. The screen also displays fault codes Keep clear of the engine exhaust and muffler.
  • Page 58 Operator's Manual Second Edition • First Printing Operating Instructions When the LCD screen displays the message Press Ok. The LCD screen will display the "Regen Required", the DPF (Diesel Particulate warning "Non-flammable Environment". Filter) requires a Standstill Regeneration. Press Ok. The LCD screen will display the warning "Machine Lockout".
  • Page 59 Second Edition • First Printing Operator's Manual Operating Instructions Aircraft Protection Package Operation The system will keep the engine on at high (if equipped) RPM until the coolant temperature reaches 35 C°. The LCD screen will then display the If the platform bumper comes into contact with an message "Standstill Regen Launch".
  • Page 60 Operator's Manual Second Edition • First 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 the platform.
  • Page 61 Second Edition • First Printing Operator's Manual Operating Instructions Pipe Cradle Operation Panel Cradle Assembly Be sure the pipe cradle assembly and Apply the warning decal to the front of each installation instructions have been followed panel cradle (if needed). properly and that the pipe cradles are secured Install rubber bumper 1 in the panel cradle to the platform railings.
  • Page 62 Operator's Manual Second Edition • First Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
  • Page 63 Second Edition • First Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 64: Transport And Lifting Instructions

    Operator's Manual Second Edition • First Printing Transport and Lifting Instructions 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 uphill, downhill or side slope rating.
  • Page 65 Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform – S-80 XC Transit Make sure the platform is in the stowed position. Always use the turntable rotation lock pin each Secure the platform with a nylon strap placed time the machine is transported.
  • Page 66 Operator's Manual Second Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. (if equipped) Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 67: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance 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.
  • Page 68 Operator's Manual Second Edition • First Printing Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 69 Second Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine 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 70 Operator's Manual Second Edition • First Printing Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed commissioning, quarterly, annually and every two years must be completed by a person trained and qualified to perform Note: This procedure does not need to be maintenance on this machine according to the performed on machines equipped with foam-filled procedures found in the service and maintenance...

  • Page 71: Specifications

    Second Edition • First Printing Operator's Manual Specifications Specifications Model S-80 XC Airborne noise emissions Height, working maximum 86 ft 26.21 m Sound pressure level at ground workstation 87 dBA Height, platform maximum 80 ft 24.38 m Sound pressure level at platform workstation 77 dBA Horizontal reach, platform 68 ft 6 in...
  • Page 72 Operator's Manual Second Edition • First Printing Specifications Model S-85 XC Airborne noise emissions Height, working maximum 91 ft 27.74 m Sound pressure level at ground workstation 87 dBA Height, platform maximum 85 ft 25.91 m Sound pressure level at platform workstation 77 dBA Horizontal reach, platform 74 ft 6 in...
  • Page 73 Second Edition • First Printing Operator's Manual Specifications S-80 XC Range of Motion Chart Maximum platform capacity 1000 lbs 454 kg 660 lbs 300 kg Vertical Values Horizontal Values -10 ft -3.05 m -10 ft -3.05 m 0 ft 0 ft 10 ft 3.05 m 10 ft...
  • Page 74 Operator's Manual Second Edition • First Printing Specifications S-85 XC Range of Motion Chart Maximum platform capacity 1000 lbs 454 kg 660 lbs 300 kg Vertical Values Horizontal Values -10 ft -3.05 m -10 ft -3.05 m 0 ft 0 ft 10 ft 3.05 m 10 ft...
  • Page 75 Second Edition • First Printing Operator's Manual Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...
  • Page 76 Operator's Manual Second Edition • First Printing Specifications Contents of UK Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...

This manual is also suitable for:

Genie s-85 xcGenie s-80 hfGenie s-85 hf

Table of Contents