Genie S-80 XC Operator's Manual
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Genie S-80 XC Operator's Manual

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Operator's Manual
S
-80 XC
®
S
-85 XC
®
Serial Number Range
™
™
from S80XCH-104
from S85XCH-101
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1279298GT

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Summary of Contents for Genie S-80 XC

  • Page 1 Operator's Manual Serial Number Range -80 XC ® ™ from S80XCH-104 -85 XC ® ™ from S85XCH-101 with Maintenance Information Original Instructions First Edition Second Printing Part No. 1279298GT...

  • Page 2: Table Of Contents

    The Netherlands Copyright © 2017 by Terex Corporation First Edition: Second Printing, May 2020 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

    This book is an operation and daily maintenance Before operating the machine, it’s the operator’s manual for the user or operator of a Genie responsibility to read and understand this machine.
  • Page 4 Operator's Manual First Edition • Second 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: •...
  • Page 5 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 importance number and serial number of your machine, along to Genie.
  • Page 6 Operator's Manual First Edition • Second 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

    First Edition • Second 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 First Edition • Second 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 & tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 9 First Edition • Second 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 Recovery procedure if tilt alarm sounds while elevated. Platform downhill: Platform uphill: Read the operator’s Access by trained...

  • Page 10: General Safety

    Operator's Manual First Edition • Second Printing General Safety General Safety ® ™ ® ™ -80 XC • S -85 XC Part No. 1279298GT...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety These decals are model, option or configuration specific. ® ™ ® ™ Part No. 1279298GT -80 XC • S -85 XC...
  • Page 12 Operator's Manual First Edition • Second Printing General Safety ® ™ ® ™ -80 XC • S -85 XC Part No. 1279298GT...

  • Page 13: Personal Safety

    First Edition • Second 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 First Edition • Second Printing Work Area Safety Work Area Safety Tip-over Hazards Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity for the not provide protection from contact with or restricted or unrestricted range of motion.
  • Page 15 First Edition • Second 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 First Edition • Second Printing Work Area Safety Do not alter or disable machine components that in Use extreme care and any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 17 First Edition • Second 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 machine. the maximum uphill, downhill or side slope rating of the machine.
  • Page 18 Hazards related with the specific product application of exiting at height have been considered in the design of the machine, for further information contact Genie (see section Contacting the Manufacturer). ® ™ ®...
  • Page 19 First Edition • Second 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 Be sure all maintenance has been performed as Avoid spilling or contacting specified in this manual and the appropriate Genie battery acid. Neutralize service manual. battery acid spills with baking Be sure all decals are in place and legible.
  • Page 21 First Edition • Second 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 First Edition • Second 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 First Edition • Second 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 First Edition • Second 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

    First Edition • Second 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 First Edition • Second Printing Controls Ground Control Panel LCD readout screen Screen displays hour meter, voltage, oil Function enable button pressure and coolant temperature. Screen also Press and hold the function enable button to displays fault codes and other service enable the functions on the ground control information.
  • Page 27 First Edition • Second 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 First Edition • Second Printing Controls Platform Control Panel ® ™ ® ™ -80 XC • S -85 XC Part No. 1279298GT...
  • Page 29 First Edition • Second Printing Operator's Manual Controls ® ™ ® ™ Part No. 1279298GT -80 XC • S -85 XC...
  • Page 30 Operator's Manual First Edition • Second 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. weight. Release the button and the horn will stop. Platform level switch Light on indicates restricted range of motion due to platform...
  • Page 31 First Edition • Second 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 First Edition • Second Printing Controls 19 Drive enable switch 24 Engine start switch To drive when the drive enable light is flashing, Move the engine start switch to either side to hold the drive enable switch to either side and start the engine.

  • Page 33: Inspections

    First Edition • Second 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 First Edition • Second 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 First 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. 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 First Edition • Second Printing Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of Press the Maintenance button hazards. above the LCD screen. Navigate to the Real-time Data screen. Turn the key switch to ground control.
  • Page 37 First Edition • Second Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 18 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 14 Enter the platform and pull out the red 19 Pull out the red Emergency Stop button to the Emergency Stop button.
  • Page 38 Operator's Manual First Edition • Second 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 First Edition • Second Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test the Drive Enable System 32 Start the engine from the platform controls. 36 Press down the foot switch and lower the boom to the stowed position. 33 Drive the right steer tire up onto a 15 cm block or curb.
  • Page 40 Operator's Manual First Edition • Second Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 40 Press down the foot switch. 46 Press down the foot switch. 41 Raise the boom approximately 15° above 47 With the boom fully stowed, drive the machine horizontal.
  • Page 41 First Edition • Second Printing Operator's Manual Inspections Test Auxiliary Controls 55 Return to level ground and stow the boom. 66 Shut off the engine. 56 Press down the foot switch. 67 Pull out the red Emergency Stop button to the 57 With the boom fully stowed, drive the machine on position.
  • Page 42 Operator's Manual First Edition • Second Printing Inspections Test the Contact Alarm (if equipped) Test Aircraft Protection Package (if equipped) 72 Do not activate the foot switch and press on the contact alarm cable to release the actuator Note: Two people may be required to perform this from the switch socket.
  • Page 43 First Edition • Second 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 1278567 Platform Control Panel 27204 Arrow — Blue 1278982 Label — Actuator Switch Socket 27205 Arrow — Yellow 1281165 Label — Wheel Load, S-80 XC* 27206 Triangle — Blue 1281166 Label — Wheel Load, S-85 XC* 27207 Triangle — Yellow 1281169 Label —...
  • Page 45 First Edition • Second Printing Operator's Manual Inspections ® ™ ® ™ Part No. 1279298GT -80 XC • S -85 XC...

  • Page 46: Operating Instructions

    Operator's Manual First Edition • Second 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 47 First Edition • Second 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 48 Operator's Manual First Edition • Second 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 49 First Edition • Second Printing Operator's Manual Operating Instructions To Position Platform 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 appropriate function control grade.
  • Page 50 Operator's Manual First Edition • Second 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 drive You will need: function has been interrupted.
  • Page 51 First Edition • Second 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 will operator.
  • Page 52 Operator's Manual First Edition • Second Printing Operating Instructions Machine Malfunction Indicator Light If the tilt alarm sounds with Light on indicates a system fault. the platform uphill: Lower the boom. Retract the boom. Push in and then pull out the red Emergency If the tilt alarm sounds with Stop button.
  • Page 53 Unrestricted Range of Motion: When the platform load is less than 300 kg. Restricted Range of Motion: When the platform load is 301-454 kg. S-80 XC Range of Motion Chart ® ™ ® ™ Part No. 1279298GT -80 XC •...
  • Page 54 Tilt/Slope Platform Load/ 300 kg. (front to back) Maximum Boom Angle 300 kg 454 kg Light on indicates restricted range S-80 XC 4° 67° 67° of motion due to platform weight. 7° 50° The range of motion light is on S-85 XC 3°...
  • Page 55 First Edition • Second Printing Operator's Manual Operating Instructions LCD Screen Contact Alarm (if equipped) The LCD screen at the ground controls displays The contact alarm is designed to alert ground hour meter, voltage, oil pressure and coolant personnel when an operator makes contact with temperature.
  • Page 56 Operator's Manual First Edition • Second Printing Operating Instructions Standstill Regeneration When the LCD screen displays the message "Regen Required", the DPF (Diesel Particulate During the DPF standstill generation process, Filter) requires a Standstill Regeneration. all boom functions are disabled. Keep clear of the engine exhaust and muffler.
  • Page 57 First Edition • Second Printing Operator's Manual Operating Instructions Press Ok. The LCD screen will display the The system will keep the engine on at high warning "Non-flammable Environment". RPM until the coolant temperature reaches 35 C°. The LCD screen will then display the message "Standstill Regen Launch".
  • Page 58 Operator's Manual First Edition • Second Printing Operating Instructions Aircraft Protection Package (if equipped) After Each Use If the platform bumpers come into contact with Select a safe parking location–firm level aircraft components, the machine will shut down surface, clear of obstruction and traffic. and no functions will operate.
  • Page 59 First 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 and the platform.
  • Page 60 Operator's Manual First Edition • Second Printing 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 61 First Edition • Second Printing Operator's Manual Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels rubber bumper 2 from contact with the platform rails. Installation of Strap rubber Open the clamp and install it around a vertical bumper 1...

  • Page 62: Transport And Lifting Instructions

    Free-wheel Configuration for  Genie customers needing to containerize any Winching lift or Genie product should source a qualified Chock the wheels to prevent the machine from freight forwarder with expertise in preparing, rolling. loading and securing construction and lifting equipment for international shipment.
  • Page 63 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing the Platform – S-80 XC Securing to Truck or Trailer for Transit Make sure the platform is in the stowed position. Always use the turntable rotation lock pin each time Secure the platform with a nylon strap placed the machine is transported.
  • Page 64 Center of gravity X Axis (1) Y Axis (2) Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand S-80 XC 2.03 m 1.37 m the machine weight. See the serial label for the S-85 XC 2.03 m...

  • Page 65: Maintenance

    Dispose of material in accordance with Oil type 15W-40 governmental regulations. Oil type - cold conditions 5W-40  Use only Genie approved replacement parts. Deutz TD2.9L Engine Oil type 15W-40 Maintenance Symbols Legend Oil type - cold conditions 5W-40 The following symbols have been used in this Deutz TCD 2.2L Stage V Engine...
  • Page 66 Operator's Manual First Edition • Second 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 67 First Edition • Second 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 68 Operator's Manual First Edition • Second Printing Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 69: Specifications

    It should (boom functions) be used only with adequate safety factors. Tire size 18-625, 16 ply FF Continuous improvement of our products is a Genie Fuel tank capacity 132 liters policy. Product specifications are subject to change without notice or obligation.
  • Page 70 It should Hydraulic pressure, maximum 200 bar be used only with adequate safety factors. (boom functions) Continuous improvement of our products is a Genie Tire size 18-625, 16 ply FF policy. Product specifications are subject to change without notice or obligation.
  • Page 71 First Edition • Second Printing Operator's Manual Specifications S-80 XC Range of Motion Chart S-85 XC Range of Motion Chart ® ™ ® ™ Part No. 1279298GT -80 XC • S -85 XC...
  • Page 72 Net Installed Power: <only for IC machines> Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines> VIN: <where applicable> Manufacturer: <Manufacturer’s name> Authorized Representative: Genie Industries B.V Boekerman 5, 4751 XK Oud Gastel, The Netherlands Empowered signatory: Place of Issue: <variable field>...

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S-85 xc

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