Terex S85XCH-3740 Operator's Manual
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Terex S85XCH-3740 Operator's Manual

Terex S85XCH-3740 Operator's Manual

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Operator's Manual
S
-80 XC
®
S
-85 XC
®
Serial Number Range
™
From SN S85XCH-3740
™
CE
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1318179GT

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Summary of Contents for Terex S85XCH-3740

  • Page 1 Operator's Manual Serial Number Range -80 XC ® ™ From SN S85XCH-3740 -85 XC ® ™ with Maintenance Information Original Instructions Third Edition First Printing Part No. 1318179GT...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2017 by Terex Corporation Third Edition: First Printing, February 2023 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

    Third 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 Third 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: •...
  • Page 5 Third 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 Third 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

    Third 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 Third 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 Third 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 Third Edition • First Printing General Safety General Safety ® ™ ® ™ -80 XC • S -85 XC Part No. 1318179GT...
  • Page 11 Third Edition • First Printing Operator's Manual General Safety ® ™ ® ™ Part No. 1318179GT -80 XC • S -85 XC...
  • Page 12 Operator's Manual Third Edition • First Printing General Safety ® ™ ® ™ -80 XC • S -85 XC Part No. 1318179GT...

  • Page 13: Personal Safety

    Third 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 Third Edition • First Printing Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 15 Third Edition • First Printing Operator's Manual Work Area Safety Tip-over Hazards Do not raise or extend the boom unless the machine Occupants, equipment and materials shall not is on a firm, level surface. exceed the maximum platform capacity for the restricted or unrestricted range of motion.
  • Page 16 Operator's Manual Third Edition • First Printing Work Area Safety If the tilt alarm sounds with the Use extreme care and platform uphill: slow speeds while driving the machine in the stowed Lower the boom. position across uneven terrain, debris, unstable or Retract the boom.
  • Page 17 Third Edition • First Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Do not place or attach in any way affect safety and stability. fixed or overhanging loads to any part of this Do not replace items critical to machine stability machine.
  • Page 18 Operator's Manual Third Edition • First Printing Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating safety belt or harness in of the machine.
  • Page 19 Third Edition • First Printing Operator's Manual Work Area Safety Collision Hazards Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Be aware of limited sight and steer functions. distance and blind spots when driving or operating.
  • Page 20 Operator's Manual Third Edition • First Printing Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Always operate the machine in a well-ventilated Do not use a damaged or malfunctioning machine. area to avoid carbon monoxide poisoning. Conduct a thorough pre-operation inspection of Do not operate the machine with a hydraulic oil or the machine and test all functions before each air leak.
  • Page 21 Third Edition • First Printing Operator's Manual Work Area Safety Battery Safety Contact Alarm Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the contact alarm. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective weight of the contact alarm assembly will reduce clothing and eye wear when...
  • Page 22 Operator's Manual Third Edition • First 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 23 Third Edition • First Printing Operator's Manual Work Area Safety Welder Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the welding power unit. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not connect weld leads or cables unless the position.

  • Page 24: Legend

    Operator's Manual Third 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

    Third 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 Third 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 Third 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 Third Edition • First Printing Controls Platform Control Panel ® ™ ® ™ -80 XC • S -85 XC Part No. 1318179GT...
  • Page 29 Third Edition • First Printing Operator's Manual Controls ® ™ ® ™ Part No. 1318179GT -80 XC • S -85 XC...
  • Page 30 Operator's Manual Third Edition • First Printing Controls Platform Control Panel Fault indicator light Horn button Light on indicates a system fault. 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 Third 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 Third 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

    Third 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 Third Edition • First Printing Inspections Pre-operation Inspection ❑ Primary boom angle sensor ❑ Turntable level sensor ❑ Be sure that the operator’s manual is ❑ String pot length sensor complete, legible and in the storage container located in the platform. ❑...
  • Page 35 Third 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 36 Operator's Manual Third 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 Third 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 Third 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 Third 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 Third Edition • First Printing Inspections Test Drive Tilt Cutout 55 Return to level ground and stow the boom. 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 Third 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 Third Edition • First Printing Inspections Test Aircraft Protection Package 75 Insert the actuator into the switch socket. (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 Third 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 Third 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 Third Edition • First Printing Operator's Manual Inspections *1281187 133067 114251 1263542 *28158 82481 72086 *1281188 133205 *28159 *28160 1284982 *82487 *82487 72086 *82366 1286362 114249 *1258949 *1258950 82487 1281169 114252 52475 114252 114249 52475 *1281165 *1281166 *1281165 1301030 *1281166 1281179 114473 *1278567...
  • Page 46 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 1281173 Label – Tip-over Hazard, S-85 XC 1281174 Label – Lanyard Anchorage Point, Fall Determine whether the decals on your machine Arrest/Fall Restrained have words or symbols.
  • Page 47 Third Edition • First Printing Operator's Manual Inspections *1281187 133067 114251 1263542 *28158 82481 72086 *1281188 133205 *28159 *28160 1284982 *82487 *82487 72086 *82366 1286362 114249 *1258949 *1258950 82487 1281169 114252 52475 114252 114249 52475 *1281165 *1281166 *1281165 1301030 *1281166 1281179 114473 *1278567...

  • Page 48: Operating Instructions

    Operator's Manual Third 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 manual.
  • Page 49 Third 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 Third Edition • First Printing Operating Instructions Operation from Ground Platform Overload Indicator Light Light flashing indicates the platform is overloaded. Turn the key switch to ground control. The engine will stop and no functions will operate. Pull out the red Emergency Stop button to the Remove weight from the platform until the light on position.
  • Page 51 Third Edition • First Printing Operator's Manual Operating Instructions Operation from Platform To Steer Press down the foot switch. Turn the key switch to platform control. Slowly move the drive control handle in the Pull out both ground and platform red direction indicated by blue or yellow triangles Emergency Stop buttons to the on position.
  • Page 52 Operator's Manual Third Edition • First Printing Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 53 Third Edition • First Printing Operator's Manual Operating Instructions Drive Enable Engine RPM Select Select engine RPM using the symbols on the Light flashing indicates that the control panel. boom has moved just past either non-steer wheel and the When the foot switch is not pressed, the engine drive function has been will idle at the lowest rpm.
  • Page 54 Operator's Manual Third Edition • First Printing Operating Instructions Operating Envelope Indicator Lights Platform Overload Indicator Light The operating envelope indicator lights will come Light flashing indicates the platform on to notify the operator that a function has been is overloaded. The engine will stop interrupted and/or an action is required by the and no functions will operate.
  • Page 55 Third Edition • First Printing Operator's Manual Operating Instructions Platform Out of Level (> ±10° error) Machine Malfunction Indicator Light When the platform level is > +/- 10° off target Light on indicates a system fault. angle, then the machine malfunction indicator light turns on and the LCD screen display fault code 98- You will need to follow the below procedures: If Platform is out of expected level see...
  • Page 56 Operator's Manual Third 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 Third Edition • First 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 58 Operator's Manual Third Edition • First 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 59 Third Edition • First 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 60 Operator's Manual Third Edition • First Printing Operating Instructions Aircraft Protection Package Operation (if Pipe Cradle Instructions equipped) The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform If the platform bumper comes into contact with an and mounted to the guardrails with U-bolts.
  • Page 61 Third Edition • First Printing Operator's Manual Operating Instructions Observe and Obey: Pipe Cradle Operation  Be sure the pipe cradle assembly and Pipe cradles must be installed on the inside of installation instructions have been followed the platform. properly and that the pipe cradles are secured ...
  • Page 62 Operator's Manual Third Edition • First Printing Operating Instructions Panel Cradle Assembly Panel Cradle Installation Apply the warning decal to the front of each Insert the hook piece through the slots in the panel cradle (if needed). panel cradle base. Install rubber bumper 1 in the panel cradle Hook the panel cradle to the bottom platform base.
  • Page 63 Third Edition • First 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 from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
  • Page 64 Operator's Manual Third Edition • First Printing 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 65: Transport And Lifting Instructions

    Third Edition • First Printing Operator's Manual 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 66 Operator's Manual Third Edition • First Printing 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 67 Third Edition • First Printing Operator's Manual 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 68: Maintenance

    Operator's Manual Third Edition • First Printing Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 69 Third Edition • First Printing Operator's Manual 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 70 Operator's Manual Third Edition • First Printing 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 71 Third Edition • First Printing Operator's Manual 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 72: Specifications

    Operator's Manual Third Edition • First Printing 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 73 Third Edition • First Printing Operator's Manual 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 74 Operator's Manual Third Edition • First Printing 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 75 Third Edition • First Printing Operator's Manual 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 76 Operator's Manual Third Edition • First Printing Specifications Contents of EC Declaration of Conformity - 1 <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, relevant harmonized standards, technical standards or specifications used: <standard(s)' name>...
  • Page 77 Third Edition • First Printing Operator's Manual Specifications Contents of EC Declaration of Conformity - 2 <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, Conformity assessment procedure: art.12 (3) (a), with the application of European Harmonized Standard <standard(s)' name>.
  • Page 78 Operator's Manual Third Edition • First Printing Specifications Contents of UK Declaration of Conformity - 1 <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) relevant designated standards, technical standards or specifications used: <standard(s)' name>...
  • Page 79 Third Edition • First Printing Operator's Manual Specifications Contents of UK Declaration of Conformity - 2 <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) conformity assessment procedure according to Part 3, 11.

This manual is also suitable for:

Genie s-85 xcGenie s-80 xc

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