Terex S8016D-236 Operator's Manual
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Terex S8016D-236 Operator's Manual

Terex S8016D-236 Operator's Manual

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Operator's Manual
S-80
S-85
Serial Number Range
from S8016D-236
CE
with
Maintenance
Information
Original Instructions
Tenth Edition
First Printing
Part No. 1267886

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Summary of Contents for Terex S8016D-236

  • Page 1 Operator's Manual Serial Number Range S-80 from S8016D-236 S-85 with Maintenance Information Original Instructions Tenth Edition First Printing Part No. 1267886...

  • Page 2: Table Of Contents

    Copyright © 1994 by Terex Corporation Tenth Edition: First Printing, June 2016 Genie and "S" are registered trademarks 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-80 •...

  • Page 3: Introduction

    Tenth Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Tenth Edition • First Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Danger Accident reporting...
  • Page 5 Tenth Edition • First Printing Operator's Manual Introduction Safety Sign Maintenance Hazard Classification Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual Tenth Edition • First Printing 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 7 Tenth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Corrosive acid. Color Coded Runaway Hazard Collision hazard Collision hazard Direction Arrows Electrocution hazard Avoid contact Disconnect battery Voltage rating for...

  • Page 8: General Safety

    Operator's Manual Tenth Edition • First Printing General Safety General Safety S-80 • S-85 Part No. 1267886...
  • Page 9 Tenth Edition • First Printing Operator's Manual General Safety 82487 219956 82487 B 219956 A 114473 114473 A 133067 114473 219956 0 to 50KV 3.0 m 50 to 200KV 4.6 m 219954 200 to 350KV 6.1 m 219958 350 to 500KV 7.6 m 500 to 750KV 10.6 m...
  • Page 10 Operator's Manual Tenth Edition • First Printing General Safety S-80 • S-85 Part No. 1267886...

  • Page 11: Personal Safety

    Tenth 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 12: Work Area Safety

    Operator's Manual Tenth 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 13 Tenth 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 14 Operator's Manual Tenth Edition • First 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 15 Tenth 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 of machine.
  • Page 16 Operator's Manual Tenth 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 17 Tenth Edition • First Printing Operator's Manual Work Area Safety Observe and use the color-coded direction arrows Bodily Injury Hazard 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 18 Operator's Manual Tenth 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 the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 19 Tenth Edition • First Printing Operator's Manual Work Area Safety Weld Line to Platform Safety Welder 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 Tenth 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 21 Tenth Edition • First Printing Operator's Manual Work Area Safety Tow Package Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the tow package. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed When vehicle is in free-wheel configuration, there position.

  • Page 22: Legend

    Operator's Manual Tenth Edition • First Printing Legend Legend Lanyard anchorage points Non-steer tire Sliding mid-rail Steer tire 10 Manual storage container Ground controls 11 Foot switch Boom Jib boom (S-85) Platform controls Platform S-80 • S-85 Part No. 1267886...

  • Page 23: Controls

    Tenth Edition • First Printing Operator's Manual Controls Controls The S-80 and S-85 machines will have one of these two styles of ground control panel. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted.
  • Page 24 Operator's Manual Tenth Edition • First Printing Controls Turntable rotate switch Ground Control Panel Move the turntable rotate switch to the right LCD readout screen and the turntable will rotate to the right. Move Screen displays hour meter, voltage, oil the turntable rotate switch to the left and the pressure and coolant temperature.
  • Page 25 Tenth Edition • First Printing Operator's Manual Controls 14 Key switch for off/ground/platform selection 19 Platform rotate switch Turn the key switch to the off position and the Move the platform rotate switch to the right machine will be off. Turn the key switch to the and the platform will rotate to the right.
  • Page 26 Operator's Manual Tenth Edition • First Printing Controls S-80 • S-85 Part No. 1267886...
  • Page 27 Tenth Edition • First Printing Operator's Manual Controls STOP 14 13 Part No. 1267886 S-80 • S-85...
  • Page 28 Operator's Manual Tenth Edition • First Printing Controls Drive speed select switch Platform Control Panel Machine on incline symbol: Low range Horn button operation for inclines. Press this button and the horn will sound. Machine on level surface symbol: High range Release the button and the horn will stop.
  • Page 29 Tenth Edition • First Printing Operator's Manual Controls 11 Dual axis proportional control handle for drive 12 Drive enable switch and steer functions To drive when the drive enable light is on, hold OR Proportional control handle for drive the drive enable switch to either side and function and thumb rocker for steer function.
  • Page 30 Operator's Manual Tenth Edition • First Printing Controls 17 Gasoline/LPG models: Fuel select switch 22 Dual axis proportional control handle for boom up/down and turntable rotate left/right Move the fuel select switch to the gasoline functions position to select gasoline. Move the fuel select switch to the LPG position to select Move the control handle up LPG.

  • Page 31: Inspections

    Tenth 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 32 Operator's Manual Tenth Edition • First Printing Inspections  Tires and wheels Pre-operation Inspection  Engine and related components  Be sure that the operator’s, safety and  Limit switches and horn responsibilities manuals are complete, legible  Alarms and beacons (if equipped) and in the storage container located in the platform.
  • Page 33 Tenth 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 34 Operator's Manual Tenth Edition • First Printing Inspections Test Machine Functions At the Ground Controls Do not push the function Select a test area that is firm, level and free of enable button. Attempt to obstruction. activate each boom and Turn the key switch to ground control.
  • Page 35 Tenth Edition • First Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 17 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 12 Turn the key switch to platform control and 18 Pull out the red Emergency Stop button to the restart the engine.
  • Page 36 Operator's Manual Tenth Edition • First Printing Inspections Test the Steering Test Drive and Braking 24 Press down the foot switch. 27 Press down the foot switch. 25 Press the thumb rocker switch on top of the 28 Slowly move the drive control handle in the drive control handle in the direction indicated direction indicated by the blue arrow on the by the blue triangle on the control panel OR...
  • Page 37 Tenth Edition • First Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test the Drive Enable System 30 Start the engine from the platform controls. 34 Press down the foot switch and lower the boom to the stowed position. 31 Drive the right steer tire up onto a 15 cm block or curb.
  • Page 38 Operator's Manual Tenth Edition • First Printing Inspections Test Limited Drive Speed Test the Lift/Drive Select Function 38 Press down the foot switch. 44 Press down the foot switch. 39 Raise the boom to just above horizontal. 45 Move the drive control handle off center and activate a boom function toggle switch.
  • Page 39 Tenth 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 40 Operator's Manual Tenth Edition • First Printing Inspections Decal Inspection Part No. Decal Description 82487 Label – Read the Manual - Panel Cradle Use the pictures on the next page to verify that all 97815 Label – Lower Mid-rail decals are legible and in place. 114249 Label –...
  • Page 41 Tenth Edition • First Printing Operator's Manual Inspections 133413 28158* 82481 1255581 1263542 28159* 82487 28160 114251 133205 82487 72086 133067 114252 114465* 1256425 219723* 1255582 114249 72086 52475 114249 133308* 52475 133309* *133308 *133309 1260107 52475 *147603 62921* *823761 62923* 114473 27204...

  • Page 42: Operating Instructions

    Operator's Manual Tenth 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 43 Tenth Edition • First Printing Operator's Manual Operating Instructions Models with automatic glow plugs: Starting the Engine The LCD screen at the ground At the ground controls, turn the key switch to controls will display the glow plug the desired position. symbol when the automatic glow Be sure both ground and platform control red plugs are on.
  • Page 44 Operator's Manual Tenth Edition • First Printing Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all machine functions and turn the on position.
  • Page 45 Tenth Edition • First Printing Operator's Manual Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 46 Operator's Manual Tenth 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 47 Tenth Edition • First Printing Operator's Manual Operating Instructions Drive Enable Drive Speed Select Light on indicates that the boom has moved just past either non-steer wheel and the drive function has been interrupted.  Machine on incline symbol: Low range To drive, hold the drive enable switch to either side operation for inclines or rough terrain and slowly move the drive control handle off...
  • Page 48 Operator's Manual Tenth Edition • First Printing Operating Instructions Machine Not Level Indicator Light Machine Malfunction Indicator Light If the tilt alarm sounds when the Light on indicates all functions have platform is raised, the Machine Not stopped. Level indicator light will come on and the drive function in one or Push in and then pull out the red Emergency both directions will not operate.
  • Page 49 Tenth Edition • First Printing Operator's Manual Operating Instructions LCD Screen (if equipped) Platform Overload Indicator Light The LCD screen displays hour Light flashing indicates the meter, voltage, oil pressure and platform is overloaded and no coolant temperature. The functions will operate. screen also displays fault codes Remove weight from the and other service information.
  • Page 50 Operator's Manual Tenth 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 51 Tenth 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 52 Operator's Manual Tenth Edition • First Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rubber rails. Position the padding to protect the panels bumper 2 from contact with the platform rails. Installation of Strap rubber bumper 1 U-bolt...

  • Page 53: Transport And Lifting Instructions

    Tenth 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 54 Operator's Manual Tenth Edition • First Printing Transport and Lifting Instructions Securing the Platform - S-80 Securing to Truck or Trailer for Transit Place a block under the platform rotator. Do not allow the block to contact the platform cylinder. Always use the turntable rotation lock pin each Secure the platform with a nylon strap placed time the machine is transported.
  • Page 55 Tenth Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable. Observe and Obey: Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 56: Maintenance

    Operator's Manual Tenth 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 57 Tenth 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 58 Operator's Manual Tenth 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 59 Tenth Edition • First Printing Operator's Manual 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 60: Specifications

    Operator's Manual Tenth Edition • First Printing Specifications Specifications Model S-80 Airborne noise emissions Height, working maximum 26.2 m Sound pressure level at ground 85 dBA workstation Height, platform maximum 24.4 m Sound pressure level at platform 78 dBA Height, stowed maximum 2.8 m workstation Horizontal reach, maximum...
  • Page 61 Tenth Edition • First Printing Operator's Manual Specifications Model S-85 Airborne noise emissions Height, working maximum 27.7 m Sound pressure level at ground 85 dBA workstation Height, platform maximum 25.9 m Sound pressure level at platform 78 dBA Height, stowed maximum 2.8 m workstation Horizontal reach, maximum...
  • Page 62 Operator's Manual Tenth Edition • First Printing Specifications S-80 Range of Motion S-85 Range of Motion 24.4 m 18.3 m 12.2 m 6.10 m -3.1 m -3.1 m 3.1 m 9.1 m 15 m 21 m S-80 • S-85 Part No. 1267886 Operator's Manual Tenth Edition •...
  • Page 63 www.genielift.com...

This manual is also suitable for:

Genie s-85Genie s-80

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