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Terex S80XCH-3101 Operator's Manual

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Operator's Manual
S
-80 XC
®
S
-85 XC
®
Front Matter
Serial Number Range
™
™
from S80XCH-3101
from S85XCH-3091
CE
with
Maintenance
Information
Original Instructions
Second Edition
Third Printing
Part No. 1311085GT

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Summary of Contents for Terex S80XCH-3101

  • Page 1 Operator's Manual Serial Number Range -80 XC ® ™ from S80XCH-3101 from S85XCH-3091 -85 XC ® ™ with Maintenance Information Original Instructions Second Edition Third Printing Part No. 1311085GT Front Matter...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2017 by Terex Corporation Second Edition: Third Printing, September 2022 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 • Third Printing Operator's Manual Introduction Intr oducti on 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 • Third 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 • Third 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 • Third 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 • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. Stop engine. starting aids on machines equipped with glow plugs.
  • Page 8 Operator's Manual Second Edition • Third 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 • Third 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 • Third Printing General Safety Gener al Safety -80 XC • S -85 XC Part No. 1311085GT ® ™ ® ™...
  • Page 11 Second Edition • Third Printing Operator's Manual General Safety These decals are model, option or configuration specific. Part No. 1311085GT -80 XC • S -85 XC ® ™ ® ™...
  • Page 12 Operator's Manual Second Edition • Third Printing General Safety -80 XC • S -85 XC Part No. 1311085GT ® ™ ® ™...

  • Page 13: Personal Safety

    Second Edition • Third Printing Operator's Manual Personal Safety Pers onal 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.

  • Page 14: Work Area Safety

    Operator's Manual Second Edition • Third Printing Work Area Safety Work Ar ea 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 Second Edition • Third Printing Operator's Manual Work Area Safety The weight of options and accessories such as Tip-over Hazards pipe cradles and welders will reduce the rated Occupants, equipment and materials shall not platform capacity, and must be subtracted from the exceed the maximum platform capacity for the platform capacity.
  • Page 16 Operator's Manual Second Edition • Third Printing Work Area Safety If the tilt alarm sounds when the platform is raised, Do not raise the boom use extreme caution. The machine not level when wind speeds may indicator light will come on and the drive function exceed 28 mph/12.5 m/s.
  • Page 17 Second Edition • Third Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Use extreme care and in 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 18 Operator's Manual Second Edition • Third Printing Work Area Safety Do not modify or alter a mobile elevating work Operation on Slopes Hazards platform without prior written permission from the Do not drive the machine on a slope that exceeds manufacturer.
  • Page 19 Second Edition • Third Printing Operator's Manual 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 20 Operator's Manual Second Edition • Third Printing 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 21 Second Edition • Third Printing Operator's Manual 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 22 Operator's Manual Second Edition • Third Printing 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 23 Second Edition • Third Printing Operator's Manual 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 24 Operator's Manual Second Edition • Third Printing 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 25: Legend

    Second Edition • Third Printing Operator's Manual 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 Part No. 1311085GT -80 XC •...

  • Page 26: Controls

    Operator's Manual Second Edition • Third Printing 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 27 Second Edition • Third Printing Operator's Manual 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 28 Operator's Manual Second Edition • Third Printing 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 29 Second Edition • Third Printing Operator's Manual Controls Platform Control Panel Part No. 1311085GT -80 XC • S -85 XC ® ™ ® ™...
  • Page 30 Operator's Manual Second Edition • Third Printing Controls -80 XC • S -85 XC Part No. 1311085GT ® ™ ® ™...
  • Page 31 Second Edition • Third Printing Operator's Manual Controls Platform Control Panel Fault indicator light Light on indicates a system fault. Horn button Press this button and the horn will sound. Restricted range of motion indicator light, Release the button and the horn will stop. weight.
  • Page 32 Operator's Manual Second Edition • Third Printing 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 and 12 Lower boom indicator light thumb rocker for steer function.
  • Page 33 Second Edition • Third Printing Operator's Manual 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 34: Inspections

    Operator's Manual Second Edition • Third Printing Inspections Ins pections 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 35 Second Edition • Third Printing Operator's Manual 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 36 Operator's Manual Second Edition • Third Printing 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 37 Second Edition • Third Printing Operator's Manual 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 38 Operator's Manual Second Edition • Third Printing 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 39 Second Edition • Third Printing Operator's Manual 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 40 Operator's Manual Second Edition • Third Printing 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 41 Second Edition • Third Printing Operator's Manual Inspections 56 Press down the foot switch. Test Drive Tilt Cutout 57 With the boom fully stowed, drive the machine 46 Press down the foot switch. onto a slope where the roll angle is greater 47 With the boom fully stowed, drive the machine than 5°...
  • Page 42 Operator's Manual Second Edition • Third Printing Inspections Test Auxiliary Power Test the Contact Alarm (if equipped) 70 Do not activate the foot switch and press on 66 Shut the engine off. the contact alarm cable to release the actuator 67 Pull out the red Emergency Stop button to the from the switch socket.
  • Page 43 Second Edition • Third Printing Operator's Manual 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 44 Operator's Manual Second Edition • Third Printing 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 You learn and practice the principles of safe ...
  • Page 45 Second Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 82481 Label – Battery/Charger Safety 82487 Label – Read the Manual Determine whether the decals on your machine 82487 Label – Read the Manual have words or symbols.
  • Page 46 Operator's Manual Second Edition • Third Printing Inspections *1281187 1256425 114251 1263542 *28158 *1281188 133067 133205 *28159 28160 1284982 1281175 1281175 -80 XC • S -85 XC Part No. 1311085GT ® ™ ® ™...
  • Page 47 Second Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1281175 Label – Lanyard Anchorage Point, Fall Restrained Determine whether the decals on your machine 1281179 Label – Transport and Lifting have words or symbols. Use the appropriate 1281184 Label –...
  • Page 48 Operator's Manual Second Edition • Third Printing Inspections *1281187 1256425 114251 1263542 *28158 *1281188 133067 133205 *28159 28160 1284982 1281175 1281175 -80 XC • S -85 XC Part No. 1311085GT ® ™ ® ™...

  • Page 49: Operating Instructions

    Second Edition • Third Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons 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 50 Operator's Manual Second Edition • Third Printing Operating Instructions Starting the Engine Diesel models At the ground controls, turn the key switch to the desired position. Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position.
  • Page 51 Second Edition • Third Printing Operator's Manual 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 52 Operator's Manual Second Edition • Third Printing 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 53 Second Edition • Third Printing Operator's Manual 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 54 Operator's Manual Second Edition • Third Printing 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 55 Second Edition • Third Printing Operator's Manual 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 56 Operator's Manual Second Edition • Third Printing 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 57 Second Edition • Third Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings - S-80 XC, S-80 XC, S-85 XC: The range of S-85 XC motion light is on when the platform load exceeds 660 lbs/300 kg. Model Tilt/Slope Maximum Boom Angle/ (front to back) Platform Load Light on indicates restricted range...
  • Page 58 Operator's Manual Second Edition • Third Printing 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 59 Second Edition • Third Printing Operator's Manual 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 60 Operator's Manual Second Edition • Third Printing 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 61 Second Edition • Third Printing Operator's Manual 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 62 Operator's Manual Second Edition • Third Printing 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 63 Second Edition • Third Printing Operator's Manual 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 64 Operator's Manual Second Edition • Third 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 65 Second Edition • Third 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 66: Transport And Lifting Instructions

    Operator's Manual Second Edition • Third Printing Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
  • Page 67 Second Edition • Third 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 68 Operator's Manual Second Edition • Third 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 69: Maintenance

    Second Edition • Third Printing Operator's Manual Maintenance Maintenanc e 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 70 Operator's Manual Second Edition • Third 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 71 Second Edition • Third 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 72 Operator's Manual Second Edition • Third 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 73: Specifications

    Second Edition • Third Printing Operator's Manual Specifications Specific ati ons 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 74 Operator's Manual Second Edition • Third 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 75 Second Edition • Third 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 76 Operator's Manual Second Edition • Third 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 77 Second Edition • Third Printing Operator's Manual 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, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...
  • Page 78 Operator's Manual Second Edition • Third Printing 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 EN 280:2013+A1:2015.
  • Page 79 Second Edition • Third Printing Operator's Manual 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) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...
  • Page 80 Operator's Manual Second Edition • Third Printing 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 xcS85xch-3091

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