Genie S-80 XC Operator'S Manual Download Page 7

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First Edition • Second Printing

Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1279298GT

-80 XC

™

• S

-85 XC

™

Symbol and Hazard Pictorials Definitions

Fire hazard

Explosion hazard

Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.

No smoking.
No flame.
Stop engine.

Fire extinguisher

No smoking

Explosion hazard

Electrocution hazard

Maintain required
clearance

Tip-over hazard

Tip-over hazard Tip-over

hazard Tire

specifications

Summary of Contents for S-80 XC

Page 1: ...Operator s Manual Serial Number Range S 80 XC from S80XCH 104 CE S 85 XC from S85XCH 101 with Maintenance Information Original Instructions First Edition Second Printing Part No 1279298GT ...

Page 2: ... Netherlands Contents Introduction 1 Symbol and Hazard Pictorials Definitions 5 General Safety 8 Personal Safety 11 Work Area Safety 12 Legend 22 Controls 23 Inspections 31 Operating Instructions 44 Transport and Lifting Instructions 60 Maintenance 63 Specifications 67 Copyright 2017 by Terex Corporation First Edition Second Printing May 2020 Genie and S are registered trademarks of Terex South Da...

Page 3: ...abel Serial label located under cover Serial number stamped on chassis Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s responsibility to read and understand this familiarization guide Each person must be trained to operate a Mobile Elevating Work Platfo...

Page 4: ...nd boom up down Turntable rotate and platform rotate Sequential functions and movement Drive and steer Interlocked functions Elevated drive speed Elevated drive in an off level condition Drive enable when the boom is rotated past the non steer wheels All platform and ground controls Limitations of use The intended use of this machine is to lift personnel including tools and materials to an aerial ...

Page 5: ...he action indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com 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 Accident reporting Questions...

Page 6: ...lations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine 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 Hazard Classification Decals ...

Page 7: ...efinitions Fire hazard Explosion hazard Explosion hazard Do not use ether or other high energy starting aids on machines equipped with glow plugs No smoking No flame Stop engine Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Tip over hazard Tip over hazard Tire specifications ...

Page 8: ...t No 1279298GT Wheel load Wind speed Maximum capacity Manual force Weight of welder reduces capacity Tie down point Lifting point Platform tie down instructions Lifting tie down instructions Lanyard anchorage points Corrosive acid Color coded direction arrows Runaway hazard Collision hazard Overhead obstruction ...

Page 9: ...sconnect battery Voltage rating for power to platform Pressure rating for air line to platform Recovery procedure if tilt alarm sounds while elevated Platform downhill 1 Retract boom 2 Lower boom Platform uphill 1 Lower boom 2 Retract boom Read the operator s manual Access by trained and authorized personnel only Read the service manual Crush hazard Crush hazard ...

Page 10: ...Operator s Manual First Edition Second Printing General Safety 8 S 80 XC S 85 XC Part No 1279298GT General Safety ...

Page 11: ...First Edition Second Printing Operator s Manual General Safety Part No 1279298GT S 80 XC S 85 XC 9 These decals are model option or configuration specific ...

Page 12: ...Operator s Manual First Edition Second Printing General Safety 10 S 80 XC S 85 XC Part No 1279298GT ...

Page 13: ...hine 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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufact...

Page 14: ...t off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity for the restricted or unrestricted range of motion Maximum platform capacity Unrestricted range of motion 300 kg Maximum occupants 2 Maximum platform capacity Restricted range of motion 454 kg Ma...

Page 15: ...n the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering The recovery mode should be used only by trained and authorized personnel If the tilt alarm sounds with the platform uphill 1 Lower the boom 2 Retract the boom If the tilt alarm sounds with the platform downhill 1 Retract the boom 2 Lower the boom Do not raise t...

Page 16: ... N Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not replace factory installed tires with tires of different specification or ply rating Do not use air filled tires These machines are equipped with foam filled tires Wheel weight is critical to stability Do ...

Page 17: ...oving or mobile surface or vehicle Be sure the tires are in good condition and the lug nuts tightened Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies only to machines in the stowed position Maximum slope rating stowed position 4WD Platform downhill 45 24 Platform uphill 30 17 Side slop...

Page 18: ... Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level 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 Collision Hazards Be aware of limited sight distance and blind spots when driving...

Page 19: ...d carbon monoxide poisoning Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain clo...

Page 20: ...fety and responsibilities manuals are complete legible and in the storage container located on the machine Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine Do not use the machine as a ground for welding Do not operate the machine in locations where extremely high magnetic fields may be present Battery Safety Burn Hazards Batteries contain acid Al...

Page 21: ...dles will reduce rated platform capacity and must be factored into total platform load The pipe cradle assembly weighs 9 5 kg The maximum capacity of the pipe cradle assembly is 91 kg The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in platform Center the load within the perimeter of the platform Secure the load to the platform Do no...

Page 22: ...Do not operate unless you are adequately instructed and are aware of all hazards associated with lifting panels Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Maximum vertical height of panels 1 2 m Maximum wind speed 6 7 m sec Maximum panel area 3 m2 Welder Safety Read understand and obey all warnings and instructions provided with the w...

Page 23: ...ter Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the non steer wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use ...

Page 24: ... 22 S 80 XC S 85 XC Part No 1279298GT Legend 1 Non steer tire 2 Steer tire 3 Ground controls 4 Boom 5 Jib boom if equipped 6 Platform controls 7 Swing gate 8 Platform 9 Lanyard anchorage points 10 Sliding mid rail 11 Manual storage container 12 Foot switch ...

Page 25: ...tation 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 When the ground control station is selected the platform controls are inoperable including the E stop switch ...

Page 26: ...m will extend 7 LCD readout screen navigation buttons 8 LCD readout screen Screen displays hour meter voltage oil pressure and coolant temperature Screen also displays fault codes and other service information 9 LCD screen menu buttons Use the LCD screen menu buttons to access different menus The Home button will show the model hour meter and access to engine gauges The Maintenance button will sho...

Page 27: ...ashing indicates the platform is overloaded The engine will stop and no functions will operate Note An alarm will sound at the platform when an overload condition occurs and will stop sounding when weight is removed from the platform 16 Platform level down button Press the platform level down button and the level of the platform will lower 17 Jib boom down button Press the jib boom down button and...

Page 28: ...Operator s Manual First Edition Second Printing Controls 26 S 80 XC S 85 XC Part No 1279298GT Platform Control Panel ...

Page 29: ...First Edition Second Printing Operator s Manual Controls Part No 1279298GT S 80 XC S 85 XC 27 ...

Page 30: ...p and the jib boom will raise Move the jib boom switch down and the jib boom will lower 5 Glow plug indicator light Light on indicates the glow plugs are on 6 Fault indicator light Light on indicates a system fault 7 Restricted range of motion indicator light weight Light on indicates restricted range of motion due to platform weight 8 Platform overload indicator light Light flashing indicates the...

Page 31: ...functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards Move the control handle in the direction indicated by the blue triangle...

Page 32: ...switch up or down and activate the desired function 23 Engine RPM select switch Move the engine RPM select switch to the turtle position to activate low idle Move the engine RPM speed select switch to the rabbit position to activate high idle 24 Engine start switch Move the engine start switch to either side to start the engine 25 Gasoline LPG models Fuel select switch Move the fuel select switch ...

Page 33: ...ction is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unaut...

Page 34: ...following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine and related components Limit switches and horn Primary boom angle sensor Turntable level ...

Page 35: ...y use the machine as it was intended 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 tagged and removed from service Repairs to the machine m...

Page 36: ...m and platform function button Result No boom and platform functions should operate 8 Press and hold the function enable button and activate each boom and platform function button Result All boom and platform functions should operate through a full cycle The descent alarm should sound while the boom is lowering Test the Tilt Sensor 9 Press the Maintenance button above the LCD screen Navigate to th...

Page 37: ...rn should sound Test the Foot Switch 18 Push in the platform red Emergency Stop button to the off position 19 Pull out the red Emergency Stop button to the on position and do not start the engine 20 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 21 Do not press down the foot switch and restart the engin...

Page 38: ...control panel OR slowly move the control handle in the direction indicated by the yellow triangle Result The steer wheels should turn in the direction that the yellow triangles point on the drive chassis Test Drive and Braking 29 Press down the foot switch 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then...

Page 39: ...Test the Drive Enable System 36 Press down the foot switch and lower the boom to the stowed position 37 Rotate the turntable until the boom moves past one of the non steer wheels Result The drive enable indicator light should flash while the boom is anywhere in the range shown 38 Move the drive control handle off center Result The drive function should not operate 39 Move and hold the drive enable...

Page 40: ...hine onto a slope where the machine pitch angle is greater than 7 front to back Result The machine should continue to drive 48 Return the machine to level ground and extend the boom approximately 46 cm 49 Drive the machine onto a slope where the pitch angle is greater than 7 front to back Result The machine should stop once the machine reaches 7 of chassis tilt and the alarm should sound at the pl...

Page 41: ...o side Result The machine should stop once the machine reaches 5 of chassis tilt and the alarm should sound at the platform controls 63 While on the slope attempt to raise and extend the boom Result The boom raise and extend functions should not operate 64 Lower the boom to the stowed position Result The machine should drive 65 Return to level ground and stow the boom Test Auxiliary Controls 66 Sh...

Page 42: ...e actuator from the switch socket Result The contact alarm lights will flash and the machine horn will sound 76 Operate each machine function Result All machine functions should not operate 77 Insert the actuator into the switch socket Result The lights and horn will turn off 78 Operate each machine function Result All machine functions should operate 1 actuator 2 contact alarm cable 3 flashing al...

Page 43: ...operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situa...

Page 44: ...67 Label Electrocution Hazard 3 133205 Label Electrocution Burn Hazard 1 133411 Label 106 dBa 1 Part No Decal Description Qty 219956 Label Platform Overload 1 219958 Label Tip over Crush Hazard 1 1256425 Label Danger Electrocution Hazard 2 1258949 Ground Control Panel S 85 XC 1 1258950 Ground Control Panel S 80 XC 1 1263542 Label Compartment Access 2 1272242 Label Machine Registration Owner Transf...

Page 45: ...First Edition Second Printing Operator s Manual Inspections Part No 1279298GT S 80 XC S 85 XC 43 ...

Page 46: ...is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to u...

Page 47: ...or press and hold the engine start button 6 If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions and turn the engine off Repair any function that operates when either red Emergency Stop button is pushed ...

Page 48: ...re not available from the ground controls Platform Overload Indicator Light Light flashing indicates the platform is overloaded The engine will stop and no functions will operate Remove weight from the platform until the light goes off and then restart the engine Note An alarm will sound at the platform when an overload condition occurs and will stop sounding when weight is removed from the platfo...

Page 49: ...ress down the foot switch 2 Increase speed Slowly move the control handle off center Decrease speed Slowly move the control handle toward center Stop Return the control handle to center or release the function enable switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when th...

Page 50: ...3 6 m Run 3 6 m Rise 0 3 m 0 3 m 3 6 m 0 083 x 100 8 3 grade If the slope exceeds the maximum uphill downhill or side slope rating then the machine must be winched or transported up or down the slope See Transport and Lifting section Drive Enable Light flashing indicates that the boom has moved just past either non steer wheel and the drive function has been interrupted To drive hold the drive ena...

Page 51: ...r outlet located at the platform or turntable To stop the generator move the generator toggle switch to the off position Note The generator indicator light will turn off and the RPM will return to normal Operating Envelope Indicator Lights The operating envelope indicator lights will come on to notify the operator that a function has been interrupted and or an action is required by the operator Ra...

Page 52: ... 2 Lower the boom Platform Overload Indicator Light Light flashing indicates the platform is overloaded The engine will stop and no functions will operate Remove weight from the platform until the light goes off and then restart the engine Machine Malfunction Indicator Light Light on indicates a system fault 1 Push in and then pull out the red Emergency Stop button 2 Lower and retract the boom 3 T...

Page 53: ... S 85 XC 51 Platform Capacity Range Range of motion is controlled automatically based on platform load 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 S 85 XC Range of Motion Chart ...

Page 54: ...ximum Platform Reach 300 kg 454 kg S 80 XC 4 20 9 m 18 7 m 7 18 7 m N A S 85 XC 3 22 7 m 19 7 m 7 19 7 m N A The range of motion light is on when the platform load exceeds 300 kg Light on indicates restricted range of motion due to platform weight The range of motion light is on when the platform load is less than 300 kg and on a slope Light on indicates restricted range of motion due to platform ...

Page 55: ...t with the platform control panel interrupting boom movement sounding an alarm and flashing warning lights When the contact alarm cable is tripped the lift and drive functions are disabled at the platform The audio and visual warnings will activate alerting others that assistance may be needed These notifications will continue until the system is reset 1 The contact alarm cable is tripped releasin...

Page 56: ...Under emergencies the DPF standstill regeneration can be interrupted in three ways The engine is turned off by the key switch The ESC button is pressed The ESTOP stop button is pushed If this occurs the standstill regeneration may need to be restarted The DPF standstill regeneration cannot begin until the engine has been run for at least two minutes and the coolant temperature has reached 35 C Whe...

Page 57: ...e engine if not already done If required the LCD screen will display the message Engine Warming 8 The system will keep the engine on at high RPM until the coolant temperature reaches 35 C The LCD screen will then display the message Standstill Regen Launch 9 If the Regeneration process has begun successfully the regeneration process auto advances and the LCD screen displays the message Standstill ...

Page 58: ... foot switch 3 Move and hold the aircraft protection function override switch 4 Move the appropriate function control handle or toggle switch to move the machine away from aircraft components After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the n...

Page 59: ...Observe and Obey Pipe cradles must be installed on the inside of the platform Pipe cradles must not obstruct the platform controls or the platform entrance The bottom of the pipe cradle tube must rest on the platform floor Be sure the platform is level before installing a pipe cradle Pipe Cradle Installation 1 Install a pipe cradle on each side of the platform Refer to the illustration on the left...

Page 60: ...e pipe cradles may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 90 7 kg Pipe Cradle Assembly Weight 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to the front of each panel cradle if needed 2 Install rubber bumper 1 in the panel cradle base See the illustration 3 Secure the bumper with 2 high profile lock nuts and 2 washers Panel Cradle Ins...

Page 61: ...ough one side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly end plate should be able to slide on the platform rail Panel Cradle Operation 1 Secure both panel cradles to the platform 2 Place the load so that it rests in both panel cradles 3 Center the loa...

Page 62: ...chine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight 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 th...

Page 63: ...he Chassis Use chains of ample load capacity Use a minimum of 6 chains Adjust the rigging to prevent damage to the chains For diagram refer to the Lifting Instructions Securing the Platform S 80 XC Make sure the platform is in the stowed position Secure the platform with a nylon strap placed parallel to the strap guides Do not use excessive downward force when securing the boom section Securing th...

Page 64: ...ines are sufficient to withstand the machine weight See the serial label for the machine weight 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 Attach the rigging only to the designated lifting points on the machine All four of the lifting points are on the turntable A...

Page 65: ...ymbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance ...

Page 66: ...pe Ultra Low Sulfur Diesel ULSD Deutz TCD 2 2L Stage V Engine Fuel Type Ultra Low Sulfur Diesel ULSD Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system prob...

Page 67: ...evel in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark on the tank or visible in the sight gauge Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with...

Page 68: ...uarterly 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: ... with option configurations See serial label for specific machine weight Airborne noise emissions Sound pressure level at ground workstation 85 dBA Sound pressure level at platform workstation 78 dBA Guaranteed sound power level 106 dBA Total vibration value to which the hand arm system is subjected does not exceed 2 5 m s2 Highest root mean square value of weighted acceleration to which the whole...

Page 70: ...y with option configurations See serial label for specific machine weight Airborne noise emissions Sound pressure level at ground workstation 85 dBA Sound pressure level at platform workstation 78 dBA Guaranteed sound power level 106 dBA Total vibration value to which the hand arm system is subjected does not exceed 2 5 m s2 Highest root mean square value of weighted acceleration to which the whol...

Page 71: ...First Edition Second Printing Operator s Manual Specifications Part No 1279298GT S 80 XC S 85 XC 69 S 80 XC Range of Motion Chart S 85 XC Range of Motion Chart ...

Page 72: ... engine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specif...

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