Genie S-45 XC CE Telescopic Boom Lift Owner’s Manual

Genie S-45 XC CE Telescopic Boom Lift

Product Information

This is an operator’s manual supplement for the 4m Platform manufactured by Terex Global GmbH. The manual provides important safety rules and operating instructions for the machine. The approved models for the 13ft / 4m platform are S-45 XC, S-45 XC Trax, S-65 XC, S-65 XC Trax, and S-85 XC. The manual also lists authorized and non-authorized platform configurations.

Product Usage Instructions

1. Read the entire operator’s manual supplement and understand all safety rules and operating instructions before operating the machine.
2. Only trained and authorized personnel should operate the machine.
3. Keep this manual with the machine at all times as it is considered a permanent part of the machine.
4. For any questions or concerns, contact Genie Industries through their website: www.genielift.com or via email at [email protected]
5. Do not install the 13ft / 4m platform on any Genie product other than the approved models listed in the manual.
6. Ensure that the appropriate software version for the 13ft / 4m platform is installed before operating the machine. Each approved model requires the specific software version.
7. Observe all warnings and instructions provided with the 13ft / 4m platform. Failure to do so may result in death or serious injury.
8. Do not exceed the rated platform capacity of the 13ft / 4m platform.
9. Verify that the 13ft / 4m platform is securely installed before use.

Introduction

2 4m Platform Part No. 1295772GT

Manufacturer:
Terex Global GmbH Bleicheplatz 2 Schaffhausen, 8200 Switzerland
EU Authorized representative:
Genie Industries B.V. Boekerman 5 4751 XK OUD GASTEL The Netherlands
UK Authorized representative:
Genie UK Limited The Maltings Wharf Road Grantham NG31 6BH UK

Contact Us:
Internet: www.genielift.com
E-mail: [email protected]

Important
Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, contact us.

Approved Model

• S®-45 XC™ CE/UK Models
• S®-45 XC™ Trax™ CE/UK Models
• S®-65 XC™ CE/UK Models
• S®-65 XC™ Trax™ CE/UK Models
• S®-85 XC™ CE/UK Models

Do not install the 13ft / 4m platform on any Genie product other than the approved models.

Copyright © 2020 by Terex Corporation First Edition: Tenth Printing, May 2023
Genie and “S” are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries.
“XC” and “TraX” are trademarks of Terex South Dakota, Inc.
These machines comply with Complies with EC Directive 2006/42/EC See EC Declaration of Conformity Supply of Machinery (Safety) Regulations 2008

S-45 XC, S-45 XC Trax, S-65 XC, S-65 XC Trax, S-85 XC with 13ft / 4m Platform

Danger
Failure to obey the instructions and safety rules in this manual will result in death or serious injury.

Note: These installation instructions only apply to the Genie models listed on the front cover.

Danger

• Using the 13ft / 4m Platform with the options below will result in death or serious injury.
• Using the 13ft / 4m Platform on a machine without the appropriate 13ft / 4m platform software will result in death or serious injury.

Authorized Platform Configurations:

• Lift Guard Contact Alarm (option)
• Pipe Cradle (option)

Non-Authorized Platform Configurations:

• Panel cradle – single piece (option)
• 6 ft Half mesh Plate/Gate (option)
• 8 ft Half mesh Plate/Gate (option)
• 6 ft Auxiliary Top Rail (option)
• 8 ft Auxiliary Top Rail (option)
• 6 ft Aircraft Protection (option)
• 8 ft Aircraft Protection (option)
• Operator Protective Structure (OPS) (option)
• Lift Tools Access Deck (option)
• Lift Tools Expo Installer (option)
• Fall Arrest Bar (option)

13ft / 4m Platform Safety
Read, understand and obey all warnings and instructions provided with the 13ft / 4m platform.
Do not exceed the rated platform capacity.
Verify the 13ft / 4m platform is securely installed.
Install the 13ft / 4m platform software appropriate for the approved model, before operating the machine.
Verify the Installation of the appropriate software of the 13ft / 4m platform before operating the machine. Each approved model requires the appropriate software version.
Do not move the platform into the unrestricted range of motion zone.

When the 13ft / 4m platform assembly is attached, this manual should be considered a permanent part of your machine and should remain with the machine at all times.

Symbol and Hazard Pictorials Definitions

Read the supplement, part number 1295772GT.

Tip-over hazard

Maximum capacity 600 lbs/272 kg

Lanyard anchorage points

Crushing hazard

Pre-operation Inspection

• Verify the operator’s manual and any necessary supplements are complete, legible and in the storage container located in the platform.
• Verify all decals are legible and in place.

Check the 13ft / 4m Platform for damage, improperly installed or missing parts and unauthorized modifications.

• Nuts, bolts and other fasteners
• Cracks in structural components
• Dents or damage to 13ft / 4m Platform

Decal Inspection – S-45 XC, S-45 XC Trax
Use the inspection to verify that all decals are legible and in place. Decals may vary depending on machine configuration. These decals are also applicable to S-45 XC Trax, even if the picture does not show the tracks.

1312387     Label – 13ft / 4m Platform, Max Allowable Chassis Inclination, Symbol| 1

Shading indicates decal is hidden from view, i.e. under covers

Decal Inspection – S-65 XC, S-65 XC Trax
Use the inspection to verify that all decals are legible and in place. Decals may vary depending on machine configuration. These decals are also applicable to S-65 XC Trax, even if the picture does not show the tracks.

1312387     Label – 13ft / 4m Platform, Max Allowable Chassis Inclination, Symbol| 1

Shading indicates decal is hidden from view, i.e. under covers

Decal Inspection – S-85 XC
Use the inspection to verify that all decals are legible and in place. Decals may vary depending on machine configuration.

1312387     Label – 13ft / 4m Platform, Max Allowable Chassis Inclination, Symbol| 1

Shading indicates decal is hidden from view, i.e. under covers

Platform Capacity Range
Range of motion is controlled automatically based on platform load.

S-45 XC, S-45 XC Trax with 13ft / 4m Platform, Range of Motion Chart

Maximum platform capacity
1 600 lbs 272 kg

S-65 XC, S-65 XC Trax with 13ft / 4m Platform, Range of Motion Chart

Maximum platform capacity
1 600 lbs 272 kg

S-85 XC with 13ft / 4m Platform, Range of Motion Chart

Maximum platform capacity
1 600 lbs 272 kg

Tilt Sensor Activation Settings

Model| Tilt/Slope (front to back)| Maximum Boom Angle/ Platform Load
---|---|---
272 kg
S-45 XC

S-45 XC Trax

| 5°| 75°
S-65 XC

S-65 XC Trax

| 4°| 71.7°
S-85 XC| 3°| 69°
Model| Tilt/Slope (front to back)| Maximum Platform Height/Platform Load
272 kg
S-45 XC

S-45 XC Trax

| 5°| 13.59 m
S-65 XC

S-65 XC Trax

| 4°| 19.81 m
S-85 XC| 3°| 25.91 m
Model| Tilt/Slope (front to back)| Maximum Platform Reach/Platform Load
272 kg
S-45 XC

S-45 XC Trax

| 5°| 9.66 m
S-65 XC

S-65 XC Trax

| 4°| 14.32 m
S-85 XC| 3°| 19.66 m

The range of motion light is on when the platform load exceeds 272 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 272 kg and on a slope.
Light on indicates restricted range of motion due to platform weight and slope angle.

Note: When the Machine On Incline indicator light is on and the tilt alarm sounds, the following functions are affected; drive and lift up functions are disabled. Follow the Operator Envelope Indicator Lights procedure to restore drive and lift functions.

Securing the Platform – S-45 XC, S-45 XC Trax with 4m Platform
Make sure the jib and platform are in the stowed position.
Transporting a machine with a 13ft / 4m Platform on a standard width trailer requires the turntable to be rotated 4 degrees. Lock the rotated turntable using the Off-center Transport Lock (p/n 1309686GT). The 13ft / 4m Platform must be fully rotated as shown in the image below.
Secure the platform with a nylon strap placed parallel to the strap guides. Do not use excessive downward force when securing the boom section.

Model                     S-45| XC, S-45 XC Trax with 13ft / 4m

Platform

---|---
Overall transportation len platform rotated| gth, 10.52 m
Turntable rotation angle| 4.0°
Platform dimensions, 13 (length x width)| ft / 4m                 400 cm x 91 cm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

Model S-45 XC, S-45 XC Trax with 13ft / 4m Platform
Overall transportation length, platform rotated 10.52 m
Turntable rotation angle 4.0°
Platform dimensions, 13ft / 4m (length x width) 400 cm x 91 cm
Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

Securing the Platform – S-65 XC, S-65 XC Trax with 4m Platform
Make sure the jib and platform are in the stowed position.
Transporting a machine with a 13ft / 4m Platform on a standard width trailer requires the turntable to be rotated 3.5 degrees. Lock the rotated turntable using the Off-center Transport Lock (p/n 1296096GT). The 13ft / 4m Platform must be fully rotated as shown in the image below.
Secure the platform with a nylon strap placed parallel to the strap guides. Do not use excessive downward force when securing the boom section.

Model                    S-65| XC, S-65 XC Trax with 13ft / 4m

Platform

---|---
Overall transportation len platform rotated| gth, 11.29 m
Turntable rotation angle| 3.5°
Platform dimensions, 13 (length x width)| ft / 4m                 400 cm x 91 cm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

Securing the Platform – S-85 XC with 4m Platform
Make sure the jib and platform are in the stowed position.
Transporting a machine with a 13ft / 4m Platform on a standard width trailer requires the turntable to be rotated 3.5 degrees. Lock the rotated turntable using the Off-center Transport Lock (p/n 1312367GT). The 13ft / 4m Platform must be fully rotated as shown in the image below.
Secure the platform with a nylon strap placed parallel to the strap guides. Do not use excessive downward force when securing the boom section.

13.73 m
Turntable rotation angle| 3.5°
Platform dimensions, 13ft / (length x width)| 4m                  400 cm x 91 cm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

Observe and Obey:

• This procedure shall be completed by a person authorized to install the 13ft / 4m Platform.
• Immediately tag and remove from service a damaged or malfunctioning machine.
• Repair any machine damage or malfunction before operating the machine.

Before Starting Installation:

• Read, understand and obey the safety rules and operating instructions in the appropriate operator’s manual.
• Be sure that all necessary tools and parts are available and ready for use.
• Read this procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.

Installation Instructions

Tools required:
Assorted SAE wrenches
Assorted SAE sockets
Ratchet
Service and Repair Manual

Tools for software update (if required):
Torx T15 screwdriver
PC or Laptop with Internet Browser
USB flash drive

Contents of Kit 1295770GT

Note: Perform this procedure on a firm, level surface with the machine in the stowed position unless otherwise instructed.

1. Adjust the jib so the platform is approximately 12 inches / 30.5 cm off the ground.

2. Remove any optional accessories from the platform and set aside.
   Example: Welder, Contact Alarm, Panel Cradle, etc.
   Note: Most optional accessories can be reinstalled on the 13ft / 4m platform. Refer to the list of accessories that are NOT approved for use on the 13ft / 4m platform.

3. Remove the cable clamp from the top of the platform mounting weldment.

4. Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side. Do not disconnect the wiring.

5. Remove the foot switch mounting fasteners.

6. Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals.

7. Tag and disconnect the foot switch wiring from the foot switch. Remove the cable from the back of the platform.

8. Remove the platform control box mounting fasteners. Lower the control box and set it aside.
   NOTICE
   Component damage hazard. Cables can be damaged if they are kinked or pinched.
   Note: If your machine is equipped with an airline to platform option, the airline must be disconnected from the platform before removal.

9. Support and secure the platform to an appropriate lifting device.

10. Remove the platform mounting fasteners and remove the platform from the machine.
    Crushing hazard. The platform could become unstable and fall when it is removed from the machine if not properly supported.

11. Install the provided Operator’s Manual Supplement into the manual storage box in the platform.

12. Install the 13ft / 4m platform using the removal procedure in reverse order.

13. Install the contact alarm onto the platform.
    Note: Do not install any optional accessories onto the platform until the platform load cell has been calibrated. Calibration is required.

14. If required, update the machine software. Software update is required when the 13ft / 4m platform is installed onto an approved model. Refer to Checking the Application and Bootloader Revisions from the Ground Controls.

DANGER

Tip-over hazard. Failure to upload the appropriate software version for the correct approved model and/or failure to select the appropriate platform type, will result in death or serious injury.

Software Update

Checking the Application and Bootloader Revisions from the Ground Controls.
Verifying the machine application and bootloader firmware revision levels must be completed before updating the software.
Not all machines will require a software update. Software update is required when the 13ft / 4m platform is installed onto a different approved model.

1. Turn the key switch to ground controls.

2. Press and hold buttons 1 and 4. Pull out the red Emergency Stop button to the on position.

3. Read and record the firmware revisions.
   Bootloader Firmware:
   Note: The application firmware revision is shown under Current Firmware.

4. Press Escape. Press OK to exit bootloader mode.
   

Bootloader Firmware Result: The Bootloader Firmware does not need to be updated. Continue to Selecting the Platform Option – Revision “F” or higher. Result: The Bootloader Firmware must be updated. Continue to Updating the Machine Software – Revision “E” or lower.
Application Firmware
S-45 XC, S-45 XC Trax, S-65 XC, S-65 XC Trax: The Application Firmware must be updated to revision 1.7.4 or higher. If the Current Firmware revision is lower, continue to Updating the Machine Software. If the Current Firmware revision is 1.7.4 or higher, continue to Selecting the Platform Option.
S-85 XC: The Application Firmware must be updated to revision 1.8.0 or higher. If the Current Firmware revision is lower, continue to Updating the Machine Software. If the Current Firmware revision is 1.8.0 or higher, continue to Selecting the Platform Option.
Note: If a Firmware update is not required, a zero load platform calibration must be performed. Refer to Repair Procedure, How to Perform a Zero Load Platform Calibration in the Service and Repair manual that is appropriate for your machine.

Bootloader Firmware

• Result: The Bootloader Firmware does not need to be updated. Continue to Selecting the Platform Option –
• Revision “F” or higher. Result: The Bootloader Firmware must be updated. Continue to Updating the Machine Software – Revision “E” or lower.

Application Firmware
S-45 XC, S-45 XC Trax, S-65 XC, S-65 XC Trax: The Application Firmware must be updated to revision 1.7.4 or higher. If the Current Firmware revision is lower, continue to Updating the Machine Software. If the Current Firmware revision is 1.7.4 or higher, continue to Selecting the Platform Option.
S-85 XC: The Application Firmware must be updated to revision 1.8.0 or higher. If the Current Firmware revision is lower, continue to Updating the Machine Software. If the Current Firmware revision is 1.8.0 or higher, continue to Selecting the Platform Option.
Note: If a Firmware update is not required, a zero load platform calibration must be performed. Refer to Repair Procedure, How to Perform a Zero Load Platform Calibration in the Service and Repair manual that is appropriate for your machine.

Updating the Machine Software

Note: Access to the internet is required to perform this procedure.

1. Click on the Hyperlink below or open an internet browser and copy and paste or type the link into the address bar and press enter. https://firmware.genielift.com/ https://www.genielift.com/en/support/firmware
2. Select the model that is appropriate for your machine under Machine Model. Select Search.
3. Select the appropriate Firmware File to be updated. Select I Accept. Save or print a copy of the ALC-600 Software Update instructions 1295343GT.
4. Follow the instructions to update the machine software in the following order.
   • Checking the File System Format of a USB Flash Drive.
   • Firmware Site Download
   • How to Enter ALC-600 Software Update Mode
   • Model Configuration and Region Settings (Note: Do not perform steps 11 and 12.)
5. Push in the red Emergency Stop button to the off position.

Selecting the Platform Option.

The appropriate platform option must be selected when installing or removing the 13ft / 4m platform.
Tip-over hazard. Not selecting the appropriate platform option will result in death or serious injury.

1. Press and hold buttons 2 and 3. Pull out the red Emergency Stop button to the on position.

2. You will be prompted for a password.
   Enter 3 – 3 – 2 – 4.

3. Press the Settings button to access the settings menu.
   Note: There will be a delay while the menu is being loaded on the display screen.

4. Select Model Configuration. Press OK.

5. Select Platform. Press OK.

6. Select the appropriate platform. Press OK.

   • Standard
   • 4m / 13 ft

7. Press Escape / Escape / Escape.

8. Push in the red Emergency Stop button to the off position.

9. Perform a zero load platform calibration. Refer to Repair Procedure, How to Perform a Zero Load Platform Calibration in the Service and Repair manual that is appropriate for your machine.

10. Perform function test. Refer to the Operator’s Manual located on your machine.

11. Return the machine to service.

Original Instructions
First Edition
Tenth Printing
Part No. 1295772GT

www.genielift.com

References

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