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Operator's Manual

Second Edition • First Printing

S-80X

Part No. 1267884

Front Matter

Contents

Introduction ........................................................... 1

Symbol and Hazard Pictorials Definitions ............. 4

General Safety ...................................................... 6

Personal Safety ................................................... 12

Work Area Safety ................................................ 13

Legend ................................................................ 23

Controls ............................................................... 24

Inspections .......................................................... 32

Operating Instructions ......................................... 46

Transport and Lifting Instructions ....................... 58

Maintenance ....................................................... 61

Specifications ...................................................... 64

Second 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.

These machines comply with
ANSI/SIA A92.5
CAN B.354.4

Summary of Contents for S-80X

Page 1: ...Operator s Manual S 80X ANSI CSA North America South America Asia with Maintenance Information Second Edition First Printing Part No 1267884 ...

Page 2: ... Work Area Safety 13 Legend 23 Controls 24 Inspections 32 Operating Instructions 46 Transport and Lifting Instructions 58 Maintenance 61 Specifications 64 Copyright 2010 by Terex Corporation Second 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 These machines comply with ANSI SIA A92 5 CAN B 354 4 ...

Page 3: ...l label located under cover Intended Use This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Bulletin Distribution and Compliance Safety of product users is of paramount importance to Genie Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners The information conta...

Page 4: ...o your machine Please register your machine by visiting us on the web at www genielift com or by calling us toll free at 1 800 536 1800 Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Kn...

Page 5: ...use symbols color coding and signal words to identify the following Safety alert symbol used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or seri...

Page 6: ...ot 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 Replace tires with tires of same specification Wheel load Wind speed Maximum capacity Side force Weight of welder reduces ca...

Page 7: ...cid Color Coded Direction Arrows Runaway Hazard Collision hazard Collision hazard Electrocution hazard Avoid contact Disconnect 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 trai...

Page 8: ...Operator s Manual Second Edition First Printing General Safety 6 S 80X Part No 1267884 General Safety ...

Page 9: ...ection of machine travel R ead and understand operator s manual WARNING Only raise the platform when the machine is on a frm level surface Tip over Hazard Tipping over this machine will result in death or serious injury DANGER 114416 Tip over Hazard If tilt alarm sounds unit is on as evere slope D eatho r serious injury will result 114416 A DANGER Platform uphill 1 Lower boom 2R etract boom Platfo...

Page 10: ...ill cause death burns or blindness 31788 C Keep all open flames and sparks away Wear personal protective equipment including face shield gloves and long sleeve shirt READ MANUALS Read all manuals prior to operation DO NOT OPERATE equipment if you do not understand the information in the manuals Consult your supervisor the owner or the manufacturer WARNING Electrocution BurnHazard Failuret o discon...

Page 11: ...Second Edition First Printing Operator s Manual General Safety Part No 1267884 S 80X 9 ...

Page 12: ...7884 1267893 114473 219958 1267894 133067 82487 1267893 1267894 114473 82487 82487 B 114473 A 133067 133067 A 0 to 50KV 3 0 m 50 to 200KV 4 6 m 200 to 350KV 6 1 m 350 to 500KV 7 6 m 500 to 750KV 10 6 m 750 to 1000KV 13 7 m 219958 1267894 A 25 14 2WD 30 17 4WD 45 24 2WD 15 9 4WD 30 17 ...

Page 13: ...Second Edition First Printing Operator s Manual General Safety Part No 1267884 S 80X 11 ...

Page 14: ...ccupants 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 manufacturer s...

Page 15: ...power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut 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...

Page 16: ...on a severe slope If the tilt alarm sounds when the platform is raised use extreme caution Identify the condition of the boom on 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 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 downhi...

Page 17: ...tside of the platform Maximum allowable side force ANSI CSA 150 lbs 667 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 replace factory installed foam filled tire...

Page 18: ...ion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls 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 2WD Platform downhi...

Page 19: ...loor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of the boom position and tailswing when rotating the turntable Check the work area fo...

Page 20: ...on 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 closed an...

Page 21: ...nd 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 Always w...

Page 22: ... available for instant use per OSHA regulation 1926 352 d Weld Line to Platform Safety Read understand and obey all warnings and instructions provided with the welding power unit Do not connect weld leads or cables unless the welding power unit is turned off at the platform controls Do not operate unless the weld cables are properly connected Connect the positive lead to the twist lock connector a...

Page 23: ... of the platform with an overhanging load Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Electrocution Hazard Keep pipes away from all energized electrical conductors Panel Cradle Safety Read understand and obey all warnings and instructions provided with the panel cradles Do not exceed the rated platform capacity The combined weight of t...

Page 24: ...ions provided with the tow package When vehicle is in free wheel configuration there are no brakes and machine may move resulting in death serious injury or property damage Do not exceed maximum towing speed or maximum towing time Maximum tow speed 8 mph 12 87 km h Maximum towing time at 8 mph 13 km h 30 minutes Maximum towing time at 6 mph 10 km h 60 minutes ...

Page 25: ... Manual Legend Part No 1267884 S 80X 23 Legend 1 Non steer tire 2 Steer tire 3 Ground controls 4 Boom 5 Platform controls 6 Platform 7 Lanyard anchorage points 8 Sliding mid rail 9 Manual storage container 10 Foot switch 1 2 6 3 5 8 9 10 7 4 ...

Page 26: ...Operator s Manual Second Edition First Printing Controls 24 S 80X Part No 1267884 Controls 1 2 3 4 5 6 25 24 23 20 21 22 19 ...

Page 27: ...Second Edition First Printing Operator s Manual Controls Part No 1267884 S 80X 25 STOP 7 8 9 10 11 12 13 18 14 17 16 15 ...

Page 28: ...ange operation for maximum drive speed 6 Emergency power switch Use emergency power if the primary power source engine fails Simultaneously hold the emergency power switch to either side and activate the desired function 7 Machine not level indicator light Light is on when the tilt alarm is sounding Move the machine to level ground 8 Generator switch if equipped Move the generator switch up to act...

Page 29: ...by the yellow arrow and the machine will drive backwards Press the left side of the thumb rocker and the machine will steer to the left Press the right side of the thumb rocker and the machine will steer to the right 15 Drive enable switch To drive when the drive enable light is on hold the drive enable switch to either side and slowly move the drive control handle off center Be aware that the mac...

Page 30: ... See the instructions in the Operating Instructions section 23 Not used 24 Thumb rocker switch for boom extend retract function Push the top of the rocker switch and boom will retract Push the bottom of the rocker switch and the boom will extend 25 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions Move the control handle up and the primary boo...

Page 31: ...round control panel The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels unless specifically noted 1000 lbs 454 kg 500 lbs 227 kg STOP 12 11 9 7 17 13 10 13 2 8 19 15 18 23 16 5 22 14 21 4 20 1 1000 lbs 454 kg 500 lbs 227 kg 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 8 18 19 ...

Page 32: ...esired function 8 Turntable rotate switch Move the turntable rotate switch to the right and the turntable will rotate to the right Move the turntable rotate switch to the left and the turntable will rotate to the left 9 Boom up down switch Move the boom up down switch up and the boom will raise Move the boom up down switch down and the boom will lower 10 Machine malfunction indicator light Light o...

Page 33: ...e platform will raise Move the platform level switch down and the level of the platform will lower 19 Platform rotate switch Move the platform rotate switch to the right and the platform will rotate to the right Move the platform rotate switch to the left and the platform will rotate to the left 20 Hour meter The hour meter displays the number of hours the machine has operated 21 Glow plug switch ...

Page 34: ...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 unauthorize...

Page 35: ...ction Check for proper tire pressure Add air if needed See Maintenance section Check the 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 ...

Page 36: ...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 may onl...

Page 37: ...itch Attempt to activate each boom and platform function toggle switch Result No boom and platform functions should operate 8 Move and hold the platform capacity select function enable switch to select 500 lbs 227 kg platform capacity Activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm should sound whil...

Page 38: ...ngine off 17 Pull out the red Emergency Stop button to the on position 18 Simultaneously hold the emergency power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions should operate At the Platform Controls Test Emergency Stop 19 Enter the platform and pull out the red Emergency Stop button Start...

Page 39: ...e and then fully extend the boom to full height Lower the boom Result The boom should stop part way down and the 500 lbs 227 kg capacity indicator light should flash 27 Retract the boom to continue and then fully retract and lower the boom Test the Foot Switch 28 Push in the platform red Emergency Stop button to the off position 29 Pull out the red Emergency Stop button to the on position and do n...

Page 40: ...t The steer wheels should turn in the direction that the yellow triangles point on the drive chassis Test Drive and Braking 36 Press down the foot switch 37 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 return the handle to the center position Result The machine should move in the direction that the blue...

Page 41: ...he Drive Enable System 43 Press down the foot switch and lower the boom to the stowed position 44 Rotate the turntable until the boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 45 Move the drive control handle off center Result The drive function should not operate 46 Move and hold the dr...

Page 42: ...ion Result The maximum achievable drive speed with the boom extended should not exceed 1 ft 30 cm per second If the drive speed with the boom raised or extended exceeds 1 ft 30 cm per second immediately tag and remove the machine from service Test Emergency Controls 53 Shut off the engine 54 Pull out the red Emergency Stop button to the on position 55 Press down the foot switch 56 Simultaneously h...

Page 43: ...or 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 situations ...

Page 44: ...r option 1 97602 Warning Explosion Hazard 1 97815 Label Lower Mid rail 1 Part No Decal Description Qty 97875 Warning Weld Line to Platform 2 111896 Instructions Continental Engine Specs 1 114258 Danger Explosion Hazard 2 114390 Danger Electrocution Hazard 3 114416 Danger Tip over Hazard Tilt Alarm 1 128953 Instructions Deutz Engine Specs 1 133177 Danger Tip over Foam filled Tires 4 133209 Label Re...

Page 45: ...78 27206 27207 27206 65278 27207 27205 52966 52967 1267891 97579 40434 28174 28235 82862 147575 823764 114416 218559 1267892 40434 114390 44981 97815 28236 1260107 133177 133177 133308 133308 133177 133177 133308 133308 52475 52475 31060 72086 82237 72875 82410 114390 72086 114258 1260107 1262543 31060 72086 97602 111896 128953 824615 1258972 1254016 52475 31060 52475 147659 28174 28235 44981 1332...

Page 46: ... 1 82487 Label Read the Manual 2 82487 Label Read the Manual Panel Cradle 2 Part No Decal Description Qty 82487 Label Read the Manual Pipe Cradle 2 97815 Label Lower Mid rail 1 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 2 114252 Label Tip over Hazard Limit Switches 4 114473 Label Tilt Alarm 1 133067 Label Electrocution Hazard 3 133205 Label Electrocution Burn Hazard 1 13330...

Page 47: ...55582 62921 27204 65278 27206 27207 27206 65278 27207 27205 52966 52967 1267893 40434 28174 28235 147575 823764 114473 219958 1267894 40434 133067 44981 97815 82487 1260107 114249 114249 133308 133308 114249 114249 133308 133308 52475 52475 114252 72086 1256425 82487 82487 133067 72086 114251 1260107 1263542 114252 72086 52475 114252 52475 147659 28174 28235 44981 1255581 1256425 ...

Page 48: ... 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 use a m...

Page 49: ...switch 3 Deutz models Hold the switch for 15 seconds pre glow Continue holding the switch while cranking and remain holding up to 180 seconds post glow Perkins models Hold the switch for 20 seconds pre glow Continue holding the switch while cranking and remain holding up to 30 seconds post glow 4 Move the engine start toggle switch to either side If the engine fails to start or dies the restart de...

Page 50: ...e red Emergency Stop button to the on position 3 Press down the foot switch when using the controls from the platform 4 Simultaneously hold the emergency power switch to either side and activate the desired function The drive and steer functions will not operate with emergency power Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on pos...

Page 51: ...ency Stop button is pushed in and pulled back out the platform capacity will need to be selected again To Steer 1 Press down the foot switch 2 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to id...

Page 52: ...etermine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the...

Page 53: ...on incline symbol Low range operation for inclines or rough terrain Machine on level surface symbol High range operation for maximum drive speed Engine Idle Select rpm Select engine idle rpm using the symbols on the control panel When the foot switch is not pressed the engine will idle at the lowest rpm Turtle symbol Foot switch activated low idle Rabbit symbol Foot switch activated high idle Gene...

Page 54: ...m downhill 1 Retract the boom 2 Lower the boom Machine Malfunction Indicator Light Light on indicates all functions have stopped 1 Push in and then pull out the red Emergency Stop button 2 Lower and retract the boom 3 Tag the machine and remove from service Functions will not operate Check Engine Light if equipped Light on and engine stopped Tag the machine and remove from service Light on and eng...

Page 55: ...resent Regeneration mode is turned off To turn the regeneration mode on 1 Push in red Emergency Stop button to turn the machine off 2 Restart the engine Flashing red lights contact service personnel Flashing green lights contact service personnel within 24 hours Deutz engine Flashing red lights contact service personnel Flashing green lights contact service personnel within 24 hours Platform Capac...

Page 56: ...The machine will stop when the machine reaches the limit of the restricted range of motion Raise or retract the boom to continue If the red Emergency Stop button is pushed in and pulled back out the platform capacity will need to be selected again If the machine is started when the platform is outside the restricted range of motion the 500 lbs 227 kg capacity light will flash Select 500 lbs 227 kg...

Page 57: ...e 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 Make ...

Page 58: ... may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 200 lbs 90 7 kg Pipe Cradle Assembly Weight 21 lbs 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 In...

Page 59: ...ne 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 load on t...

Page 60: ...g 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 that exceeds the uphill downhill or side slope rating See D...

Page 61: ...pin Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items For diagram refer to the Lifting Instructions Securing the Platform S 80X Place a block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed through the lower platform support Do not us...

Page 62: ...ne weight Lifting Instructions Fully lower and retract the boom Remove all loose items on the machine Use the turntable rotation lock to secure the turntable 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 Adjust the rigging to pre...

Page 63: ...s 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 and service life Operating the machine with an improper oil level c...

Page 64: ...ons Hydraulic oil type Chevron Rando HD equivalent Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system prob...

Page 65: ...a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel The use of a good quality fuel will give the following result long engine life and acceptable exhaust emissions levels Minimum diesel fuel requirements for each engine are listed below Perkins ...

Page 66: ...bar System voltage 12V Tire size 18 625 16 ply FF Ground clearance 13 in 33 cm Fuel tank capacity diesel 35 gallons 132 liters Fuel tank capacity gasoline 30 gallons 113 6 liters Weight 35 500 lbs 16 103 kg Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating stowed position 2WD Platform uphill 30 17 Platform downhill 15 9 Side slope 25 ...

Page 67: ...Second Edition First Printing Operator s Manual Specifications Part No 1267884 S 80X 65 S 80X Range of Motion S 80X Part No 1267884 Operator s Manual Second Edition First Printing ...

Page 68: ...stributed By www genielift com California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

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