Genie S-80X Operating Manual
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Genie S-80X Operating Manual

Genie S-80X Operating Manual

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Operator's Manual
S-80X
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Second Edition
First Printing
Part No. 1267884

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  • 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: Table Of Contents

    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...

  • Page 3: Introduction

    This book is an operation and daily maintenance manual for the user or operator of a Genie Bulletin Distribution and machine. Compliance...
  • Page 4 Second Edition • First Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At...
  • Page 5 Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a property damage message. Part No. 1267884 S-80X...

  • Page 6: Symbol And Hazard Pictorials Definitions

    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 capacity S-80X Part No. 1267884...
  • Page 7 Recovery procedure if tilt alarm sounds while elevated. Platform downhill: Platform uphill: Read the operator’s Access by trained and manual authorized personnel 1 Retract boom. 1 Lower boom. only 2 Lower boom. 2 Retract boom. Part No. 1267884 S-80X...

  • Page 8: General Safety

    Operator's Manual Second Edition • First Printing General Safety General Safety S-80X Part No. 1267884...
  • Page 9 A runaway machine could result Move drive speed select switch to in death or serious injury. machine on incline symbol. 1267892 A Part No. 1267884 S-80X...
  • Page 10 No smoking. No Fuel and fumes flame. Stop Do not alter or disable limit switch(s). can explode engine. and burn. 31060 B 114258 A 52865 82237 31060 31060 97875 97602 1263543 133177 97875 114258 133177 114390 S-80X Part No. 1267884...
  • Page 11 Second Edition • First Printing Operator's Manual General Safety Part No. 1267884 S-80X...
  • Page 12 7.6 m 500 to 750KV 10.6 m 750 to 1000KV 13.7 m 133067 A 1267894 1267894 133067 2WD: 30% (17°) 4WD: 45% (24°) 2WD: 15% (9°) 4WD: 30% (17°) 82487 25% (14°) 1267894 A 219958 1267893 S-80X Part No. 1267884...
  • Page 13 Second Edition • First Printing Operator's Manual General Safety Part No. 1267884 S-80X...

  • Page 14: Personal Safety

    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 instructions. S-80X Part No. 1267884...

  • Page 15: Work Area Safety

    Do not attach a platform rated at 500 lbs / 227 kg (unrestricted range of motion) or 1000 lbs / 454 kg (restricted range of motion) to machines with any other rated load. See the serial label for the maximum rated load. Part No. 1267884 S-80X...
  • Page 16 Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability. S-80X Part No. 1267884...
  • Page 17 Do not place loads outside the platform perimeter. Do not push off or pull toward any object outside of the platform. Maximum allowable side force – ANSI & CSA 150 lbs / 667 N Part No. 1267884 S-80X...
  • Page 18 Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls. S-80X Part No. 1267884...
  • Page 19 Lower the platform entry mid-rail or close the entry governmental rules regarding use of personal gate before operating. protective equipment. Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level. Part No. 1267884 S-80X...
  • Page 20 Do not operate the machine or charge the battery No stunt driving or horseplay while operating a in hazardous locations or locations where machine. potentially flammable or explosive gases or particles may be present. Do not spray ether into engines equipped with glow plugs. S-80X Part No. 1267884...
  • Page 21 Be sure all maintenance has been performed as Avoid spilling or contacting specified in this manual and the appropriate Genie battery acid. Neutralize service manual. battery acid spills with Be sure all decals are in place and legible.
  • Page 22 Do not operate unless the weld cables are properly connected. Connect the positive lead to the twist-lock connector at the turntable and platform. Clamp the negative lead to the ground post at the turntable and platform. S-80X Part No. 1267884...
  • Page 23 Do not cause a horizontal force or side load to machine by raising or lowering a fixed or Maximum panel area: 32 sq ft / 3 m overhanging load. Electrocution Hazard: Keep pipes away from all energized electrical conductors. Part No. 1267884 S-80X...
  • Page 24 Do not exceed maximum towing speed, or maximum towing time. Maximum tow speed 8 mph / 12.87 km/h Maximum towing time at 30 minutes 8 mph / 13 km/h Maximum towing time at 60 minutes 6 mph / 10 km/h S-80X Part No. 1267884...

  • Page 25: Legend

    Second Edition • First Printing Operator's Manual Legend Legend Platform Non-steer tire Lanyard anchorage points Steer tire Sliding mid-rail Ground controls Manual storage container Boom 10 Foot switch Platform controls Part No. 1267884 S-80X...

  • Page 26: Controls

    Operator's Manual Second Edition • First Printing Controls Controls S-80X Part No. 1267884...
  • Page 27 Second Edition • First Printing Operator's Manual Controls STOP 17 16 Part No. 1267884 S-80X...
  • Page 28 500 lbs / 227 kg. The range of motion is unrestricted. Machine on incline symbol: Low range operation for inclines. 12 Used for optional equipment Machine on level surface symbol: High range operation for maximum drive speed. S-80X Part No. 1267884...
  • Page 29 19 Models with LCD screen: Engine shut-down left. Press the right side of the thumb rocker indicator light and the machine will steer to the right. Light on indicates that the engine has shut down. Contact service personnel. Part No. 1267884 S-80X...
  • Page 30 Move the control handle to the right and the turntable will rotate to the right. Move the control handle to the left and the turntable will rotate to the left. S-80X Part No. 1267884...
  • Page 31 Second Edition • First Printing Operator's Manual Controls The S-80X machines will have one of these two styles of ground control panel. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted.
  • Page 32 Simultaneously hold the emergency power control panel functions to operate. The range switch to either side and activate the desired of motion is restricted if 1000 lbs / 454 kg function. platform capacity is selected. S-80X Part No. 1267884...
  • Page 33 23 Check engine light Light on and engine stopped: Tag the machine and remove from service. Light on and engine still running: Contact service personnel within 24 hours. Part No. 1267884 S-80X...

  • Page 34: Inspections

    Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual. S-80X Part No. 1267884...
  • Page 35  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 Part No. 1267884 S-80X...
  • Page 36 3 Always perform function tests prior to use. Know and understand the function tests before going on to the next section. 4 Inspect the workplace. 5 Only use the machine as it was intended. S-80X Part No. 1267884...
  • Page 37 11 Move and hold the platform capacity select/function enable switch to select 1000 lbs / 454 kg platform capacity. Retract the boom. 12 Retract the boom to continue and then fully retract and lower the boom. Part No. 1267884 S-80X...
  • Page 38 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. S-80X Part No. 1267884...
  • Page 39 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. Part No. 1267884 S-80X...
  • Page 40 Note: The brakes must be able to hold the machine on any slope it is able to climb. S-80X Part No. 1267884...
  • Page 41 Note: When the drive enable system is in use, the machine may drive in the opposite direction that the drive and steer control handle is moved. Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction of travel. Part No. 1267884 S-80X...
  • Page 42 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. S-80X Part No. 1267884...
  • Page 43 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. Part No. 1267884 S-80X...
  • Page 44 Tires (option) 28159 Label – Diesel 28160 Label – Liquid Petroleum Gas 147575 Platform Control Panel 147659 Cosmetic – Genie S-80X 28174 Label – Power to Platform, 230V 28235 Label – Power to Platform, 115V 147755 Ground Control Panel 823658...
  • Page 45 82862 27205 28236 52966* 52967* 52865 82237 31060 1255581 133209 72086 147659 *111896 31060 *128953 97875 *824615 *1258972 *1254016 97602 1262543 52475 133177 133308 *28174 97875 *28235 114258 133308 1260107 52475 44981 72086 133177 52475 114390 Part No. 1267884 S-80X...
  • Page 46 133387 Drive Enable Patch 27206 Triangle – Blue 147575 Platform Control Panel 27207 Triangle – Yellow 147659 Cosmetic – Genie S-80X 28158 Label – Unleaded 147755 Ground Control Panel 28159 Label – Diesel 219958 Label – Tip-over, Crush Hazard 28160 Label –...
  • Page 47 40434 40434 27207 *28174 133067 65278 *28235 44981 27206 97815 27207 27205 82487 52966* 52967* 1256425 114252 1255581 72086 147659 114252 1263542 52475 114249 133308 *28174 *28235 114251 133308 1260107 52475 44981 72086 114249 52475 133067 Part No. 1267884 S-80X...

  • Page 48: Operating Instructions

    That means 4 Inspect the workplace. every new operator should perform a pre-operation inspection, function tests, and a workplace 5 Only use the machine as it was inspection before using the machine. intended. S-80X Part No. 1267884...
  • Page 49 If the engine fails to start or dies, the restart delay will disable the start switch for 3 seconds. Part No. 1267884 S-80X...
  • Page 50 Press down the foot switch when using the ground controls. controls from the platform. 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. S-80X Part No. 1267884...
  • Page 51 Use the color-coded direction arrows on the be selected again. platform controls and the drive chassis to identify the direction the machine will travel. Machine travel speed is restricted when the boom is raised. Part No. 1267884 S-80X...
  • Page 52 0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade If the slope exceeds the maximum slope or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section. S-80X Part No. 1267884...
  • Page 53 Machine on incline symbol: Low range outlet. operation for inclines or rough terrain To stop the generator, move the generator toggle  Machine on level surface symbol: High range switch to the off position. operation for maximum drive speed Part No. 1267884 S-80X...
  • Page 54 If the tilt alarm sounds with the Light on and engine still running: platform downhill: Contact service personnel within 24 hours. Retract the boom. Lower the boom. Engine Shut-down indicator light (if equipped) Light on: Tag and remove the machine from service. S-80X Part No. 1267884...
  • Page 55 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. Part No. 1267884 S-80X...
  • Page 56 500 lbs / 227 kg capacity light will flash. Select 500 lbs / 227 kg capacity to continue. Do not exceed the platform capacity of 500 lbs / 227 kg. S-80X Part No. 1267884...
  • Page 57 Install two U-bolts from the outside of the platform rails through each pipe cradle mount. Secure each U-bolt with 2 washers and 2 nuts. strap U-bolts pipe cradle mount upper platform railing pipe cradle weldment middle platform railing flat washers nylock nuts Part No. 1267884 S-80X...
  • Page 58 Place the tube between the panel cradle and the platform floor. Insert the U-bolt through the 21 lbs Pipe Cradle Assembly Weight floor, around the tube and into the panel cradle 9.5 kg base. Repeat above for the second set of parts. S-80X Part No. 1267884...
  • Page 59 Secure both panel cradles to the platform. Place the load so that it rests in both panel cradles. padding Center the load on the platform. Secure the load to the platform using the strap. Tighten the strap. clamp hook Part No. 1267884 S-80X...

  • Page 60: Transport And Lifting Instructions

     Winching Genie customers needing to containerize any lift or Genie product should source a qualified Chock the wheels to prevent the machine from freight forwarder with expertise in preparing, rolling. loading and securing construction and lifting equipment for international shipment.
  • Page 61 Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform - S-80X Securing to Truck or Trailer for Transit Place a block under the platform rotator. Do not allow the block to contact the platform cylinder.
  • Page 62 See the serial label for the Adjust the rigging to prevent damage to the machine weight. machine and to keep the machine level. Center of gravity X Axis Y Axis S-80X 61.30 in 52.12 in 1.56 m 1.32 m S-80X Part No. 1267884...

  • Page 63: Maintenance

    5W-30 and the requirements specified in the responsibilities manual. Perkins 804D-33 Engine  Oil type 15W-40 Use only Genie approved replacement parts. Oil type - cold conditions 5W-20 Maintenance Symbols Legend Perkins 404F-22T Engine Oil type 15W-40 The following symbols have been used in this...
  • Page 64 Chevron Rando HD equivalent Check the fluid level 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. S-80X Part No. 1267884...
  • Page 65 Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service. Part No. 1267884 S-80X...

  • Page 66: Specifications

    It should be used only with adequate safety factors. Platform rotation 160° Continuous improvement of our products is a Genie AC outlet in platform standard policy. Product specifications are subject to change Hydraulic pressure, maximum...
  • Page 67 Second Edition • First Printing Operator's Manual Specifications S-80X Range of Motion S-80X Part No. 1267884 Operator's Manual Second Edition • First Printing Part No. 1267884 S-80X...
  • Page 68 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. www.genielift.com...

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