Terex Genie S-80 J Operator's Manual
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Terex Genie S-80 J Operator's Manual

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Operator's Manual
S
-80 J
®
S
-80 J TraX
®
Serial Number Range
from S80JH-101
™
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
First Edition
First Printing
Part No. 1306265GT

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Summary of Contents for Terex Genie S-80 J

  • Page 1 Operator's Manual Serial Number Range -80 J ® from S80JH-101 ANSI/CSA North America -80 J TraX ® ™ South America Asia with Maintenance Information Original Instructions First Edition First Printing Part No. 1306265GT...

  • Page 2: Table Of Contents

    Maintenance ............64 Specifications ............68 Copyright © 2020 by Terex Corporation First Edition: First Printing, January 2021 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/SAIA A92.20 CAN/CSA B354.6...

  • Page 3: Introduction

    First Edition • First Printing Operator's Manual Introduction Introduction 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 First Edition • First Printing Operator's Manual 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: Boom up/down...
  • Page 5 First Edition • First 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 First Edition • First Printing Operator's Manual 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

    First Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 8 First Edition • First Printing Operator's Manual 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 & tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 9 First Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution Avoid contact Disconnect battery Voltage rating for Pressure rating for hazard power to platform air line to platform Recovery procedure if tilt alarm sounds while elevated. Platform downhill: Platform uphill: Read the Access by trained...

  • Page 10: General Safety

    First Edition • First Printing Operator's Manual General Safety General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 11 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 12 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 13 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 14 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 15 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 16 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...
  • Page 17 First Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. -80 J •...

  • Page 18: Personal Safety

    First Edition • First Printing Operator's Manual Personal Safety Personal 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. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 19: Work Area Safety

    First Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. Keep away from the machine if it contacts Electrocution Hazards...
  • Page 20 First Edition • First Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds with the boom unless the machine platform uphill: is on a firm, level surface. Lower the boom. Retract the boom. If the tilt alarm sounds with the platform downhill: Retract the boom.
  • Page 21 First Edition • First Printing Operator's Manual Work Area Safety Use extreme care and Do not alter or disable machine components that slow speeds while driving in any way affect safety and stability. the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 22 First Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 23 First Edition • First 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 24 First Edition • First Printing Operator's Manual 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 25 First Edition • First 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 26 First Edition • First Printing Operator's Manual Work Area Safety Contact Alarm Safety Panel 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 panel cradles. Be sure the contact alarm is securely installed.
  • Page 27 First Edition • First Printing Operator's Manual Work Area Safety Welder Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the welding power unit. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not connect weld leads or cables unless the position.

  • Page 28: Legend

    First Edition • First Printing Operator's Manual Legend Legend Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. Non-steer tire Swing gate Steer tire...

  • Page 29: Controls

    First Edition • First Printing Operator's Manual Controls Controls Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. The ground control station is to be used as a means to raise the platform for storage purposes and for function tests.
  • Page 30 First Edition • First Printing Operator's Manual Controls Ground Control Panel LCD readout screen Function enable button Screen displays hour meter, voltage, oil 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 31 First Edition • First Printing Operator's Manual 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 32 First Edition • First Printing Operator's Manual Controls Platform Control Panel -80 J • S ™ ® ® -80 J TraX Part No. 1306265GT...
  • Page 33 First Edition • First Printing Operator's Manual Controls -80 J • S ™ ® ® Part No. 1306265GT -80 J TraX...
  • Page 34 First Edition • First Printing Operator's Manual Controls Platform Control Panel Fault indicator light Horn button Light on indicates a system fault. Platform overload indicator light Press this button and the horn will sound. Release the button and the horn will stop. Light flashing indicates the platform is Platform level switch overloaded.
  • Page 35 First Edition • First Printing Operator's Manual Controls 13 Dual axis proportional control handle for drive 15 Drive enable switch and steer functions. To drive when the drive enable light is flashing, hold the drive enable switch to either Proportional control handle for drive function side and slowly move the drive control handle and thumb rocker for steer function.
  • Page 36 First Edition • First Printing Operator's Manual Controls 22 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. 23 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions Move the control handle up and...

  • Page 37: Inspections

    First Edition • First Printing Operator's Manual Inspections Inspections Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a...
  • Page 38 First Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Tires and wheels  Engine and related components  Verify the operator’s manual, safety manual,  Limit switches and horn responsibilities manual and any necessary supplements are complete, legible and in the ...
  • Page 39 First Edition • First Printing Operator's Manual 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 40 First Edition • First 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 41 First Edition • First Printing Operator's Manual 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 42 First Edition • First 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 43 First Edition • First Printing Operator's Manual 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 5° above horizontal.
  • Page 44 First Edition • First Printing Operator's Manual Inspections Test Drive Tilt Cutout 56 Press down the foot switch. 46 Press down the foot switch. 57 With the boom fully stowed, drive the machine onto a slope where the roll angle is greater 47 With the boom fully stowed, drive the machine than 4.5°...
  • Page 45 First Edition • First Printing Operator's Manual Inspections Test the Lift/Drive Select Function (if Test the Contact Alarm (if equipped) equipped) 69 Do not activate the foot switch and press on the contact alarm cable to release the actuator 66 Start the engine. from the switch socket.
  • Page 46 First Edition • First Printing Operator's Manual Inspections Test Auxiliary Controls Test Aircraft Protection Package (if equipped) 76 Shut off the engine. Note: Two people may be required to perform this 77 Pull out the red Emergency Stop button to the test.
  • Page 47 First Edition • First Printing Operator's Manual 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 ...
  • Page 48 First Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Danger, Warning – Tip-over, Crush Determine whether the decals on your machine 218559 Hazard have words or symbols. Use the appropriate Label – Platform Overload inspection to verify that all decals are legible and 219487 in place.
  • Page 49 First Edition • First Printing Operator's Manual Inspections -80 J • S ™ ® ® Part No. 1306265GT -80 J TraX...
  • Page 50 97815 1296503 Label – Wheel Load, S-80 J Label – Tip-over Hazard, Tires 114249 1305331 Label – Boom, Genie S-80 J Blue Label – Explosion Hazard 114251 1305332 Label – Boom, Genie S-80 J Black Label – Tip-over Hazard, Limit 114252 1305444 Label –...
  • Page 51 First Edition • First Printing Operator's Manual Inspections -80 J • S ™ ® ® Part No. 1306265GT -80 J TraX...

  • Page 52: Operating Instructions

    First Edition • First Printing Operator's Manual Operating Instructions Operating Instructions Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation.
  • Page 53 First Edition • First Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop Push in the red Emergency Stop button to the off Diesel models position at the ground controls or the platform controls to stop all machine functions and turn the At the ground controls, turn the key switch to engine off.
  • Page 54 First Edition • First Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 55 First Edition • First Printing Operator's Manual Operating Instructions To Drive To determine the slope grade: Press down the foot switch. Measure the slope with a digital inclinometer OR use the following procedure. Increase speed: Slowly move the control handle off center. You will need: Decrease speed: Slowly move the control carpenter’s level...
  • Page 56 First Edition • First Printing Operator's Manual Operating Instructions Rotating turntable on slope Engine RPM Select Turntable rotate functions can be disabled when Select engine RPM using the symbols on the machine is on a slope greater than 10 degrees. control panel.
  • Page 57 First Edition • First Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light (if Platform Overload Indicator Light equipped) Light flashing indicates the platform is overloaded. The engine will stop Machine On Incline indicator light and no functions will operate. is on: The light is on and the tilt alarm sounds when the machine Remove weight from the platform...
  • Page 58 First Edition • First Printing Operator's Manual Operating Instructions Tilt Sensor Activation Conditions LCD Screen The LCD screen at the ground controls displays Model Chassis Angle hour meter, voltage, oil pressure and coolant S-80 J 4.5° temperature. The screen also displays fault codes S-80 J Trax and other service information.
  • Page 59 First Edition • First Printing Operator's Manual Operating Instructions Aircraft Protection Package (if equipped) Pipe Cradle Instructions If the platform bumpers come into contact with The pipe cradle assembly consists of 2 pipe aircraft components, the machine will shut down cradles positioned at either side of the platform and no functions will operate.
  • Page 60 First Edition • First Printing Operator's Manual 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 61 First Edition • First Printing Operator's Manual Operating Instructions If the panel cradle is installed at a platform Panel Cradle Assembly floor support tube, insert the U-bolt through the Apply the warning decal to the front of each floor, around the tube and into the panel cradle panel cradle (if needed).
  • Page 62 First Edition • First Printing Operator's Manual 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 63: Transport And Lifting Instructions

    First Edition • First Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. ...
  • Page 64 First Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 6 chains. time the machine is transported.
  • Page 65 First Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. 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 66: Maintenance

    First Edition • First Printing Operator's Manual Maintenance Maintenance Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life.
  • Page 67 First Edition • First Printing Operator's Manual 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 68 First Edition • First 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 69 First Edition • First Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, 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 and maintenance manuals for this machine.

  • Page 70: Specifications

    First Edition • First Printing Operator's Manual Specifications Specifications Ambient operating temperature -20° F to 120° F S-80 J Model -29° C to 49° C S-80 J Trax Controls 12V DC proportional Height, working maximum 86 ft 5 in 26.51 m AC outlet in platform Standard Height, platform maximum...
  • Page 71 First Edition • First Printing Operator's Manual Specifications Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-80 J TRAX, even if the picture does not show the tracks. Range of Motion Chart - S-80 J and S-80 J TRAX Maximum Platform Capacity 660 lbs...

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Genie s-80 j trax

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