Genie S 80, S 85 aerial work platform Operator's Manual

Operator’s Manual

with Maintenance Information

Third Edition

Second Printing

Part No. 82200

Operator's Manual Third Edition • Second Printing

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, call Genie Industries.

Contents

Page

Safety Rules .............................................................. 1

Controls ..................................................................... 7

Pre-operation Inspection ........................................... 10

Maintenance ............................................................. 12

Function Tests .......................................................... 16

Workplace Inspection ................................................ 22

Operating Instructions ............................................... 23

Transport and Lifting Instructions .............................. 27

Decals ...................................................................... 30

Specifications ........................................................... 32

Contact us:

Internet: http://www.genielift.com

e-mail: [email protected]

Copyright © 1994 by Genie Industries

First Edition: Fifth Printing, October 1996

Second Edition: Fifth Printing, July 2000

Third Edition: Second Printing, March 2002

"Genie" is a registered trademark of

Genie Industries in the U.S.A. and many other countries. "S" is a trademark of Genie Industries.

These machines comply with

ANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Genie S-80 & Genie S-85 Part No. 82200

Third Edition • Second Printing Operator's Manual

Safety Rules

Part No. 82200

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.

Know and understand the safety rules before going on to the next section.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

You read, understand and obey:

Manufacturer's instructions and safety rules—safety and operator's manuals and machine decals employer's safety rules and worksite regulations applicable governmental regulations

You are properly trained to safely operate the machine.

Genie S-80 & Genie S-85 1


SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and will

not provide protection from contact with or proximity to electrical current.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Voltage

Phase to Phase

Minimum Safe

Approach Distance

Feet Meters

0 to 300V

300V to 50KV

Avoid Contact

10 3.05

50KV to 200KV

200KV to 350KV

350KV to 500KV

500KV to 750KV

750KV to 1000KV

15

20

25

35

45

4.60

6.10

7.62

10.67

13.72

Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds.

Keep away from the machine if it contacts energized 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 and equipment shall not exceed the maximum platform capacity.

Maximum platform capacity

S - 8 5


S-80 with 8 Ft Platform


S-80 with 6 Ft Platform


S-80 with foam-filled tires and proper counterweight configuration

Maximum occupants

500 lbs

500 lbs

600 lbs

750 lbs

227 kg

227 kg

272 kg

340 kg

2

2 Genie S-80 & Genie S-85 Part No. 82200


SAFETY RULES

Do not raise or extend the boom unless both axles are extended.

Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended.

Do not push off or pull toward any object outside of the platform.

Maximum allowable side force-ANSI & CSA

150 lbs

667 N

Maximum allowable manual force - CE

90 lbs

400 N

Do not raise or extend the boom unless the machine is on a firm, level surface.

Do not depend on the tilt alarm as a level indicator.

The tilt alarm sounds in the platform only when the machine is on a severe slope.

If the tilt alarm sounds:

Do not extend, rotate or raise the boom above horizontal. Move the machine to a firm, level surface before raising the platform. If the tilt alarm sounds when the platform is raised, use extreme caution to retract the boom and lower the platform.

Do not rotate the boom while lowering. Move the machine to a firm, level surface before raising the platform.

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.

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 modify or alter an aerial work platform.

Mounting attachments for holding tools or other materials onto the platform, toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load.

Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

Part No. 82200 Genie S-80 & Genie S-85 3


SAFETY RULES

Do not place or attach overhanging loads to any part of this machine.

Fall Hazards

Occupants must wear a safety belt or harness in accordance with governmental regulations.

Attach the lanyard to the anchor provided in the platform.

Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

Do not place ladders or scaffolds in the platform or against any part of this machine.

Do not use the machine on a moving or mobile surface or vehicle.

Be sure all tires are in good condition, air-filled tires are properly inflated and lug nuts are properly tightened.

Models with 750 lb / 340 kg Capacity: Do not use air-filled tires. Models are equipped with foamfilled tires. The wheel weight and the proper counterweight configuration are critical for machine stability.

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.

Do not climb down from the platform when raised.

Keep the platform floor clear of debris.

Lower the platform entry mid-rail or close the entry gate before operating.

Bodily Injury Hazard

Do not operate the machine with a hydraulic oil or air leak. An air or hydraulic leak can penetrate and/or burn skin.

Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.



SAFETY RULES

Collision Hazards

Be aware of limited sight distance and blind spots when driving or operating.

Be aware of boom position and tailswing when rotating the turntable.

Check the work area for overhead obstructions or other possible hazards.

Do not lower the boom unless the area below is clear of personnel and obstructions.

Be aware of crushing hazards when grasping the platform guard rail.

It is recommended that operators wear an approved hard hat when operating the machine.

Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.

Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel and any other factors which may cause collision.

Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision.

No stunt driving or horseplay while operating a 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.

Be sure the hydraulic shutoff valves (located by the hydraulic tank) are open before starting the engine.



SAFETY RULES

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other explosive substances.

Do not refuel the machine with the engine running.

Refuel the machine and charge the battery only in an open, well-ventilated area away from sparks, flames and lighted tobacco.

Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine.

Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine.

Be sure all maintenance has been performed as specified in this manual and the

Genie S-80 &

Genie S-85 Service Manual.

Be sure all decals are legible and in place.

Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located on the platform.

Decal Legend

Genie product decals use symbols, color coding and signal words to identify the following:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Green—used to indicate operation or maintenance information.



Controls

Ground Control Panel

1 Platform rotate switch

2 Turntable rotate switch

3 Boom up/down switch

4 Boom extend/retract switch

5 Deutz Diesel models: Glow plug switch

Perkins models: Glow plug indicator light

Gasoline/LPG models: Gasoline/LPG select switch

6 Key switch for platform/off/ground selection

7 Auxiliary power switch

8 Gasoline/LPG models: Water temperature gauge (if equipped)

Deutz Diesel models: Oil temperature gauge

(if equipped)

Part No. 82200 Genie S-80 & Genie S-85

9 Oil pressure gauge (if equipped)

10 Voltage gauge (if equipped)

11 Red Emergency Stop button

12 Hour meter

13 Check engine light (if not equipped with gauges)

14 Function enable switch

15 Engine start switch

16 15A breaker for engine electrical circuits

17 20A breaker for oil cooler and options

18 15A breaker for control electrical circuits

19 S-85 only: Jib boom up/down switch

20 Platform level switch

7

Operator's Manual

CONTROLS

1

Third Edition • Second Printing

2 3 4 5 6

19

18

17 16

Platform Control Panel

1 Horn button

2 Platform level switch

3 Platform rotate switch

4 S-85 only: Jib boom up/down switch

5 Auxiliary power switch

6 Drive speed select switch

8

7 Deutz Diesel models:Glow plug switch

Perkins models: Glow plug indicator light

8 Engine start switch

9 Engine idle (rpm) select switch

· Rabbit & Foot Switch: foot switch activated high idle

· Turtle: low idle

· Rabbit: high idle

Genie S-80 & Genie S-85 Part No. 82200


7

8 9 10

Operator's Manual

C O N T R O L S

11

15

14 13

13

12

10 Gasoline/LPG models: Gasoline/LPG select switch

11 Red Emergency Stop button

12 Proportional control handle for drive function and thumb rocker for steer function

13 Optional equipment

14 Drive enable indicator light

15 Drive enable switch

16 Proportional control handle for boom extend/retract

17 Axle indicator light

18 Axle extend/retract switch

19 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions


Operator's Manual

Pre-operation Inspection




1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

Know and understand the pre-operation inspection before going on to the next section.




Fundamentals

It is the responsibility of the operator to perform a

Pre-operation Inspection and routine maintenance.

The Pre-operation Inspection is a visual inspection performed by the operator prior to each work shift.

The inspection 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 and locations for modifications, damage or loose or missing parts.

A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. After repairs are completed, the operator must perform a pre-operation inspection again before going on to the function tests.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.



PRE-OPERATION INSPECTION

Pre-operation Inspection

o

Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform.

o

Be sure that all decals are legible and in place.

See Decals section.

o

Check for engine oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

o

Check for hydraulic oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

o

Check for engine coolant leaks and proper level of coolant. Add coolant if needed. See

Maintenance section.

o

Check for battery fluid leaks and proper fluid level. Add distilled water if needed. See

Maintenance section.

o

Check for proper tire pressure. Add air if needed.

See Maintenance section.

Check the following components or areas for damage and improperly installed, loose or missing parts: o

Electrical components, wiring and electrical cables o

Hydraulic hoses, fittings, cylinders and manifolds o

Fuel and hydraulic tanks o

Drive and turntable motors and drive hubs o

Boom wear pads o

Axle wear pads o

Tires and wheels o

Engine and related components o

Limit switches and horn o

Alarms and beacons (if equipped) o

Nuts, bolts and other fasteners o

Platform entry mid-rail or gate

Check entire machine for: o

Crack in welds or structural components o

Dents or damage to machine o

Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened.

o

After you complete your inspection, be sure that all compartment covers are in place and latched.


Operator's Manual

Maintenance


Observe and Obey:

Only routine maintenance items specified in this manual shall be performed by the operator.

Scheduled maintenance inspections shall be completed by qualified service technicians, according to the manufacturer's specifications and the requirements specified in the responsibilities manual.

Maintenance Symbols Legend

The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

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 can damage engine components.

Check the oil level with the engine off.

1 Check the engine oil dipstick.

GM Models:

Result: The oil level should be within the

ADD

and

FULL

marks on the dipstick.

Deutz Models:

Result: The oil level should be within the two marks on the dipstick.

Perkins Models:

Result: The oil level should be within the two notches on the dipstick.

Gm 3.0L EFI Engine

Oil viscosity requirements

below 0° F / -17.8° C above 0° F / -17.8° C

5W-30

10W-30

Only use engine oils labeled "For Gasoline

Engines" by the American Petroleum Institute (API).

Units ship with 10W-30.

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.



MAINTENANCE

Deutz F4L 913 Engine

Engine oil viscosity requirements

below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C above -4°F / -34°C

10W-40

15W-40

Engine oil should have properties of API classification

CC/SE or CC/SF grades OR ACEA classification E1-96.

Perkins 704-30 Engine

Oil viscosity requirements

below 60°F / 15.5°C

-10°F to 90°F / -23°C to 32°C

15W-40

10W-30 above -4°F / -20°C 15W-40

Engine oil should have properties of API classification

CF4 grade. Units ship with 10-40 CC/SG.

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 problems.

1 Be sure that the boom is in the stowed position, then visually inspect the sight gauge located on the side of the hydraulic oil tank. Add oil as needed.

Result: The hydraulic oil level should be within the top 2 inches / 5 cm of the sight gauge.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent



MAINTENANCE

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 problems.

Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may cause severe burns.

1 Check the fluid level in the coolant recovery tank. Add fluid as needed.

Result: The fluid level should be at the

FULL

mark.

Do not remove the radiator cap.

Check the Batteries

Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions.

This procedure does not need to be performed on machines with sealed or maintenance-free batteries.

Electrocution hazard. Contact with hot or live circuits may result in death or serious injury. Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections are tight and free of corrosion.

3 Be sure that the battery hold-down bars are secure.

4 Remove the battery vent caps.

5 Check the battery acid level. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill.

6 Install the vent caps.

Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.



MAINTENANCE

Check the Tire Pressure

This procedure does not need to be performed on machines equipped with the foam-filled tire option.

Bodily injury hazard. An overinflated tire can explode and could cause death or serious injury.

Tip-over hazard. Do not use temporary flat tire repair products.

To safeguard maximum stability, achieve optimum machine handling and minimize tire wear, it is essential to maintain proper pressure in all air-filled tires.

1 Check each tire with an air pressure gauge. Add air as needed.

Tire Pressure

High Flotation Tire Pressure

100 psi

6.89 bar

60 psi

4.14 bar

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 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.


Operator's Manual

Function Tests






3 Always perform function tests prior to use.

Know and understand the function tests before going on to the next section.



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 only be made by a qualified service technician, according to the manufacturer's specifications.

After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service.

1 Select a test area that is firm, level and free of obstruction.

At the Ground Controls

2 Turn the key switch to ground control.

3 Pull out the red Emergency Stop button to the on position.

Result: The beacon (if equipped) should flash.

4 Start the engine. See Operating Instructions section.

Test Emergency Stop

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

Result: The engine should turn off and all functions should not operate.

6 Pull out both red Emergency Stop buttons to the on position and restart the engine.

Test the Extendable Axles

Note: Start this test with the axles retracted.

7 Hold the function enable switch to either side and activate the boom up function.

Result: The boom should raise to 5° above horizontal and then stop. The axle extend/ retract indicator light should be on. The boom should not raise above the limit switch unless both axles are extended.

8 Hold the function enable switch to either side and activate the boom down function.

Result: The boom should lower and return to the stowed position.



FUNCTION TESTS

9 Hold the function enable switch to either side and activate the boom extend function.

Result: The boom will extend approximately

1 foot / 30 cm and then stop. The axle extend/ retract indicator light should be on. The boom should not extend farther unless both axles are extended.

10 Hold the function enable switch to either side and activate the boom retract function.

Result: The boom should retract.

11 Turn the key switch to platform control. At the platform controls, move the drive control handle in the forward direction and activate the axle extend function.

Result: The machine should drive and the axles should extend.

Note: The steer function will override the axle extend or the axle retract function.

12 Return to the ground controls. Turn the key switch to ground control. At the ground controls, hold the function enable switch to either side and and activate the boom up and the boom down function.

Result: The boom should raise and lower normally.

13 At the ground controls, hold the function enable switch to either side and and activate the boom extend and the boom retract function.

Result: The boom should extend and retract normally.

Test the Machine Functions

17 Do not hold the function enable switch to either side. Attempt to activate each boom and platform function toggle switch.

Result: All boom and platform functions should not operate.

18 Hold the function enable switch to either side and activate each boom and platform function toggle switch.

Result: All boom and platform functions should operate through a full cycle. The descent alarm

(if equipped) should sound while the boom is lowering.

Machines equipped with Platform Level Control

Disable Function: The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches.

Test the Tilt Sensor

19 Turn the key switch to platform control.

20 Open the tank side turntable cover and locate the tilt sensor next to the control box.

21 Press down one side of the tilt sensor.

Result: The alarm, located in the platform, should sound.



FUNCTION TESTS

Test Auxiliary Controls

22 Turn the key switch to ground control and shut the engine off.

23 Pull out the ground red Emergency Stop button to the on position.

24 Simultaneously hold the auxiliary 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

25 Turn the key switch to platform control and restart the engine.

26 Push in the platform red Emergency Stop button to the off position.

Result: The engine should turn off and all functions should not operate.

27 Pull out the red Emergency Stop button and restart the engine.

Test the Hydraulic Oil Return Filters

28 Move the engine idle select switch to high idle

(rabbit symbol).

29 Locate and check the 2 hydraulic filter condition indicators.

Result: The filter should be operating with the plunger or the needle in the green area.

30 Move the engine idle select switch to foot switch activated high idle (rabbit and foot switch symbol).

Test the Horn

31 Push the horn button.

Result: The horn should sound.

Test the Foot Switch

32 Push in the platform red Emergency Stop button to the off position.

33 Pull out the red Emergency Stop button to the on position but do not start the engine.

34 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.

35 Do not press down the foot switch and restart engine.

36 Do not press down the foot switch and test each machine function.

Result: The machine functions should not operate.



FUNCTION TESTS

Test Machine Functions

37 Press down the foot switch.

38 Activate each machine function control handle or toggle switch.

Result: All boom/platform functions should operate through a full cycle.

Test the Steering


41 Press the thumb rocker switch on top of the drive control handle in the direction indicated by the blue triangle on the control panel OR slowly move the drive/steer control handle in the direction indicated by the blue triangle.

Result: The steer wheels should turn in the direction that the blue triangles point on the drive chassis.

42 Press the thumb rocker switch in the direction indicated by the yellow triangle on the control panel OR slowly move the drive/steer 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


44 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 arrow points on the drive chassis, then come to an abrupt stop.

45 Slowly move the drive control handle in the direction indicated by the yellow 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 yellow arrow points on the drive chassis, then come to an abrupt stop.

Note: The brakes must be able to hold the machine on any slope it is able to climb.



FUNCTION TESTS

Test the Oscillating Axle (if equipped)

46 Drive the right steer tire up onto a 6 inch / 15 cm curb or block.

Result: The three remainining tires should stay in firm contact with the ground.

Test the Drive Enable System

47 Press down the foot switch and lower the boom to the stowed position.

48 Rotate the turntable until the boom moves past one of the non-steer tires.

Result: The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown.

49 Move the drive control handle off center.

Result: The drive function should not operate.

50 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center.

Result: The drive function should operate.

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.

Blue

Yellow

Test Limited Drive Speed


52 Raise the boom to just above horizontal.

53 Slowly move the drive control handle to the full drive position.

Result: The maximum achievable drive speed with the boom raised should not exceed

1 foot / 30 cm per second.

54 Lower the boom to the stowed position.

55 Extend the boom 1 foot / 30 cm.

56 Slowly move the drive control handle to the full drive position.

Result: The maximum achievable drive speed with the boom extended should not exceed

1 foot / 30 cm per second.

If the drive speed with the boom raised or extended exceeds 1 foot / 30 cm per second, immediately tag and remove the machine from service.



Test Auxiliary Controls

57 Shut off the engine.

58 Pull out the platform red Emergency Stop button to the on position.


60 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch.

Note: To conserve battery power, test each function through a partial cycle.

Result: All boom and steer functions should operate. Drive functions should not operate with auxiliary power.

Test the Lift/Drive Select Function

(if equipped)


62 Move the drive control handle off center.

63 Activate each boom function toggle switch.

Result: No boom functions should operate. The machine will move in the direction indicated on the control panel.

Operator's Manual

FUNCTION TESTS


Operator's Manual

Workplace Inspection







4 Inspect the workplace.

Know and understand the workplace inspection before going on to the next section.


Fundamentals

The Workplace Inspection helps the 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

Be aware of and avoid the following hazardous situations:

· drop-offs or holes

· bumps, floor obstructions or debris

· overhead obstructions and high voltage conductors

· hazardous locations

· inadequate surface support to withstand all load forces imposed by the machine

· wind and weather conditions

· the presence of unauthorized personnel

· other possible unsafe conditions



Operating Instructions







5 Only use the machine as it was intended.

Fundamentals

The Operating Instructions section provides instructions for each aspect of machine operation.

It 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 and tools 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 machine at different times in the same work shift, they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator's, safety and responsibilities manuals. That means every new operator should perform a pre-operation inspection, function tests, and a workplace inspection before using the machine.

Starting the Engine

1 At the ground controls, turn the key switch to the desired position.

2 Pull out the ground control red Emergency Stop button to the on position.

Pull out the platform control red Emergency

Stop button to the on position if the platform control will be used.

3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position.

4 Move the engine start toggle switch to either side. If the engine fails to start or dies, the restart delay will disable the start switch for 3 seconds.

If engine fails to start after 15 seconds of cranking, determine the cause and repair any malfunction.

Wait 60 seconds before trying to start again.

In cold conditions, 20°F / -6°C and below, warm the engine for 5 minutes to prevent hydraulic system damage.

In extreme cold conditions, 0°F / -18°C and below, machines should be equipped with optional cold start kits. Attempting to start the engine when temperatures are below 0°F / -18°C may require the use of a booster battery.

Gasoline/LPG models: In cold conditions, 20°F /

-6°C and below, the machine should be started on gasoline and warmed for 2 minutes, then switched to LPG. Warm engines can be started on LPG.



OPERATING INSTRUCTIONS

Emergency Stop

Push in either ground or platform red Emergency

Stop button to the off position to stop all functions and turn the engine off.

Repair any function that operates when the red

Emergency Stop button is pushed in.

Selecting and operating the ground controls will override the platform red Emergency Stop button.

Auxiliary Controls

Use auxiliary power if the primary power source

(engine) fails.

1 Turn the key switch to ground or platform control.


3 Press down the foot switch when operating the auxiliary controls from the platform.

4 Simultaneously hold the auxiliary power switch on and activate the desired function.

The drive function will not operate with auxiliary power.

Operation from Ground

1 Turn the key switch to ground control.



4 Start the engine.

To Position Platform

1 Extend the axles.

2 Hold the function enable switch to either side.

3 Move the appropriate toggle switch according to the markings on the control panel.

Drive and steer functions are not available from the ground controls.

Machines equipped with Platform Level Control

Disable Function: The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches.




Operation from Platform

1 Turn the key switch to platform control.

2 Pull out both ground and platform red

Emergency Stop buttons to the on position.


4 Start the engine. Do not press down the foot switch when starting the engine.

To Position Platform

1 Extend the axles.


3 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel.

To Steer


2 Slowly move the drive/steer 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 identify the direction the wheels will turn.

To Drive


2 Increase speed: Slowly move the drive control handle off center.

Decrease speed: Slowly move the drive control handle toward center.

Stop: Return the drive control handle to center or release the foot 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 the boom is raised or extended.

Drive Enable

Light on indicates that the boom has moved just past either non-steer wheel and the drive function has been interrupted.

To drive, hold the drive enable switch to either side and slowly move the drive control handle off center.

If the drive control handle is not moved within two seconds of holding the drive enable switch, the drive function will not operate. Release and hold the drive enable switch again.

Be aware that the machine may move in the opposite direction that the drive and steer controls are moved.

Always use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel.




Generator

To operate the generator, move the generator toggle switch to the generator position. The engine will continue to run but no drive or platform functions will operate.

Plug a power tool into the power to platform GFCI outlet.

To resume machine functions, move the generator toggle switch to the machine functions position. All functions will operate.

Axle Indicator Light

Axle indicator light on: Extend the axles or return the machine to the fully stowed position.

Engine Idle Select (rpm)

Select engine idle (rpm) using the symbols on the control panel.

· Rabbit and foot switch symbol: foot switch activated high idle

· Turtle symbol: low idle

· Rabbit symbol: high idle

Check Engine Light

(if equipped)

Light on and engine stopped: Tag the machine and remove from service.

Light on and engine still running: Contact service personnel within 24 hours.

Stopping the Engine

Push in the red Emergency Stop button and turn the key switch to the off position.

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 non-steer wheels.

4 Turn the key switch to the off position and remove the key to secure from unauthorized use.

5 Chock the wheels.



Transport and Lifting Instructions


The transport vehicle must be parked on a level surface.

The transport vehicle must be secured to prevent rolling while the machine is being loaded.

Be sure the vehicle capacity, loading surfaces and chains or straps are sufficient to withstand the machine weight. See serial plate.

Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.

Free-wheel Configuration for

Winching

Chock the wheels to prevent the machine from rolling.

2WD models: Release the non-steer wheel brakes by turning over the drive hub disconnect caps.

4WD models: Release the wheel brakes by turning over all four drive hub disconnect caps.

Disengage

Engage

Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions.

Reverse the procedures described to re-engage the brakes.

Note: The pump free-wheel valve should always remain closed.



TRANSPORT AND LIFTING INSTRUCTIONS

Securing to Truck or Trailer for

Transit

Always use the turntable rotation lock pin each time the machine is transported.

Turn the key switch to the off position and remove the key before transporting.

Inspect the entire machine for loose or unsecured items.

Securing the Chassis

Use chains of ample load capacity.

Use a minimum of 5 chains.

Adjust the rigging to prevent damage to the chains.

Securing the Platform - S-80

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 use excessive downward force when securing the boom section.

Securing the Platform - S-85

Place a block under the jib knuckle. Do not allow the block to contact the platform cylinder.

Secure the platform with a nylon strap placed over the jib knuckle. Do not use excessive downward force when securing the boom section.

Fully raise the jib for transport.




Only qualified riggers should rig and lift the machine.

Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight. See serial plate.

TRANSPORT AND LIFTING INSTRUCTIONS

Lifting Instructions

Fully lower and retract the boom. Move the jib boom parallel with the ground. 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. There are two lifting points on the chassis and two on the turntable.

Adjust the rigging to prevent damage to the machine and to keep the machine level.

S - 8 0

S - 8 5

X Axis

5.64 ft

1.72 m

5.67 ft

1.73 m

Y Axis

4.69 ft

1.43 m

4.53 ft

1.38 m

Part No. 82200

Chassis

Lifting

Points (2)

Genie S-80 & Genie S-85

X Axis

Turntable

Lifting

Points (2)

Y Axis

29

Operator's Manual

Decals


Decal Inspection

Use the pictures on the next page to verify that all decals are legible and in place.

Below is a numerical list with quantities and descriptions.

Part No. Decal Description Quantity

28157

28158

28159

28160

28161

28163

28164

28165

25994

27204

27205

27206

27207

27564

Caution - Component Damage Hazard

Arrow - Blue

Arrow - Yellow

Triangle- Blue

Triangle - Yellow

Danger - Electrocution Hazard

Label - Dexron

Label - Unleaded

Label - Diesel

Label - Liquid Petroleum Gas

Warning - Crushing Hazard

Notice - Max Side Force - 150 lbs/667N 1

Notice - Hazardous Materials 1

Notice - Foot Switch 1

2

1

1

2

9

2

2

3

1

1

1

28171

28174

28175

28176

28177

28181

28235

28236

Label - No Smoking

Label - Power to Platform, 230V

Caution - Compartment Access

Notice - Missing Manuals

Warning - Platform Rotate

Warning - No Step or Ride

Label - Power to Platform, 115V

Warning - Failure To Read . . .

30080* Notice - Maximum Load 500 lbs/227 kg 1

31060 Danger - Tip-over Hazard, Interlock 2

32700

32728

32932

Danger - Safety Rules

Label - Generator (option)

Danger - Tip Over- Axles 2

2

1

1

2

1

1

1

2

2

2

Part No.

Decal Description Quantity

82194

82195

82202

82203

82204

82207

82242

82253

82264

82265

62920

62921

62922

62923

72168

72169


32999 Notice - Tire Pressure 4

33952

40434

Danger - Tilt-Alarm

Label - Lanyard Anchorage

1

3


43595 Danger - Tip-over, Tires 1

43663 Notice - Function Enable 1

44981

44986

52967

Airline to Platform

Cosmetic - 4 x 4

2

Notice - Max Manual Force - 90 lbs/400N 1

1

Cosmetic - Genie S-80

Cosmetic - S-80

Cosmetic - Genie S-85

Cosmetic - S-85

Notice - Starter Battery

Notice - Controls Battery

Platform Control Panel

Ground Control Panel

Notice - Perkins Engine Specifications

Notice - GM Engine Specifications

Notice - Deutz Engine Specifications

Notice - Operating Instructions

Label - Gasoline/LPG Select

Notice - High Floatation Tire Specs

Warning - Welding Safety/Inst

Label - Welder On/Off

2

1

4

1

1

1

1

1

1

1

2

1

1

1

2

1

*Please reference the Specifications section or the chart on page 2 to determine the capacity of your machine.



DECALS

Drive

Chassis

Platform

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

Ground

Controls

Side

Engine

Side


Operator's Manual

Specifications


Model

Height, working maximum 86 ft

80 ft Height, platform maximum

Height, stowed maximum 9 ft 2 in

Horizontal reach maximum 71 ft 11 in

Width, axles retracted

Length, stowed

Maximum load capacity

6 foot platform

8 ft

36 ft 8 in

600 lb


8 foot platform

500 lb

Maximum load capacity 750 lb with foam-filled tires and proper counterweight configuration

9 ft 0 in Wheelbase

Turning radius (outside)

Turning radius (inside)

23 ft 1 in

10 ft 7

1

/

2

in

Turntable tailswing

Turntable rotation (degrees)

Power source

227 kg

340 kg

2.7 m

7.0 m

3 ft 9 in

3.2 m

1.14 cm continuous

GM 3.0L Gas/LPG or Deutz F4L 913 or Perkins 704-30

Drive speeds

Drive speed, stowed

Drive speed, raised or extended

- all models

4.0 mph 6.4 km/h

40 ft/6.8 sec

12.2 m/6.8 sec

0.68 mph 1.1 km/h

40 ft/40 sec

12.2 m/40 sec

S - 8 0

26.2 m

24.4 m

2.79 m

21.9 m

2.44 m

11.2 m

272 kg

Controls

Platform dimensions,

6 foot (length x width)

Platform dimensions,

8 foot (length x width)

12V DC proportional

72 in x 30 in 1.8 m x 76 cm

96 in x 36 in 2.4 m x 91 cm

Platform leveling

Platform rotation

AC outlet in platform

Hydraulic pressure

(maximum, boom functions)

Tire size

High floatation tire size

3000 psi self-leveling

160° standard

207 bar

15-22.5 SAT

41/18LL x 22.5, 14 ply

Gradeability, stowed

Ground clearance

45 %

28 cm 11 in

Fuel tank capacity 33 gallons 150 liters

Weight See Serial Plate

(Machine weights vary with option configurations)

Airborne noise emissions 80 dB

Maximum sound level at normal operating workstations

(A-weighted)

Floor Loading Information

GVW+Rated Load 34,750 lbs

28,600 lbs

15,762 kg

12,973 kg Axle load, maximum

Wheel load, maximum

Localized pressure per tire

16,400 lbs 7,439 kg

100 psi 7.03 kg/cm

2

689 kPa

Occupied pressure 285 psf 13.6 kPa

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice or obligation.

Note: Floor loading information is approximate and does not incorporate different option configurations.

It should be used only with adequate safety factors.



SPECIFICATIONS

Model

Height, working maximum 91 ft

85 ft Height, platform maximum

Height, stowed maximum 9 ft 2 in

Horizontal reach maximum 76 ft 11 in

Width 7 ft 11

1

/

2

in

Length, stowed


6 foot platform


8 foot platform

40 ft 7 in

500 lb

500 lb 227 kg

Wheelbase

Turning radius (outside)

Turning radius (inside)

Turntable tailswing

Turntable rotation (degrees)

Power source

9 ft 0 in

23 ft 1 in

10 ft 7

1

/

2

in

3 ft 8

1

/

2

in

2.7 m

7.0 m

3.2 m

113.0 cm continuous

GM 3.0L Gas/LPG or Deutz F4L 913 or Perkins 704-30

Drive speeds

Drive speed, stowed

Drive speed, raised or extended

- all models

S - 8 5

27.7 m

25.9 m

2.79 m

23.4 m

2.43 m

12.4 m

227 kg

4.0 mph 6.4 km/h

40 ft/6.8 sec

12.2 m/6.8 sec

0.68 mph 1.1 km/h

40 ft/40 sec

12.2 m/40 sec

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice or obligation.

Controls

Platform dimensions, 6 foot

(length x width)

Platform dimensions, 8 foot

(length x width)

12V DC proportional

72 in x 30 in

1.8 m x 76 cm

96 in x 36 in

2.4 m x 91 cm

Platform leveling

Platform rotation

AC outlet in platform

Hydraulic pressure (maximum)

(boom functions)

Tire size

High floatation tire size self-leveling

160° standard

3000 psi

207 bar

15-22.5 SAT

41/18LL x 22.5, 14 ply

Gradeability, stowed

Ground clearance

38 %

28 cm 11 in

Fuel tank capacity 30 gallons 114 liters

Weight See Serial Plate

(Machine weights vary with option configurations)

Airborne noise emissions 80 dB

Maximum sound level at normal operating workstations

(A-weighted)

Floor Loading Information

GVW+Rated Load 37,100 lbs

31,200 lbs

6473 kg

3447 kg Axle load, maximum

Wheel load, maximum

Localized pressure per tire

18,000 lbs 1724 kg

100 psi 7.03 kg/cm

2

689 kPa

Occupied pressure 294 psf 14.07 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations.

It should be used only with adequate safety factors.


80 ft

24.4 m

60 ft

18.3 m

40 ft

12.2 m

20 ft

6.1 m

0 ft

0 m

20 ft

6.1 m

Operator's Manual

SPECIFICATIONS

S-80 Range of Motion Chart


0 ft

0 m

10 ft

3.0 m

30 ft

9.1 m

50 ft

15.2 m

70 ft

21.3 m

S-85 Range of Motion Chart

80 ft

24.4 m

60 ft

18.3 m

40 ft

12.2 m

20 ft

6.1 m

0 ft

0 m

20 ft

6.1 m

0 ft

0 m

10 ft

3.0 m

30 ft

9.1 m

50 ft

15.2 m

70 ft

21.3 m


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.

Genie Holland

Phone +

31 70 51 78836

Fax +

31 70 51 13993

Genie Scandinavia

Phone +

46 31 3409612

Fax +

46 31 3409613

Genie France

Phone +

Fax +

33 (0)2 37 26 09 99

33 (0)2 37 26 09 98

Genie Iberica

Phone +

34 93 579 5042

Fax +

34 93 579 5059

Genie Germany

Phone +

49 (0)4202 88520

Fax +

49 (0)4202 8852-20

Genie U.K.

Phone +

Fax +

44 (0)1476 584333

44 (0)1476 584334

Genie Mexico City

Phone +

52 5 653 03 84

Fax +

52 5 664 40 16

Genie North America

Phone

425.881.1800

Toll Free

Fax

USA and Canada

800.536.1800

425.883.3475

Genie Australia Pty Ltd.

Phone +

Fax +

61 7 3375 1660

61 7 3375 1002

Genie China

Phone +

86 21 53852570

Fax +

86 21 53852569

Genie Malaysia

Phone +

Fax +

60 4 228 1235

60 4 226 6872

Genie Japan

Phone +

81 3 3453 6082

Fax +

81 3 3453 6083

Genie Korea

Phone +

82 2 558 7267

Fax +

82 2 558 3910

Genie Africa

Phone +

Fax +

27 11 455 0373

27 11 455 0355

Genie Latin America

Phone +

55 11 4055 2499

Fax +

55 11 4043 1661

Genie S 80, S 85 aerial work platform Operator's Manual

Assistant Bot

Operator’s Manual

with Maintenance Information

Important

Contents

Contact us:

Safety Rules

Danger

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

Do Not Operate Unless:

Electrocution Hazards

Tip-over Hazards

Fall Hazards

Bodily Injury Hazard

Collision Hazards

Component Damage Hazards

Explosion and Fire Hazards

Damaged Machine Hazards

Decal Legend

Controls

Pre-operation Inspection

Do Not Operate Unless:

Fundamentals

Pre-operation Inspection

Maintenance

Observe and Obey:

Check the Engine Oil Level

Check the Hydraulic Oil Level

Check the Engine Coolant

Level - Liquid Cooled Models

Check the Batteries

Check the Tire Pressure

Scheduled Maintenance

Function Tests

Do Not Operate Unless:

Fundamentals

At the Ground Controls

At the Platform Controls

Workplace Inspection

Do Not Operate Unless:

Fundamentals

Workplace Inspection

Operating Instructions

Do Not Operate Unless:

Fundamentals

Starting the Engine

Emergency Stop

Auxiliary Controls

Operation from Ground

Operation from Platform

Axle Indicator Light

Engine Idle Select (rpm)

Check Engine Light

(if equipped)

Stopping the Engine

After Each Use

Transport and Lifting Instructions

Observe and Obey:

Free-wheel Configuration for

Winching

Securing to Truck or Trailer for

Transit

Observe and Obey:

Lifting Instructions

Decals

Decal Inspection

Drive

Chassis

Platform

Ground

Controls

Side

Engine

Side

Specifications

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.

Key Features