Genie S 80, S 85 aerial work platform Operator's Manual
Below you will find brief information for aerial work platform S 80, aerial work platform S 85. The Genie S-80 and S-85 are aerial work platforms designed to lift personnel and tools to an aerial work site. These models provide a stable working platform with a variety of functions to meet your needs. The S-85 model provides a 30-foot working height, while the S-80 offers a 25-foot working height. Both models feature a tilt alarm, platform level control, and hydraulic oil return filters.
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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
Operator's Manual Third Edition • Second Printing
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
Maximum platform capacity
S-80 with 8 Ft Platform
Maximum platform capacity
S-80 with 6 Ft Platform
Maximum platform capacity
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
Third Edition • Second Printing Operator's Manual
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
Operator's Manual Third Edition • Second Printing
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.
4 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
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.
Part No. 82200 Genie S-80 & Genie S-85 5
Operator's Manual Third Edition • Second Printing
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.
6 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
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
Third Edition • Second Printing
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
Part No. 82200 Genie S-80 & Genie S-85 9
Operator's Manual
Pre-operation Inspection
Third Edition • Second Printing
Do Not Operate Unless:
You learn and practice the principles of safe machine operation contained in this operator's manual.
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.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
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.
10 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's 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.
Part No. 82200 Genie S-80 & Genie S-85 11
Operator's Manual
Maintenance
Third Edition • Second Printing
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.
12 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
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
Part No. 82200 Genie S-80 & Genie S-85 13
Operator's Manual Third Edition • Second Printing
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.
14 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
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.
Part No. 82200 Genie S-80 & Genie S-85 15
Operator's Manual
Function Tests
Third Edition • Second Printing
Do Not Operate Unless:
You learn and practice the principles of safe machine operation contained in this operator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
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.
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.
16 Genie S-80 & Genie S-85 Part No. 82200
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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.
Part No. 82200 Genie S-80 & Genie S-85 17
Operator's Manual Third Edition • Second Printing
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.
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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
40 Press down the foot switch.
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
43 Press down the foot switch.
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.
Part No. 82200 Genie S-80 & Genie S-85 19
Operator's Manual Third Edition • Second Printing
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
51 Press down the foot switch.
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.
20 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing
Test Auxiliary Controls
57 Shut off the engine.
58 Pull out the platform red Emergency Stop button to the on position.
59 Press down the foot switch.
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)
61 Press down the foot switch.
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
Part No. 82200 Genie S-80 & Genie S-85 21
Operator's Manual
Workplace Inspection
Third Edition • Second Printing
Do Not Operate Unless:
You learn and practice the principles of safe machine operation contained in this operator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
Know and understand the workplace inspection before going on to the next section.
5 Only use the machine as it was intended.
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
22 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
Operating Instructions
Do Not Operate Unless:
You learn and practice the principles of safe machine operation contained in this operator's manual.
1 Avoid hazardous situations.
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.
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.
Part No. 82200 Genie S-80 & Genie S-85 23
Operator's Manual Third Edition • Second Printing
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.
2 Pull out the red Emergency Stop button to the on position.
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.
2 Pull out the red Emergency Stop button to the on position.
3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position.
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.
24 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
OPERATING INSTRUCTIONS
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.
3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position.
4 Start the engine. Do not press down the foot switch when starting the engine.
To Position Platform
1 Extend the axles.
2 Press down the foot switch.
3 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel.
To Steer
1 Press down the foot switch.
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
1 Press down the foot switch.
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.
Part No. 82200 Genie S-80 & Genie S-85 25
Operator's Manual Third Edition • Second Printing
OPERATING INSTRUCTIONS
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.
26 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
Transport and Lifting Instructions
Observe and Obey:
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.
Part No. 82200 Genie S-80 & Genie S-85 27
Operator's Manual Third Edition • Second Printing
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.
28 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
Observe and Obey:
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
Third Edition • Second Printing
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
32998* Notice - Maximum Load 600 lbs/272 kg 1
32999 Notice - Tire Pressure 4
33952
40434
Danger - Tilt-Alarm
Label - Lanyard Anchorage
1
3
43594* Notice - Maximum Load 750 lbs/340 kg 1
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.
30 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
DECALS
Drive
Chassis
Platform
Shading indicates decal is hidden from view, i.e. under covers
Ground
Controls
Side
Engine
Side
Part No. 82200 Genie S-80 & Genie S-85 31
Operator's Manual
Specifications
Third Edition • Second Printing
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
Maximum load capacity
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.
32 Genie S-80 & Genie S-85 Part No. 82200
Third Edition • Second Printing Operator's Manual
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
Maximum load capacity
6 foot platform
Maximum load capacity
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.
Part No. 82200 Genie S-80 & Genie S-85 33
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
Third Edition • Second Printing
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
34 Genie S-80 & Genie S-85 Part No. 82200
California Proposition 65
WARNING
The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
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Phone
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Toll Free
Fax
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Key Features
- 30-foot/25-foot working height
- Tilt alarm
- Platform level control
- Hydraulic oil return filters
- Function enable switch
- Drive enable system
- Auxiliary power
- Limited drive speed
- Foot switch activated high idle