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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 ..................................................................... 8
Pre-operation Inspection ........................................... 11
Maintenance ............................................................. 13
Function Tests .......................................................... 17
Workplace Inspection ................................................ 23
Operating Instructions ............................................... 24
Transport and Lifting Instructions .............................. 29
Decals ...................................................................... 32
Specifications ........................................................... 36
Printed in U.S.A.
Safety Rules
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
SAFETY RULES
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maintain safe distances from electrical power lines
and apparatus in accordance with applicable Maximum platform capacity
governmental regulations and the following chart. S-85 500 lbs 227 kg
SAFETY RULES
Do not raise or extend the boom unless both axles Do not drive the machine on or near uneven terrain,
are extended. 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
Do not raise or extend the boom unless the 90 lbs
machine is on a firm, level surface. 400 N
SAFETY RULES
SAFETY RULES
Collision Hazards Do not lower the boom unless the area below is
clear of personnel and obstructions.
Be aware of limited sight
distance and blind spots
when driving or operating.
SAFETY RULES
Do not start the engine if you smell or detect liquid Improper contact with components under any cover
petroleum gas (LPG), gasoline, diesel fuel or other will cause serious injury. Only trained maintenance
explosive substances. personnel should access compartments. Access
by the operator is only advised when performing a
Do not refuel the machine with the engine running. pre-operation inspection. All compartments must
Refuel the machine and charge the battery only in remain closed and secured during operation.
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Battery Safety
Do not operate the machine in hazardous locations
or locations where potentially flammable or
Burn Hazards
explosive gases or particles may be present. Batteries contain acid. Always wear protective
clothing and eyewear when working with batteries.
Do not spray ether into engines equipped with glow
plugs. Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Damaged Machine Hazards
Explosion Hazard
Do not use a damaged or malfunctioning machine.
Keep sparks, flames and lighted tobacco away
Conduct a thorough pre-operation inspection of the from batteries. Batteries emit explosive gas.
machine and test all functions before each work
shift. Immediately tag and remove from service a Electrocution Hazard
damaged or malfunctioning machine.
Avoid contact with electrical terminals.
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.
SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Controls
1 2 3 4 5 6
20 19 18 17
CONTROLS
7 8 9 10 11
16 15 14 13 12
CONTROLS
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
PRE-OPERATION INSPECTION
Pre-operation Inspection
o Limit switches and horn
o Be sure that the operator’s, safety and
responsibilities manuals are complete, legible o Alarms and beacons (if equipped)
and in the storage container located in the
o Nuts, bolts and other fasteners
platform.
o Platform entry mid-rail or gate
o Be sure that all decals are legible and in place.
See Decals section. Check entire machine for:
o Check for engine oil leaks and proper oil level. o Cracks in welds or structural components
Add oil if needed. See Maintenance section.
o Dents or damage to machine
o Check for hydraulic oil leaks and proper oil level.
o Be sure that all structural and other critical
Add oil if needed. See Maintenance section.
components are present and all associated
o Check for engine coolant leaks and proper level fasteners and pins are in place and properly
of coolant. Add coolant if needed. See tightened.
Maintenance section.
o After you complete your inspection, be sure that
o Check for battery fluid leaks and proper fluid all compartment covers are in place and
level. Add distilled water if needed. See latched.
Maintenance section.
o Check for proper tire pressure. Add air if needed.
See Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
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
Maintenance
Only routine maintenance items specified in this Check the oil level with the
manual shall be performed by the operator. engine off.
Scheduled maintenance inspections shall be 1 Check the oil dipstick. Add oil as needed.
completed by qualified service technicians,
GM 3.0L EFI Engine
according to the manufacturer's specifications
and the requirements specified in the Oil type 10W-30
responsibilities manual.
Oil type - cold conditions 5W-30
MAINTENANCE
Check the Hydraulic Oil Level Check the Engine Coolant Level
- Liquid Cooled Models
MAINTENANCE
Check the Batteries 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,
Proper battery condition is essential to good engine replenish with distilled water to the bottom of the
performance and operational safety. Improper fluid battery fill tube. Do not overfill.
levels or damaged cables and connections can
result in engine component damage and hazardous 6 Install the vent caps.
conditions. Adding terminal protectors and a
This procedure does not need to corrosion preventative sealant will
be performed on machines with help eliminate corrosion on the
sealed or maintenance-free battery terminals and cables.
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.
The controls battery is behind the
starter battery.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
MAINTENANCE
Function Tests
1 Select a test area that is firm, level and free of
obstruction.
FUNCTION TESTS
9 Hold the function enable switch to either side Test the Machine Functions
and activate the boom extend function.
14 Do not hold the function enable switch to either
Result: The boom will extend approximately side. Attempt to activate each boom and
1 foot / 30 cm and then stop. The axle extend/ platform function toggle switch.
retract indicator light should be on. The boom
should not extend farther unless both axles are Result: All boom and platform functions should
extended. not operate.
10 Before serial number 3647: Hold the function 15 Hold the function enable switch to either side
enable switch to either side and activate the and activate each boom and platform function
boom down and boom retract function. toggle switch.
After serial number 3646: Hold the function Result: All boom and platform functions should
enable switch to either side and activate the operate through a full cycle. The descent alarm
boom retract function. (if equipped) should sound while the boom or jib
boom is lowering.
Result: The boom should retract.
Machines equipped with Platform Level Control
11 Turn the key switch to platform control. At the Disable Function: The platform level toggle switch
platform controls, move the drive control handle will not operate when the boom is raised or
in the forward direction and activate the axle extended past the drive speed limit switches.
extend function.
Test the Tilt Sensor
Result: The machine should drive and the axles
should extend. 16 Turn the key switch to platform control.
Note: The steer function will override the axle 17 Open the tank side turntable
extend or the axle retract function. cover and locate the tilt sensor
between the fuel tank and the
12 Return to the ground controls. Turn the key oil cooler.
switch to ground control. At the ground controls,
hold the function enable switch to either side 18 Press down one side of the tilt
and activate the boom up and the boom down sensor.
function. Result: The alarm, located in
Result: The boom should raise and lower the platform, should sound.
normally.
13 At the ground controls, hold the function enable
switch to either side and activate the boom
extend and the boom retract function.
Result: The boom should extend and retract
normally.
FUNCTION TESTS
20 Pull out the ground red Emergency Stop button 26 Locate and check the 2 hydraulic filter condition
to the on position. indicators.
21 Simultaneously hold the auxiliary Result: The filter should be operating with the
power switch on and activate each plunger or the needle in the green area.
boom function toggle switch.
27 Move the engine idle select switch to foot switch
Note: To conserve battery power, test each activated high idle (rabbit and foot switch
function through a partial cycle. symbol).
Result: All boom functions should operate. Test the Horn
FUNCTION TESTS
37 Press the thumb rocker switch on top of the 41 Slowly move the drive control handle in the
drive control handle in the direction indicated by direction indicated by the yellow arrow on the
the blue triangle on the control panel OR slowly control panel until the machine begins to move,
move the drive/steer control handle in the then return the handle to the center position.
direction indicated by the blue triangle. Result: The machine should move in the
Result: The steer wheels should turn in the direction that the yellow arrow points on the
direction that the blue triangles point on the drive chassis, then come to an abrupt stop.
drive chassis. Note: The brakes must be able to hold the machine
on any slope it is able to climb.
38 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.
FUNCTION TESTS
Test the Oscillating Axle (if equipped) Test Limited Drive Speed
42 Drive the right steer tire up onto a 6 inch / 15 cm 47 Press down the foot switch.
curb or block.
48 Raise the boom to just above horizontal.
Result: The three remainining tires should stay
in firm contact with the ground.
Test the Drive Enable System
43 Press down the foot switch and lower the boom
to the stowed position. 49 Slowly move the drive control handle to the full
44 Rotate the turntable until the boom moves past drive position.
one of the non-steer tires. Result: The maximum achievable drive speed
Result: The drive enable with the boom raised should not exceed
indicator light should 1 foot / 30 cm per second.
come on and remain on 50 Lower the boom to the stowed position.
while the boom is
anywhere in the range 51 Extend the boom 1 foot / 30 cm.
shown. 52 Slowly move the drive control handle to the full
45 Move the drive control handle off center. drive position.
Result: The drive function should not operate. Result: The maximum achievable drive speed
with the boom extended should not exceed
46 Move and hold the drive enable toggle switch to 1 foot / 30 cm per second.
either side and slowly move the drive control
handle off center. If the drive speed with the boom raised or extended
exceeds 1 foot / 30 cm per second, immediately
Result: The drive function should operate. tag and remove the machine from service.
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
Blue
arrows on the platform
controls and the drive
chassis to identify the
direction of travel.
Yellow
FUNCTION TESTS
Workplace Inspection
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
· drop-offs or holes
· bumps, floor obstructions or debris
Do Not Operate Unless: · sloped surfaces
You learn and practice the principles of safe · unstable or slippery surfaces
machine operation contained in this operator's
manual. · overhead obstructions and high voltage
conductors
1 Avoid hazardous situations.
· hazardous locations
2 Always perform a pre-operation
inspection. · inadequate surface support to withstand all load
forces imposed by the machine
3 Always perform function tests prior to use.
· wind and weather conditions
4 Inspect the workplace.
· the presence of unauthorized personnel
Know and understand the workplace
inspection before going on to the next · other possible unsafe conditions
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.
Operating Instructions
The Operating Instructions section provides 4 Move the engine start toggle switch to either
instructions for each aspect of machine operation. side. If the engine fails to start or dies, the
It is the operator's responsibility to follow all the restart delay will disable the start switch for 3
safety rules and instructions in the operator's, seconds.
safety and responsibilities manuals. All models
Using the machine for anything other than lifting If engine fails to start after 15 seconds of cranking,
personnel, along with their tools and materials, to determine the cause and repair any malfunction.
an aerial work site is unsafe and dangerous. Wait 60 seconds before trying to start again.
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.
OPERATING INSTRUCTIONS
In cold conditions, 20°F / -6°C and below, warm the Extend the Axles
engine for 5 minutes to prevent hydraulic system
damage. 1 Turn the key switch to platform control.
In extreme cold conditions, 0°F / -18°C and below, 2 Move the drive control handle in the forward
machines should be equipped with optional cold direction and activate the axle extend function.
start kits. Attempting to start the engine when
3 The machine will drive and the axles will
temperatures are below 0°F / -18°C may require the
extend.
use of a booster battery.
Gasoline/LPG models: In cold conditions, 20°F / Operation from Ground
-6°C and below, the machine should be started on
1 Turn the key switch to ground control.
gasoline and warmed for 2 minutes, then switched
to LPG. Warm engines can be started on LPG. 2 Pull out the red Emergency Stop button to
the on position.
Emergency Stop
3 Gasoline/LPG models: Choose fuel by moving
Push in either ground or platform red Emergency the fuel select switch to the desired position.
Stop button to the off position to stop all functions 4 Start the engine.
and turn the engine off.
To Position Platform
Repair any function that operates when the red
Emergency Stop button is pushed in. 1 Extend the axles.
Selecting and operating the ground controls will 2 Hold the function enable switch to
override the platform red Emergency Stop button. either side.
3 Move the appropriate toggle switch according to
Auxiliary Controls the markings on the control panel.
Use auxiliary power if the primary Drive and steer functions are not available from the
power source (engine) fails. ground controls.
1 Turn the key switch to ground or platform Machines equipped with Platform Level Control
control. Disable Function: The platform level toggle switch
will not operate when the boom is raised or
2 Pull out the red Emergency Stop button to the
extended past the drive speed limit switches.
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.
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
Select engine idle (rpm) using the symbols on the Light on and engine still running:
control panel. Contact service personnel within 24
hours.
OPERATING INSTRUCTIONS
Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Lifting Instructions
Fully lower and retract the boom. Move the jib
boom parallel with the ground. Remove all loose
items on the machine.
X Axis Y Axis
Turntable
Lifting
Points (2)
Chassis Y Axis
Lifting
Points (2)
X Axis
Decals
Part No. Decal Description Quantity Part No. Decal Description Quantity
DECALS
Ground
Controls
Side
Drive
Chassis
Platform
Shading indicates
decal is hidden from
view, i.e. under
covers
Engine
Side
DECALS
Part No. Decal Description Quantity Part No. Decal Description Quantity
DECALS
Ground
Controls
Side
Drive
Chassis
Platform
Shading indicates
decal is hidden from
view, i.e. under
covers
Engine
Side
Specifications
SPECIFICATIONS
SPECIFICATIONS
80 ft 80 ft
24.4 m 24.4 m
60 ft 60 ft
18.3 m 18.3 m
40 ft 40 ft
12.2 m 12.2 m
20 ft 20 ft
6.1 m 6.1 m
0 ft 0 ft
0m 0m
20 ft 20 ft
6.1 m 6.1 m
0 ft 10 ft 30 ft 50 ft 70 ft 0 ft 10 ft 30 ft 50 ft 70 ft
0m 3.0 m 9.1 m 15.2 m 21.3 m 0m 3.0 m 9.1 m 15.2 m 21.3 m
WARNING
The exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.