Genie S-85, 43650, S-80 User Manual

Operator’s Manual

with Maintenance Information

Second Edition

Fifth Printing

Part No. 43650

Operator's Manual Second Edition· Fifth 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

Work Place Inspection .............................................. 22

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

Transport Instructions ............................................... 27

Decals ...................................................................... 28

Specifications ........................................................... 30

Internet: http://www.genielift.com e-mail: techpub@genieind.com

First Edition: First Printing, August 1994

Second Printing, February 1995 Third Printing, March 1996 Fourth Printing, September 1996 Fifth Printing, October 1996

Second Edition: First Printing, November 1996

Second Printing, March 1997 Third Printing, March 1998 Fourth Printing, August 1999 Fifth Printing, July 2000

"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. 43650

Operator's ManualSecond Edition · Fifth Printing

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:

You learn and practice the principles of safe

machine operation contained in this operator's manual.

1 Avoid hazardous situations. Know and understand the above principle

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 work place. 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.

Part No. 43650 Genie S-80 & Genie S-85 1

Operator's Manual Second Edition· Fifth 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 Minimum Safe Phase to Phase Approach Distance Feet Me ter s

0 to 300V Avoid Contact

300V to 50KV 10 3.05

50KV to 200KV 15 4.60

200KV to 350KV 20 6.10

350KV to 500KV 25 7.62

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-85 500 lbs 227 kg

Maximum platform capacity S-80 with 8 Ft Platform 500 lbs 227 kg

Maximum platform capacity S-80 with 6 Ft Platform 600 lbs 272 kg

Maximum platform capacity S-80 with 6 Ft Platform with foam-filled tires and proper counterweight configuration 750 lbs 340 kg

Maximum occupants 2

500KV to 750KV 35 10.67

750KV to 1000KV 45 13.72

2 Genie S-80 & Genie S-85 Part No. 43650

Operator's ManualSecond Edition · Fifth Printing

SAFETY RULES

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

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

Do not depend on tilt alarm as a level indicator. Tilt alarm sounds in platform only when machine is on a severe slope.

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

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 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.

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.

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

Part No. 43650 Genie S-80 & Genie S-85 3

Operator's Manual Second Edition· Fifth Printing

SAFETY RULES

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

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

Do not use 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.

Fall Hazards

Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach lanyard to anchor provided in 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 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.

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.

4 Genie S-80 & Genie S-85 Part No. 43650

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

Operator's ManualSecond Edition · Fifth Printing

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 turntable.

Check work area for overhead obstructions or other possible hazards.

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

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

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

Limit travel speed according to condition of 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

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

Part No. 43650 Genie S-80 & Genie S-85 5

Do not use any battery or charger greater than 12V to jump-start the engine.

Do not use machine as a ground for welding.

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

Operator's Manual Second Edition· Fifth Printing

SAFETY RULES

Explosion and Fire Hazards

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

Do not refuel machine with engine running.

Refuel machine and charge 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-85 Service Manual.

Be sure all decals are in place and legible.

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

Genie S-80 &

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 presense 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. 43650

Operator's ManualSecond Edition · Fifth Printing

Controls

8 9 10

Ground Control Panel

1 Platform rotate switch 2 Turntable rotate switch 3 Boom up/down switch 4 Boom extend/retract switch 5 not used 6 Key switch for platform/off/ground selection 7 Auxiliary power switch 8 Gasoline/LPG models: Water temperature

gauge

Deutz Diesel models: Oil temperature gauge 9 Oil pressure gauge 10 Voltage gauge

1618

15171920

11 Emergency Stop button 12 Hour meter 13 Gasoline/LPG models: Check engine light

Deutz Diesel models: Glow plug switch

(option) 14 Function enable switch 15 Engine start switch 16 15A breaker for engine electrical circuits 17 Gasoline/LPG select switch 18 15A breaker for control electrical circuits 19 S-85 only: Jib boom up/down switch 20 Platform level switch

Part No. 43650 Genie S-80 & Genie S-85 7

Operator's Manual Second Edition· Fifth Printing

CONTROLS

2 3 4 5 6

Platform Control Panel

1 Service 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

7 Check engine 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

8 Genie S-80 & Genie S-85 Part No. 43650

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