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

®

Contact us:

Internet: http://www.genielift.com
e-mail: [e-mail]

Copyright © 1994 by Genie Industries

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

11

7

6

5

4

3

2

1

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

12

13

14

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

Operator's Manual Second Edition· Fifth Printing

CONTROLS

1

2 3 4 5 6

17

13

16

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

Operator's ManualSecond Edition · Fifth Printing

CONTROLS

7

8 9 10 11

15

1314

13

10 Gasoline/LPG models: Gasoline/LPG select

switch

Deutz Diesel models: Glow plug switch (option)
11 Emergency Stop button
12 Proportional control handle for drive function and

thumb rocker for steer function

14 Drive enable indicator light
15 Drive enable switch
16 Proportional control handle for boom

extend/retract

17 Dual axis proportional control handle for boom

up/down and turntable rotate left/right functions

12

13 Optional equipment

Part No. 43650 Genie S-80 & Genie S-85 9

Operator's Manual Second Edition· Fifth Printing

Pre-operation Inspection

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.

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 above principles

before going on to the next section.

3 Always perform function tests prior to use.
4 Inspect the work place.
5 Only use the machine as it was intended.

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. 43650

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.

Operator's ManualSecond Edition · Fifth Printing

PRE-OPERATION INSPECTION

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.

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

Part No. 43650 Genie S-80 & Genie S-85 11

Operator's Manual Second Edition· Fifth Printing

Maintenance

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

Observe and Obey:

can damage engine components.

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.

Indicates that tools will be required to
perform this procedure.

Check the oil level with the
engine off.

1 Check the oil dipstick.
Gasoline/LPG Engine: located above the

bellhousing on the bulkhead side of the engine.
Diesel Engine: located on the engine block near

the engine oil filter.

Result: The oil level should be at the full mark

on the dipstick. Add oil as needed.

Ford LRG-425 EFI Engine
Oil capacity (including filter) 4.5 quarts 4.3 liters

Oil viscosity requirements

below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 5W-30

above -10°F / -23°C 5W-30

above 25°F / -4°C 10W-30

Use oils meeting API classification SH or SG grade.
Units ship with 10-40 CC/SG.

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. 43650

Operator's ManualSecond Edition · Fifth Printing

MAINTENANCE

Deutz F4L 1011F Engine
Oil capacity (including filter) 8.5 quarts 8 liters

Oil viscosity requirements

below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -34°C 15W-40

Engine oil should have properties of API classification
CC/SE or CC/SF grades.
Units ship with 10-40 CC/SG.

Perkins 704-30 Engine
Oil capacity (including filter) 9.6 quarts 9 liters

Oil viscosity requirements

below 60°F / 15.5°C 15W-40

-10°F to 90°F / -23°C to 32°C 10W-30

above -4°F / -34°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

Tank capacity 45 gallons

170 liters

Hydraulic system 55 gallons
(including tank) 208 liters

Part No. 43650 Genie S-80 & Genie S-85 13

Operator's Manual Second Edition· Fifth 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.

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

free of corrosion.

3 Be sure that the battery hold downs and cable

connections are tight.
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. 43650

Operator's ManualSecond Edition · Fifth Printing

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 specifications

The Schedule

There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, two year. To
account for repeated procedures, the

Scheduled
Maintenance Procedures Section and the
Maintenance Inspection Report

have been divided
into five subsections—A, B, C, D and E. Use the
following chart to determine which group(s) of
procedures are required to perform a scheduled
inspection.

Inspection Table or Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Tire size 15-22.5SAT

Pressure 100 psi

6.89 bar

Scheduled Maintenance

The scheduled maintenance items 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.

Inspections and maintenance described below
require the qualified entity to record and retain
records of all inspections and maintenance items
for four years.

Machines that have been out of service for more
than three months must receive the quarterly
inspection before placing the machine back into
service.

Maintenance Inspection Report

The maintenance inspection report contains
checklists for each type of scheduled inspection.

Make copies of the

Maintenance Inspection Report

to use for each inspection. Store completed forms
for three years.

Part No. 43650 Genie S-80 & Genie S-85 15

Operator's Manual Second Edition· Fifth Printing

Function Tests

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

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's
manual.

4 Start the engine (see

ON position.

Result: Beacon (if equipped) should flash.

Starting The Engine

page 17).

,

1 Avoid hazardous situations.
2 Always perform a pre-operation

inspection.

3 Always perform function tests prior to

use.

Know and understand the above principles

before going on to the next section.

4 Inspect the work place.
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.

Test Emergency Stop

5 Push in the red Emergency Stop button to the

OFF position.

Result: Engine should turn off and all functions

should not operate.

6 Pull out the red Emergency Stop button to

the ON position and restart the engine.

Test the Extendable Axles

7 Hold the function enable switch to either side

and activate the boom raise function.

Result: The boom should raise to horizontal and

then stop. 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 lower function.

Result: The boom should lower and return to the

stowed position.

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

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

Operator's ManualSecond Edition · Fifth Printing

FUNCTION TESTS

9 Hold the function enable switch to either side

and activate the boom extend function.

Result: The boom should extend no more than 6

inches (15 cm) and then stop. The boom should
not extend beyond the limit switch 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 At the extendable axle controls, extend the jack.

Result: The jack should extend and raise the

machine.

12 Extend the axle.

Result: The axle should extend.

13 Retract the jack.

Result: The jack should retract and lower the

machine.
14 Repeat steps 11-13 for the other jack and axle.
15 Hold the function enable switch to either side

and activate the boom raise and lower function.

Result: The boom should raise and lower

normally.
16 Hold the function enable switch to either side

and activate the boom extend and retract

functions.

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. Descent alarm (if
equipped) should sound while 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 Pull out the platform red Emergency Stop button

to the ON position. 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. 43650 Genie S-80 & Genie S-85 17

Operator's Manual Second Edition· Fifth Printing

FUNCTION TESTS

Test Auxiliary Controls

22 Turn the key switch to ground control and shut

the engine off.
23 Pull out the 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.

Test the Hydraulic Oil Return Filter

28 Move the engine idle select switch to high idel

(rabbit symbol).

29 Locate and check the hydraulic filter condition

indicator.

Result: The filter should

be operating with the
plunger in the green
area.

30 Move the engine idle

select switch to foot
switch activated high
idle (rabbit and foot
switch symbol).

Test the Service Horn

31 Push the horn button.

Result: The service horn should sound.

Test the Foot Switch

32 Push in the platform Emergency Stop button to

the OFF position.

27 Pull out the red Emergency Stop button and

restart the engine.

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

33 Pull out the Emergency Stop button to

the ON position but do not start the engine.

34 Press down the foot switch and attempt to start

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 Move the lift/drive select switch to the lift

position (if equipped).

37 Do not press down the foot switch. Then test

each machine function.

Result: The machine functions should not

operate.

Operator's ManualSecond Edition · Fifth Printing

FUNCTION TESTS

Test Machine Functions

38 Move the lift/drive select switch to the lift

position (if equipped).
39 Press down the foot switch.
40 Activate each machine function control handle

or toggle switch.

Result: All boom/platform functions should

operate through a full cycle.
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 Steering

41 Move the lift/drive select switch to the drive

position (if equipped).
42 Press down the foot switch.
43 Depress the thumb rocker switch on top of the

drive control handle in the direction identified by

the blue triangle on the control panel.

Test Drive and Braking

45 Move the lift/drive select switch to the drive

position (if equipped).
46 Press down the foot switch.
47 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.
48 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 drive brakes must be able to hold the

machine on any slope it is able to climb.

Result: The steer wheels should turn in the

direction that the blue triangles point on the
drive chassis.

44 Depress the thumb rocker switch in the

direction identified by the yellow triangle on the
control panel.

Result: Steer wheels should turn in the direction

that the yellow triangles point on the drive
chassis.

Part No. 43650 Genie S-80 & Genie S-85 19

Operator's Manual Second Edition· Fifth Printing

FUNCTION TESTS

Test the Drive Enable System

49 Move the lift/drive select switch to the lift

position (if equipped).

50 Press down the foot switch. Then lower the

boom to the stowed position.

51

Result: The drive enable

indicator light should
come on and remain on
while the boom is
anywhere in the range
shown.

52 Move the lift/drive select

switch to the drive position (if equipped).

53 Move the drive control handle off center.

Result: The drive function should not operate.

54 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.

Test Limited Drive Speed

55 Move the lift/drive select switch to the lift

position (if equipped).
56 Press down the foot switch.
57 Raise the boom to just above horizontal.

58 Move the lift/drive select switch to the drive

position (if equipped).
59 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

per second (0.3 meters per second).
60 Move the lift/drive select switch to the lift

position (if equipped).
61 Lower the boom to the stowed position.
62 Extend the boom 1 foot (30 cm).
63 Move the lift/drive select switch to the drive

position (if equipped).

Use the color-coded direction
arrows on the platform
controls and the drive
chassis to identify the
direction of travel.

Blue

Yellow

64 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 per second (0.3 meters per second).
If the drive speed with the boom raised or extended

exceeds 1 foot per second (0.3 meters per second),
immediately tag and remove the machine from
service.

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

Operator's ManualSecond Edition · Fifth Printing

FUNCTION TESTS

Test Auxiliary Controls

65 Shut off the engine.
66 Pull out the red Emergency Stop button to

ON position.

the

67 Move the lift/drive select switch to the lift

position (if equipped).
68 Press down the foot switch.
69 Simultaneously hold 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 Switch (if
equipped)

70 Move the lift/drive select switch to the lift

position.
71 Press down the foot switch.
72 Move the drive control handle off center.

Result: No drive functions should operate.

73 Activate each boom function toggle switch.

Result: All boom functions should operate.

74 Move the lift/drive select switch to the drive

position.
75 Press down the foot switch.
76 Activate each boom function toggle switch.

Result: No boom functions should operate.

77 Move the drive control handle off center.

Result: The drive functions should operate.

Part No. 43650 Genie S-80 & Genie S-85 21

Operator's Manual Second Edition· Fifth Printing

Work Place Inspection

Work Place Inspection

Be aware of and avoid the following hazardous
situations:

· drop-offs or holes

· bumps, floor obstructions or debris

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 work place.

· 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

Know and understand the above principles

before going on to the next section.

5 Only use the machine as it was intended.

Fundamentals

The Work Place Inspection helps the operator
determine if the work place is suitable for safe
machine operation. It should be performed by the
operator prior to moving the machine to the work
place.

It is the operator's responsibility to read and
remember the work place hazards, then watch for
and avoid them while moving, setting up and
operating the machine.

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

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 work place.

5 Only use the machine as it was intended.

Operator's ManualSecond Edition · Fifth Printing

Operating Instructions

Starting the Engine

1 At the ground controls, turn the key switch to

the desired position.

2 Be sure both ground and platform control red

Emergency Stop buttons are pulled out to the

ON position.

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 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 cause and repair any malfunction. Wait
60 seconds before trying to start again.

All models: In extreme cold conditions, 20°F (-6°C)
and below, warm engine for 5 minutes to prevent
hydraulic system damage.

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 work place
inspection before using the machine.

Gasoline/LPG models:In extreme cold conditions,
20°F (-6°C) and below, machine should be started
on gasoline, then switched to LPG.

Emergency Stop

Push in either ground or platform red Emergency
Stop button to the OFF position to stop all functions
and turn engine off.

Repair any function that operates when the
Emergency Stop button is pushed in.

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

Part No. 43650 Genie S-80 & Genie S-85 23

Operator's Manual Second Edition· Fifth Printing

OPERATING INSTRUCTIONS

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 Move the lift/drive select switch to the lift

position (if equipped) when operating the
auxiliary controls from the platform.

4 Press down the foot switch when operating the

auxiliary controls from the platform.

5 Simultaneously hold auxiliary power switch ON

and activate desired function.

The drive function will not operate with auxiliary
power.

Extendable Axles

Be sure the machine is on a firm, level surface.
Use shoring material under the jack foot pad as
required.

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

fuel select switch to 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 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.

1 Push and hold the jack control handle to

extend the jack. Do not release handle.

2 Push the axle control handle to extend the

axle. Pull the axle control handle to retract the
axle.

3 Release the handles when the axle is fully

extended or retracted.
4 Pull the jack control handle to retract the jack.
5 Repeat for other axle.

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

Operator's ManualSecond Edition · Fifth Printing

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
3 Gasoline/LPG models: Choose fuel by moving

fuel select switch to desired position.
4 Start engine. Do not press down the foot switch

when starting engine.

To Position Platform

1 Extend the axles.
2 Move the lift/drive select switch to the lift

position (if equipped).
3 Press down the foot switch.
4 Slowly move the appropriate function control

handle or toggle switch according to the

markings on the control panel.
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.

To Steer

1 Move the lift/drive select switch to the drive

position (if equipped).
2 Press down the foot switch.
3 Turn the steering wheels with the thumb rocker

switch located on top of the drive control

handle.

ON position.

To Drive

1 Move the lift/drive select switch to the drive

position (if equipped).
2 Press down the foot switch.
3 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 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-steering wheel and drive function
has been interrupted.

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

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 machine will travel.

Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction wheels will turn.

Part No. 43650 Genie S-80 & Genie S-85 25

Operator's Manual Second Edition· Fifth Printing

OPERATING INSTRUCTIONS

Generator

To operate 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 power tool into the power to platform GFCI
outlet.

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

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)

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-steering wheels.

4 Turn the key switch to the

remove the key to secure from unauthorized
use.

5 Chock the wheels.

OFF position and

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

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

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

Observe and Obey:

Transport vehicle must be parked on a level

surface.

Transport vehicle must be secured to prevent

rolling while machine is being loaded.

Operator's ManualSecond Edition · Fifth Printing

Transport Instructions

Use lower platform mount between boom end and
platform to secure boom from side-to-side
movement. Do not use excessive downward
force when securing boom section.

Use chains or straps of ample load capacity.
Turn key switch to the OFF position and remove

key before transporting.
Inspect entire machine for loose or unsecured

items.

Free-wheel Configuration for
Winching

Be sure vehicle capacity, loading surfaces and

straps or lines are sufficient to withstand
machine weight. See Specifications section.

Securing to Truck or Trailer for
Transit

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

Always chock machine wheels in preparation for
transport.

Use tie points on drive chassis for anchoring down
to transport surface.

Disengage
Position

Engage
Position

Chock wheels to prevent machine from rolling.
2WD models: Release non-steer wheel brakes by

turning over torque hub disconnect caps (see
below).

4WD models: Release wheel brakes by turning
over all four torque hub disconnect caps (see
below).

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

Reverse procedures described to re-engage
brakes.

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

Part No. 43650 Genie S-80 & Genie S-85 27

Operator's Manual Second Edition· Fifth Printing

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

25994 Caution - Component Damage Hazard 1
27204 Arrow - Blue 1
27205 Arrow - Yellow 1
27206 Triangle- Blue 2
27207 Triangle - Yellow 2
27564 Danger - Electrocution Hazard 3
28157 Label - Dexron 1
28158 Label - Unleaded 2
28159 Label - Diesel 2
28160 Label - Liquid Petroleum Gas 1
28161 Danger - Crushing Hazard 4
28163 Notice - Maximum Side Force - 150 lbs 1
28164 Notice - Hazardous Materials 1
28165 Notice - Foot Switch 1
28171 Label - No Smoking 2
28174 Label - Power to Platform, 230V 2
28175 Caution - Compartment Access 1
28176 Notice - Missing Manuals 1
28177 Warning - Platform Rotate 2
28181 Warning - No Step or Ride 1
28235 Label - Power to Platform, 115V 2
28236 Warning - Failure To Read . . . 1
30080* Notice - Maximum Load 500 lbs 1
31060 Danger - Tip-over Hazard, Interlock 1
32700 Danger - Safety Rules 2
32726 Label - Glow Plug (option) 1
32728 Label - Generator (option) 1
32932 Danger - Tip Over- Axles 2

Part No. Decal Description Quantity

32933 Serial Plate - S-80 1
32996 Notice - Axle Extension Operation 2
32997 Warning - Hand and Foot 4
32998* Notice - Maximum Load 600 lbs 1
32999 Notice - Tire Pressure 2
33463 Serial Plate - S-85 1
33550 Safety Tape —
33952 Danger - Tilt-Alarm 1
33956 Notice - Ford Engine Specs-Ford LRG 1
33986 Notice - Deutz Diesel Engine Specs 1
35599 Notice - Align Air Hoses 1
40434 Label - Lanyard Anchorage 4
43594* Notice - Maximum Load 750 lbs 1
43595 Danger - Tip-over, Tires 1
43649 Ground Control Panel 1
43647 Notice - Operating Instructions 2
43663 Notice - Function Enable 1
49741 Notice - Ford Engine Specs-LRG-425 EFI 1
44769 Lift/Drive Select (option) 1
44981 Airline to Platform 2
44986 Notice - Maximum Manual Force - 90 lbs 1
49926 Ground Control Panel 1
52156 Platform Control Panel 1
52966 Cosmetic - 4 x 2 1
52967 Cosmetic - 4 x 4 1
52972 CE Mark 1
62920 Cosmetic - Genie S-80 1
62921 Cosmetic - S-80 2
62922 Cosmetic - Genie S-85 1
62923 Cosmetic - S-85 2
72160 Ground Control Panel 1
72162 Platform Control Panel 1

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

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

DECALS

Operator's ManualSecond Edition · Fifth Printing

Ground

Controls

Side

Engine
Side

Drive
Chassis

Platform

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

Part No. 43650 Genie S-80 & Genie S-85 29

Operator's Manual Second Edition· Fifth Printing

Specifications

Model S-80 S-85

Height, working maximum 86 ft 91 ft

26.2 m 27.7 m

Height, platform maximum 80 ft 85 ft

24.4 m 25.9 m

Height, stowed maximum 9 ft 2 in 9 ft 2 in

2.79 m 2.79 m

Horizontal reach maximum 71 ft 11 in 76 ft 11 in

21.9 m 23.4 m

Width 7 ft 111/2 in 7 ft 111/2 in

2.43 m 2.43 m

Length, stowed 36 ft 8 in 40 ft 7 in

11.2 m 12.4 m

Maximum load capacity 600 lb 500 lb
6 foot platform 272 kg 227 kg

Maximum load capacity 500 lb 500 lb
8 foot platform 227 kg 227 kg

Maximum load capacity
6 foot platform with foam-filled tires
and proper counterweight 750 lb N/A
configuration 340 kg N/A

Wheelbase 9 ft 0 in 9 ft 0 in

2.7 m 2.7 m

Turning radius (outside) 23 ft 1 in 23 ft 1 in

7.0 m 7.0 m

Turning radius (inside) 10 ft 71/2 in 10 ft 71/2 in

3.2 m 3.2 m
Turntable rotation (degrees) continuous
Turntable tailswing 3 ft 81/2 in 3 ft 81/2 in

113.0 cm 113.0 cm

Power source Ford 63 Hp Gasoline/LPG LRG-423
(choice) or LRG-425 EFI

Deutz 56 Hp Diesel F4L 1011

Drive speeds 2WD 4WD

Drive speed, stowed 3.8 mph 3.1 mph
Gasoline/LPG models 6.1 km/h 4.9 km/h

40 ft/7.2 sec 40 ft/8.8 sec

12.2 m/7.2 sec 12.2 m/8.8 sec

Drive speed, stowed 3.3 mph 3 mph
Deutz Diesel models 5.3 km/h 4.8 km/h

40 ft/8.3 sec 40 ft/9.1 sec

12.2 m/8.3 sec 12.2 m/9.1 sec

Drive speed, 0.68 mph 0.68 mph
raised or extended 1.1 km/h 1.1 km/h

- all models 40 ft/40 sec 40 ft/40 sec

12.2 m/40 sec 12.2 m/40 sec

Model S-80 S-85

Controls 12V DC proportional
Platform dimensions, 6 foot 72 in x 30 in 72 in x 30 in

(length x width) 1.8 m x 76 cm 1.8 m x 76 cm
Platform dimensions, 8 foot 96 in x 36 in 96 in x 36 in

(length x width) 2.4 m x 91 cm 2.4 m x 91 cm
Platform leveling self-leveling self-leveling
Platform rotation 160° 160°
AC outlet in platform standard standard
Hydraulic pressure (maximum) 3000 psi 3000 psi

(boom functions) 207 bar 207 bar
Tire size 15-22.5 SAT 15-22.5 SAT
Gradeability, stowed (2WD/4WD) 30% / 38 %
Ground clearance 11 in 11 in

28 cm 28 cm

Hydraulic tank capacity 45 gallons 45 gallons

170 liters 170 liters

Fuel tank capacity 30 gallons 30 gallons

114 liters 114 liters

Weight 33,380 lbs 35,860 lbs

15,141 kg 16,266 kg

Airborne noise emissions 80 dB
Maximum sound level at normal operating workstations
(A-weighted)

Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice or obligation.

80 ft

24.4 m

S-85

60 ft

18.3 m

40 ft

12.2 m

20 ft

6.1 m

0 m

20 ft

6.1 m

0 ft

0 ft

10 ft

3.0 m

30 ft

9.1 m

0 m

S-80

50 ft

15.2 m

70 ft

21.3 m

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

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 +

Genie Scandinavia

Phone +

Genie France

Phone +

Genie Iberica

Phone +

Genie Germany

Phone +

Genie U.K.

Phone +

31 70 51 78836

Fax +

31 70 51 13993

46 31 3409612

Fax +

46 31 3409613

33 (0)2 37 26 09 99

Fax +

33 (0)2 37 26 09 98

34 93 579 5042

Fax +

34 93 579 5059

49 (0)4202 88520

Fax +

49 (0)4202 8852-20

44 (0)1476 584333

Fax +

44 (0)1476 584334

Genie North America

Phone

Fax

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

425.881.1800
USA and Canada

800.536.1800

425.883.3475

61 7 3375 1660
61 7 3375 1002

86 21 53852570
86 21 53852569

60 4 228 1235
60 4 226 6872

81 3 3453 6082
81 3 3453 6083

82 2 558 7267
82 2 558 3910

27 11 455 0373
27 11 455 0355

Toll Free

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Africa

Genie Mexico City

Phone +

Fax +

52 5 653 03 84
52 5 664 40 16

Genie Latin America

Phone +

55 11 4055 2499

Fax +

55 11 4043 1661

Distributed By: