Operator`s Manual
Contents
1. PartNo Decal Description Quantity PartNo Decal Description Quantity1 25994 Caution Component Damage Hazard 1 43595 Danger Tip over Tires 750 Ibs 340 kg 1 27204 Arrow Blue 1 44981 Label Air Line to Platform option 2 27205 Arrow Yellow 1 44986 Notice Max Manual Force 27206 Triangle Blue 2 90 Ibs 400N CE and AUS 1 27207 Triangle Yellow 3p 22906 _Sgemelicn exe 27564 Danger Electrocution Hazard g 9230r Roem 1 28158 Label Unleaded 1 62920 Cosmetic Genie S 80 1 28159 Label Diesel 1 62921 Cosmetic S 80 2 28160 Label Liquid Petroleum Gas option 1 82922 Cosmetic Genie S 85 L 28161 Warning Crushing Hazard m peen C Gosment E Sa 2 28164 Notice Hazardous Materials 1 ahs Noueer Staley Banery l 28165 Notice Foot Switch 1 72169 Notice Controls Battery 1 28171 Label No Smoking 1 82253 Notice High Flotation Tire Specs 4 28174 Label Power to Platform 230V go OERS PAPEN O NOON YON 28175 Caution Compartment Access 1 Beers Ground Control Panel d 28176 Notice Missing Manuals 1 52029 Lapel Wneeltoad S80 4 28177 Warning Platform Rotate B Gabe gt Labels Wheel bad S83 3 28181 Warning No Step or Ride 1 82762 Platform Control Panel 1 28235 Label Power to Platform 115V 2 ones Nolita x RPNE Enone bers 1 28236 Warning Failure To Read i eee SI s Explosion Hazard 302. A a N AA x oO estan Operator s Manual maim with Maintenance Information Part No 1000231 S 80 S 35 Operator s Manual Fifth Edition Third Printing Ooo ey 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 0 ccccecceeeeeeeeeeeeeeeeeeaeeeeeeeeeeseaaeeeneas 1 CONTOS erora a R 8 E a o PE E A E 11 Pre operation Inspection seeeesessssriresereerrnsssrseens 12 Maintenance ccee cece eee eeeeeeeeeeeeeeeeaaneaeeaeeeeeeeeeees 14 FUNCTION Tests 2 2 c eeeeeeeeceeecaeceeeeeeeeeeeeeeeeeeeeeeees 18 Workplace Inspection ccceeceeeeecteeeeseeeeeeeeeeeees 24 Operating Instructions 0 cceeeeeeeeeteeeteeeeeeeteeeeeees 25 Transport and Lifting Instructions 0 0 00 31 Decals sargia eaa A E EEA 34 Specifications 2 2 eeececeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeseeaeeeees 38 Contact us Copyright 1994 by Genie Industries First Edition Fifth Printing October 1996 Internet http www genielift com ie oe e mail techpub genieind com Second Edition Fifth Printing July 2000 Third Edition Third Printing Oc
3. 80 ft 80 fi 24 4 m 24 4 m 60 ft 60 fi 18 3 m 18 3 m 40 ft 40 fi 12 2 m 12 2 m 20 ft 20 fi 6 1m 6 1m Oft 0 Om Om 20 ft 20 ft 6 1m 6 1m oft 10 ft 30 ft 50 ft 70 ft oft 10 ft 30 ft 50 ft 70 ft Om 3 0m 9 1m 15 2m 21 3m Om 3 0m 9 1m 15 2m 21 3m enie A TEREX COMPANY 40 S 80 S 85 Part No 1000231 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 North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 5511 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
4. Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications L Electrical components wiring and electrical cables L Hydraulic hoses fittings cylinders and manifolds _ Fuel and hydraulic tanks _ Drive and turntable motors and drive hubs L Boom wear pads _ Axle wear pads _ Tires and wheels L Engine and related components L Check for hydraulic oil leaks and proper oil level PRE OPERATION INSPECTION _ Limit switches and horn J Alarms and beacons if equipped J Nuts bolts and other fasteners _ Platform entry mid rail or gate Check entire machine for J Cracks in welds or structural components Dents or damage to machine Excessive rust corrosion or oxidation _ Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened _ After you complete your inspection be sure that all compartment covers are in place and latched Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 13 Operator s Manual Fifth Edition Third Printing Maintenance Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirem
5. Ground controls Boom A Platform controls pi N Platform Jib boom S 85 Lanyard anchorage point LIN oO ON OO FP WO N Sliding mid rail 10 Manual storage container 11 Foot switch Genie A TEREX COMPANY Part No 1000231 S 80 S 85 11 Operator s Manual Fifth Edition Third Printing Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform apre 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 A TEREX COMPANY 12 S 80 S 85 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
6. SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current N ZX j Tu Dn fg a 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 Meters 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 500KV to 750KV 35 10 67 750KV to 1000KV 45 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 unless the machine is equipped with the weld line to platform option and it is properly connected Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity Maximum platform capacity S 85 500 Ibs 227 kg Maximum platform capacity S 80 with 8 Ft Platform 500 Ibs 227 kg Maximum platform capacity S 80 with 6 Ft Platform 600 Ibs 272 kg Maximum platform capacity S 80 with foam filled tires and proper counter
7. 1000231 A TEREX COMPANY S 80 S 85 5 Operator s Manual Fifth Edition Third Printing SAFETY RULES 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 unless the machine is equipped with the weld line to platform option and is properly connected 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 Do not spray ether into engines equipped with glow plugs 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 amp 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 locat
8. Controls 12V DC proportional 72 in x 30 in 1 8mx 76cm Platform dimensions 6 foot length x width Platform dimensions 8 foot 96 in x 36 in length x width 2 4mx 91cm Platform leveling self leveling Platform rotation 160 AC outlet in platform standard Hydraulic pressure maximum 3000 psi boom functions 207 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Counterweight downhill 30 17 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Floor Loading Information Tire load maximum 18 000 Ibs 8165 kg Tire contact pressure 100 psi 7 03 kg cm2 689 kPa Occupied floor pressure 301 psf 1469 kg m2 14 42 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 39 Operator s Manual Fifth Edition Third Printing C UUU SPECIFICATIONS S 80 Range of Motion Chart S 85 Range of Motion Chart
9. does not incorporate different option configurations It should be used only with adequate safety factors Genie A TEREX COMPANY 38 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual SPECIFICATIONS Model S 85 System voltage 12V Height working maximum 91 ft 27 7 m Tire size 15 22 5 SAT Height platform maximum 85 ft 25 9 m High flotation tire size 41 18LL x 22 5 14 ply Height stowed maximum 9ft2in 2 79 m Ground clearance 11 in 28 cm Horizontal reach maximum 77 ft 5 in 23 6 m Fuel tank capacity 33 gallons 125 liters Width 8ft 2 44 m Weight See Serial Label Machine weights vary with option configurations Length stowed 40 ft 7 in 12 4m Airborne noise emissions 80 dB Maximum load capacity 500 Ib 227kg Maximum sound level at normal operating workstations 6 foot platform A weighted Maximum load capacity 500 Ib 227 kg Drive speeds 8 foot platform r Drive speed stowed 3 5 mph 5 6 km h Maximum wind speed 28 mph 12 5 m s 40 ft 7 8 sec 12 2 m 7 8 sec Wheelbase 9 ft O in 2 7M Drive speed 0 68 mph 1 1 km h Turning radius outside 23 ft 7 0m raised or extended 40 ft 40 sec 12 2 m 40 sec Turning radius inside 10 t8 in 33m Maximum slope rating stowed position 2WD i i O e Turntable tailswing 3 ft 81 2in 113m COVNterweight uphill SONS i i O o Turntable rotation degrees continuous Commer weight Sow til Pee
10. 9 Operator s Manual Fifth Edition Third Printing CONTROLS Se Oe Ground Control Panel 1 2 3 4 O uo Turntable rotate switch Boom up down switch Boom extend retract switch Platform overload indicator light if equipped not used Auxiliary power switch Gasoline LPG models Water temperature gauge if equipped Deutz Diesel models Oil temperature gauge if equipped Key switch for platform off ground selection 10 11 12 13 14 15 Oil pressure gauge if equipped Voltage gauge if equipped Red Emergency Stop button Check engine light if not equipped with gauges Hour meter Gasoline LPG models Gasoline LPG select switch Deutz models Glow plug switch Perkins models Glow plug indicator light Genie 16 17 18 19 20 21 23 Function enable switch Engine start switch 15A breaker for engine electrical circuits 20A breaker for oil cooler and options 15A breaker for control electrical circuits S 85 only Jib boom up down switch Platform level switch Platform rotate switch A TEREX COMPANY S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Legend Non steer tire Steer tire 6
11. ie ose j i or 27206 A Chassis 28165 27205 Shading indicates 28236 decal is hidden from 97887 52966 E view i e under or 44986 or 52967 E covers 72169 28161 72168 97602 28181 62921 or 62923 27564 31060 97758 or 97576 or 114169 28175 28164 32999 or 82253 28 82623 28161 or 28235 or 82624 27564 or 82624 Genie Part No 1000231 S 80 S 85 35 40434 28177 Engine Side Operator s Manual Fifth Edition Third Printing EEE DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place PartNo Decal Description Quantity PartNo Decal Description Quantity 27204 Arrow Blue 1 82487 Label Read the Manual 2 27205 Arrow Yellow 1 82544 Danger Electrocution Hazard 3 27206 Triangle Blue 2 82545 Danger Maximum Load 227 kg 1 27207 Triangle Yellow 2 82546 Danger Maximum Load 272 kg 1 28158 Label Unleaded 1 82547 Danger Maximum Load 340 kg 1 28159 Label Diesel 1 82548 Warning Platform Rotate 2 28160 Label Liquid Petroleum Gas option 1 82581 Ground Control Panel 1 28171 Label No Smoking 1 82602 Danger Max Manual Force 28174 Label Power to Platform 230V 2 poe ANS 28235 Label P
12. to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example lt run rise bA Piece of wood 144 inches 3 6 m Run 144 inches 3 6 m Rise 12 inches 0 3 m 12 in 144 in 0 083 x 100 8 3 grade 0 3 m 3 6 m 0 083 x 100 8 3 grade If the slope exceeds the maximum uphill downhill or side slope rating then the machine must be winched or transported up or down the slope See Transport and Lifting Instructions section Genie A TEREX COMPANY 28 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual 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 Axle Indicator Light lj i gt iL__i gt Engine Idle Select rpm Axle indicator light on Extend
13. 080 Notice Maximum Load 500 Ibs 227kg 1 9 758 Notice Perkins Engine Specs l 31060 Danger Tip over Hazard Interlock By lel Lrapel Poon Metal 1 32728 Label Generator option 1 97875 Label Weld Line to Platform option 2 32932 Danger Tip Over Axles 2 Arga A E T 1 32998 Notice Maximum Load 600 Ibs 272 kg 1 97890 Danger Safety Rules 2 32999 Notice Tire Pressure 4 114169 Notice Ford Engine Specs 423 EFI 1 33952 Danger Tilt Alarm 1 114099 Label Transport Diagram 2 40434 Label Lanyard Anchorage 3 1000254 Notice Operating Instructions 2 43594 Notice Maximum Load 750 lbs 340 kg 1 Please reference the Specifications section or the chart on page 2 to determine the capacity of your machine Genie 34 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual DECALS 82581 1000254 Serial label 28161 28177 Ground 97890 27564 28160 31060 Controls 32932 Side 82366 Ns ZO B ss 28158 Z Sh i ns Tess S s 28171 44981 32999 FEDS 97875 or 82253 xe 33952 82623 32932 or 82624 43595 114099 30798 82623 89762 or 82624 1000254 32999 97890 or 82253 97815 oe 28174 67 62923 oer sg 28235 R 44981 27204 n y f A 28176 Pol Pas 30080 2720
14. 2923 D c al al ae ae i 27204 i a i h J ead Lal 27206 i Drive or Boede 27207 Chassis or 82547 2 206 Se ie 97205 Law 82602 Shading indicates or 82604 i decal is hidden from 52966 i view i e under or 52967 covers 82472 62921 40434 or 62923 82544 82473 82548 82544 39696 i 82472 28174 82623 or Engine 62920 or 28235 82625 or 82624 82623 Side or 62922 82671 or 82626 114099 or 82624 Genie A TEREX COMPANY Part No 1000231 S 80 S 85 37 Operator s Manual Fifth Edition Third Printing Specifications Model S 80 System voltage 12V Height working maximum 86 ft 26 2 m Tire size 15 22 5 SAT Height platform maximum 80 ft 24 4 m High flotation tire size 41 18LL x 22 5 14 ply Height stowed maximum 9ft2in 2 79 m Ground clearance 11 in 28 cm Horizontal reach maximum 72 ft5in 22 1 m Fuel tank capacity 33 gallons 125 liters Width axles retracted 8ft 2 44 m Weight See Serial Label Machine weights vary with option configurations Length stowed 37 ft 3 in 11 35 m Airborne noise emissions 80 dB Maximum load capacity 600 Ib 272kg Maximum sound level at normal operating workstations 6 foot platform A weighted Maximum load capacity 500 Ib 227kg Drive speeds 8 foot platform 7 Drive speed stowed 3 5 mph 5 6 km h Maximum load capacity 750 lb 340 kg 40
15. A TEREX COMPANY 18 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual 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 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 activate the boom extend and the boom retract function Result The boom should extend and retract normally FUNCTION TESTS Test the Machine Functions 14 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle
16. Part No 1000231 Fifth Edition Third Printing Operator s Manual Operating Instructions Do Not Operate Unless M 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 along with their tools and materials 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 PartNo 1000231 A TEREX COMPANY S 80 S 85 Starting the Engine 1 At the ground controls turn the key switch to the de
17. _ k 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 SAFETY RULES Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies to machines in the stowed position Maximum slope rating stowed position 2WD Counterweight uphill 30 179 Counterweight downhill 15 9 Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Counterweight downhill 30 17 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Do not push off or pull toward any object outside of the platform Maximum allowable side force ANSI amp CSA A 150 Ibs A M 667 N Maximum allowable RN manual force CE DA 90 Ibs 400 N Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 Operator s Manual Fifth Edition Third Printing SAFETY RULES 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 aeri
18. al work platform without prior written permission from the manufacturer 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 place or attach overhanging loads to any part of this machine AY Do not place ladders or scaffolds in the platform or against any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform 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 Ib 340 kg Capacity Do not use air filled tires Models are equipped with foam filled 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 groundcontrols 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 f
19. apacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial plate for the machine weight 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 Center of Gravity Location X Axis Y Axis S 80 5 64 ft 4 69 ft 1 72 m 1 43 m S 85 5 67 ft 4 53 ft 1 73 m 1 38 m Turntable Lifting 7 Points 2 Q a oe A 3 Chassis en Lifting aus gt 9 Points 2 x Axis Genie Part No 1000231 S 80 S 85 33 Operator s Manual Fifth Edition Third Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place
20. ct switch Turtle foot switch activated low idle 5 Auxiliary power switch Rabbit foot switch activated high idle 4 85 only Jib boom up down switch 6 Drive speed select switch Genie A TEREX COMPANY 8 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual DRIVE ENABLE OPERATION Light on indicates that boom has moved past a non steer tire and Les drive function is turned off To drive hold drive enable switch to side and slowly move drive control handle Machine may drive in opposite direction that drive and steer controls are moved o tion arrows on hassis to identify e will travel Use color coded dir this panel and drive the direction machi of Q amp CONTROLS STOP L 10 Gasoline LPG models Gasoline LPG select 15 Drive enable indicator light switch 11 Red Emergency Stop button 16 Drive enable switch 17 Proportional control handle for boom 12 Proportional control handle for drive function and extend retract thumb rocker for steer function 13 Platform overload indicator light if equipped 14 Machine not level indicator light if equipped 18 Axle indicator light 19 Axle extend retract switch 20 Dual axis proportional control handle for boom up down and turntable rotate left right functions Genie PartNo 1000231 A TEREX COMPANY S 80 S 85
21. ctions 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 apre 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 8 above 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 down function Result The boom should lower and return to the stowed position Genie
22. e 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 50 Lower the boom to the stowed position 51 Extend the boom 1 foot 30 cm 52 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 Genie A TEREX COMPANY 22 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual E FUNCTION TESTS Test Auxiliary Controls 53 Shut off the engine 54 Pull out the platform red Emergency Stop button to the on position 55 Press down the foot switch 56 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 ifequipped 57 Press down the foot switch 58 Move the drive control handle off center 59 Activate each boom function toggle switch Result No boom functions should operate The machine will move in the direction indicated on the c
23. ed on the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation Weld Line to Platform Safety if equipped Read understand and obey all warnings and instructions provided with the welding power unit Do not connect weld leads or cables unless the welding power unit is turned off at the platform controls Do not operate unless the weld cables are properly connected Connect the leads to the twist lock connectors at the turntable and platform Genie A TEREX COMPANY 6 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eyewear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazard Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas Electrocution Hazard Avoid contact with elec
24. ents 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 amaintenance procedure it conveys the meaning below Y 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 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 oil dipstick Add oil as needed Ford LRG 423 EFI Engine EPA compliant Oil type 10W 40 Oil type cold conditions 5W 30 Deutz BF4L 2011 Engine Tier II Oil type 15W 40 Oil type cold conditions 5W 30 Perkins 804C 33 Engine Oil type 15W 40 Oil type cold conditions 5W 40 Genie A TEREX COMPANY 14 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual 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
25. ft 7 8 sec 12 2 m 7 8 sec with foam filled tires and proper counterweight configuration Drive speed 0 68 mph 1 1 km h raised or extended 40 ft 40 sec 12 2 m 40 sec Maximum wind speed 28 mph 12 5 m s Maximum slope rating stowed position 2WD Wheelbase 9 ft 0 in 2 7 m Counterweight uphill 30 17 Turning radius outside 23 ft 7 0m Counterweight downhill 15 9 Turning radius inside 10 ft 8 in 3 3m Side slope 25 14 Turntable tailswing 3 ft 8in 1 12 m Maximum slope rating stowed position 4WD Turntable rotation degrees continuous Controls 12V DC proportional Platform dimensions 72 in x 30 in 1 8 m x 76cm 6 foot length x width Counterweight uphill 45 24 Counterweight downhill 30 17 Side slope 25 14 Platform dimensions 96 in x 36 in 2 4m x 91 cm 8 foot length x width Note Slope rating is subject to ground conditions and adequate traction Platform leveling self leveling Floor loading information Platform rotation 160 Tire load maximum 16 000 Ibs 7255 kg AC outlet in platform standard Tire contact pressure 100 psi 7 03 kg cm2 3 689 kPa Hydraulic pressure maximum 3000 psi 207 bar boom functions Occupied floor pressure 282 psf 1377 kg m 13 5 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
26. iate toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Genie A TEREX COMPANY 26 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Operation from Platform 1 Turn the key switch to platform control 2 Pullout 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 OPERATING INSTRUCTIONS 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 a
27. ill turn off and the machine functions will operate Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions 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 Genie A TEREX COMPANY 30 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Transport and Lifting Instructions Observe and Obey M Genie Industries provides this securement information as a recommendation Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations other localized regulations and their company policy I Genie customers needing to containerize any lift or Genie product should source a qualified freight forwarder with expertise in preparing loading and securing construction and lifting equipment for international shipment KI Only qualified aerial lift operators should move the machine on or off the
28. irm footing on the platform floor at a De Do not climb down from the platform when raised iS Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating Genie A TEREX COMPANY 4 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual 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 Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Observe and use the color coded direction arrows on the platform controls and drive chassis for drive and steer functions SAFETY RULES Do not lower the boom unless the area below is clear of personnel and obstructions 11 Vesper a 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 Genie PartNo
29. nd restart the engine 23 Push in the platform red Emergency Stop button to the off position Result The engine should turn off and all functions should not operate 24 Pull out the red Emergency Stop button and restart the engine Test the Hydraulic Oil Return Filters 25 Move the engine idle select switch to high idle rabbit symbol 26 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 27 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol Test the Horn 28 Push the horn button Result The horn should sound Test the Foot Switch 29 Push in the platform red Emergency Stop button to the off position 30 Pull out the red Emergency Stop button to the on position but do not start the engine 31 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 32 Do not press down the foot switch and restart engine 33 Do not press down the foot switch and test each machine function Result The machine functions should not operate Genie A TEREX COMPANY 20 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Test Machine Functions 34 Press down the foot switch 35 Activate each machine function control handle or
30. 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 Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 21 Operator s Manual Fifth Edition Third Printing FUNCTION TESTS Test the Oscillating Axle if equipped 42 Drive the right steer tire up onto a 6 inch 15cm curb or block 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 44 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 45 Move the drive control handle off center Result The drive function should not operate 46 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 Blue arrows on the platform controls and the drive 4 chassis to identify the direction of travel Yellow Test Limited Drive Speed 47 Press down the foot switch 48 Raise the boom to just above horizontal 49 Slowly mov
31. ontrol panel Genie A TEREX COMPANY Part No 1000231 S 80 S 85 23 Operator s Manual Fifth Edition Third Printing 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 M 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 f 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 T wind and weather conditions 4 Inspectthe workplace the presence of unauthorized personnel Know and understand the workplace inspection before going on to the next section other possible unsafe conditions 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 Genie A TEREX COMPANY 24 S 80 S 85
32. ower to Platform 115V 2 Beeus eee Manual koree 1 32728 Label Generator option 1 82623 Label Wheel Load S 80 4 40434 Label Lanyard Anchorage 3 gog04 Label Wheel Load S 85 4 44981 Label Airline to Platform 2 82625 aboli Tire Pressire 4 52966 Cosmetic 4x2 1 82626 Label High Flotation Tire Specs 4 32907 Cosmetics t4 1 82646 Label Drive Enable Patch 1 62920 Cosmetic Genie 5 80 1 82674 Label Weld Line to Platform option 2 paved HoSmeiG aago 2 82762 Platform Control Panel 1 poe Cosmetic Genie 85 i 82924 Caution Component Damage Hazard 1 Given Cesmele 2 2 97815 Label Lower Mid rail 1 82472 Warning Crushing Hazard 11 114099 Label Transport Diagram 2 82473 Caution Compartment Access 1 Please reference the Specifications section or the chart on page 2 to determine the capacity of your machine Genie A TEREX COMPANY 36 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual DECALS 82581 82544 28160 82472 Ground Serial label Controls 28171 A a Side i 82671 Pis AA or o cossa i A 82924 Fe DA Papiu 40434 89625 or 82626 KO e TAIN yn 82623 O A B or a Oy 82671 114099 82646 82623 82762 32728 or 82624 Platform 97815 82625 f 5 or 82626 82487 62921 ee KI o 38235 or 6
33. rrows 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 Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 27 Operator s Manual Fifth Edition Third Printing OPERATINGINSTRUCTIONS Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maximum slope rating counterweight uphill gradeability 2WD 30 17 AWD 45 24 Maximum slope rating counterweight downhill Dz 2WD 15 9 4WD 30 17 Maximum side slope rating 25 14 Note Slope rating is subject to ground conditions and adequate traction The term gradeability applies to the counterweight uphill configuration only Be sure the boom is below horizontal and the platform is between the non steer wheels Move the drive speed select switch to machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the vertical distance from the bottom of the piece of wood
34. should always remain closed Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 31 Operator s Manual Fifth Edition Third 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 Truck bed Securing the Platform S 80 Place a wooden 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 wooden 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 Genie A TEREX COMPANY 32 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Observe and Obey M Only qualified riggers should rig and lift the machine M Be sure the crane c
35. sired position 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position Gasoline LPG models 3 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 Perkins models 3 Move the engine start toggle switch to either side The glow plug light will come on After a few seconds the engine will start Deutz models 3 Move the glow plug switch to either side and hold for 3 to 5 seconds 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 All models If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again Genie 25 Operator s Manual Fifth Edition Third Printing OPERATINGINSTRUCTIONS 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 sho
36. switch Result All boom and platform functions should not operate 15 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 or jib 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 16 Turn the key switch to platform control 17 Open the tank side turntable cover and locate the tilt sensor between the fuel tank and the oil cooler 18 Press down one side of the tilt sensor Result The alarm located in the platform should sound Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 19 Operator s Manual Fifth Edition Third Printing FUNCTION TESTS Test Auxiliary Controls 19 Turn the key switch to ground control and shut the engine off 20 Pull out the ground red Emergency Stop button to the on position Note To conserve battery power test each function through a partial cycle 21 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch Result All boom functions should operate At the Platform Controls Test Emergency Stop 22 Turn the key switch to platform control a
37. t damage and hazardous conditions This procedure does not need to be performed on machines with sealed or maintenance free batteries Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING 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 Puton protective clothing and eye wear 2 Besure that the battery cable connections are tight and free of corrosion Genie A TEREX COMPANY Be sure that the battery hold down bars are secure Remove the battery vent caps Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill Install the vent caps Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 16 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury Tip over hazard Do not use AWARNING temporary flat tire repair products To safeguard ma
38. that might indicate the presence of hydraulic system problems 1 Be sure that the axles are fully retracted and the boom is in the stowed position 2 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 Chevron Rykon Premium MV equivalent MAINTENANCE Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems Burn hazard Beware of hot engine ACAUTION 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 Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 15 Operator s Manual Fifth Edition Third Printing MAINTENANCE Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can resultin engine componen
39. the axles or return the machine to the fully stowed position OPERATING INSTRUCTIONS Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Machine Not Level Indicator Light if equipped A Light on indicates machine is not level The tilt alarm will be sounding when this light is on Move the machine to a firm level surface Check Engine Light if equipped cry Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 Select engine idle rpm using the symbols on the hours control panel Se e7 When the foot switch is not pressed the engine will idle at the lowest rpm Turtle symbol Foot switch activated low idle Rabbit symbol Foot switch activated high idle Genie PartNo 1000231 S 80 S 85 29 Operator s Manual Fifth Edition Third Printing EEE OPERATINGINSTRUCTIONS Generator if equipped To start the generator move the generator toggle switch to the on position Plug a power tool into the power to platform GFCI outlet To turn off the generator move the generator toggle switch to the off position Note Machine functions will not operate while the generator is running and the foot switch is not pressed down When the foot switch is pressed down the generator w
40. the operator Refer to the list on the next page and check each of the items If damage or any unauthorized 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 Genie PartNo 1000231 Fifth Edition Third Printing Operator s Manual Pre operation Inspection J Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Q Be sure that all decals are legible and in place See Decals section L Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section Add oil if needed See Maintenance section L Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section L Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section L Check for proper tire pressure Add air if needed See Maintenance section
41. tober 2002 Fourth Edition Third Printing July 2004 Fifth Edition Third Printing May 2006 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 A TEREX COMPANY S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual 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 M 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Genie A TEREX COMPANY Part No 1000231 S 80 S 85 1 Operator s Manual Fifth Edition Third Printing
42. toggle switch Result All boom platform functions should operate through a full cycle Test the Steering 36 Press down the foot switch 37 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 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 Drive and Braking 39 Press down the foot switch 40 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 41 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
43. trical terminals SAFETY RULES 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 ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury gt Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury AWARNING A 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 ACAUTION A Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 7 Operator s Manual Fifth Edition Third Printing Controls 0 8 7 Platform Control Panel 1 Horn button 7 Deutz models Glow plug switch gt Platform level switch Perkins models Glow plug indicator light 3 Platform rotate switch 8 Engine start switch 9 Engine idle rpm sele
44. truck MI The transport vehicle must be parked on a level surface KI The transport vehicle must be secured to prevent rolling while the machine is being loaded M Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial plate for the machine weight See the Decals section for the serial plate location MI Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation M Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section MI If the slope of the transport vehicle bed exceeds the uphill or downhill maximum slope rating the machine must be loaded and unloaded using a winch as described See the Specifications section for the slope ratings 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 Disengage 4WD models Release the wheel brakes by turning over all four drive hub disconnect caps 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
45. uld be started on gasoline and warmed for 2 minutes then switched to LPG Warm engines can be started on LPG 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 1 Turn the key switch to ground or platform control Auxiliary Controls Use auxiliary power if the primary power source engine fails 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 Extend the Axles 1 Turn the key switch to platform control 2 Move the drive control handle in the forward direction and activate the axle extend function 3 The machine will drive and the axles will extend 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 Startthe engine To Position Platform 1 Extend the axles 2 Hold the function enable switch to either side 3 Move the appropr
46. weight configuration 750 Ibs 340 kg Maximum occupants 2 The weight of options and accessories such as pipe cradles panel cradles and welders will reduce the rated platform capacity and must be factored into the total platform load See the decals on the options Do not raise or extend the boom unless both axles are extended it Do not raise or extend the boom unless the machine is on a firm level surface Genie A TEREX COMPANY 2 S 80 S 85 Part No 1000231 Fifth Edition Third Printing Operator s Manual 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 raise the boom when wind speeds may exceed 28 mph 12 5 m s If wind speeds exceed 28 mph 12 5 m s when the boom is raised lower the boom and do not continue to operate the machine 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 Sy
47. ximum 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 MAINTENANCE 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 Tire Pressure 100 psi 6 89 bar High Flotation Tire Pressure 60 psi 4 14 bar Genie PartNo 1000231 A TEREX COMPANY S 80 S 85 17 Operator s Manual Fifth Edition Third Printing Function Tests Do Not Operate Unless M 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 fun
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