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Operator’s Manualwith Maintenance InformationSecond EditionFifth PrintingPart No. 43650

Operator's ManualSecond Edition· Fifth PrintingImportantRead, understand and obey these safety rules andoperating instructions before operating this machine.Only trained and authorized personnel shall bepermitted to operate this machine. This manualshould be considered a permanent part of yourmachine and should remain with the machine at alltimes. If you have any questions, call Genie Industries.ContentsPageSafety Rules . 1Controls . 7Pre-operation Inspection . 10Maintenance . 12Function Tests . 16Work Place Inspection . 22Operating Instructions . 23Transport Instructions . 27Decals . 28Specifications . 30 Copyright 1994 by Genie IndustriesContact us:First Edition:Internet: http://www.genielift.come-mail: techpub@genieind.comFirst Printing, August 1994Second Printing, February 1995Third Printing, March 1996Fourth Printing, September 1996Fifth Printing, October 1996Second Edition: First Printing, November 1996Second Printing, March 1997Third Printing, March 1998Fourth Printing, August 1999Fifth Printing, July 2000"Genie" is a registered trademark ofGenie Industries in the U.S.A. and many othercountries. "S" is a trademark of Genie Industries.These machines comply withANSI/SIA 92.5-1992.Printed on recycled paperPrinted in U.S.A.Genie S-80 & Genie S-85Part No. 43650

Second Edition · Fifth PrintingOperator's ManualSafety RulesDangerFailure to obey the instructions andsafety rules in this manual will resultin death or serious injury.Do Not Operate Unless:You learn and practice the principles of safemachine operation contained in this operator'smanual.1 Avoid hazardous situations.Know and understand the above principlebefore 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 safetyrules—safety and operator's manualsand machine decalsemployer's safety rules and worksiteregulationsapplicable governmental regulationsYou are properly trained to safely operate themachine.Part No. 43650Genie S-80 & Genie S-851

Operator's ManualSecond Edition· Fifth PrintingSAFETY RULESAllow for platform movement, electrical line sway orsag and beware of strong or gusty winds.Electrocution HazardsThis machine is not electrically insulated and willnot provide protection from contact with orproximity to electrical current.Keep away from the machine if it contactsenergized power lines. Personnel on the ground orin the platform must not touch or operate themachine until energized power lines are shut off.Do not operate the machine during lightning orstorms.Do not use the machine as a ground for welding.Tip-over HazardsOccupants and equipment shall not exceed themaximum platform capacity.Maintain safe distances from electrical power linesand apparatus in accordance with applicablegovernmental regulations and the following chart.VoltagePhase to PhaseMinimum SafeApproach DistanceFeet Meters0 to 300VAvoid Contact300V to 50KV103.0550KV to 200KV154.60200KV to 350KV206.10350KV to 500KV257.62500KV to 750KV3510.67750KV to 1000KV4513.722Maximum platform capacityS-85500 lbs227 kgMaximum platform capacityS-80 with 8 Ft Platform500 lbs227 kgMaximum platform capacityS-80 with 6 Ft Platform600 lbs272 kgMaximum platform capacityS-80 with 6 Ft Platformwith foam-filled tires and propercounterweight configuration750 lbs340 kgMaximum occupantsGenie S-80 & Genie S-852Part No. 43650

Second Edition · Fifth PrintingOperator's ManualSAFETY RULESDo not raise or extend the boom unless both axlesare extended.Do not drive the machine on or near uneven terrain,unstable surfaces or other hazardous conditionswith the boom raised or extended.Do not push off or pull toward any object outsideof the platform.Maximum allowableside force-ANSI & CSA150 lbs667 NMaximum allowablemanual force - CE90 lbs400 NDo not raise or extend the boom unless themachine is on a firm, level surface.Do not depend on tilt alarm as a level indicator. Tiltalarm sounds in platform only when machine is ona severe slope.If tilt alarm sounds:Do not extend, rotate or raise boom abovehorizontal. Move machine to a firm, level surfacebefore raising platform. If tilt alarm sounds whenplatform is raised, use extreme caution to retractboom and lower platform. Do not rotate boom whilelowering. Move machine to a firm, level surfacebefore raising platform.Do not alter or disable machine components that inany way affect safety and stability.Do not replace items critical to machine stabilitywith items of different weight or specification.Do not modify or alter an aerial work platform.Mounting attachments for holding tools or othermaterials onto the platform, toeboards or guard railsystem can increase the weight in the platform andthe surface area of the platform or the load.Do not operate the machine in strong or gustywinds. Do not increase the surface area of theplatform or the load. Increasing the area exposed tothe wind will decrease machine stability.Use extreme care and slow speeds while drivingthe machine in stowed position across uneventerrain, debris, unstable or slippery surfaces andnear holes and drop-offs.Part No. 43650Genie S-80 & Genie S-853

Operator's ManualSecond Edition· Fifth PrintingSAFETY RULESDo not place or attach overhanging loads to anypart of this machine.Fall HazardsOccupants must wear asafety belt or harness inaccordance withgovernmental regulations.Attach lanyard to anchorprovided in platform.Do not sit, stand or climb on the platform guardrails. Maintain a firm footing on the platform floor atall times.Do not place ladders or scaffolds in platform oragainst any part of this machine.Do not use machine on a moving or mobile surfaceor vehicle.Be sure all tires are in good condition, air-filled tiresare properly inflated and lug nuts are properlytightened.Models with 750 lb (340 kg) Capacity: Do notuse air-filled tires. Models are equipped with foamfilled tires. The wheel weight and the propercounterweight configuration are critical for machinestability.Do not climb down from the platform when raised.Do not use the platform controls to free a platformthat is caught, snagged or otherwise preventedfrom normal motion by an adjacent structure. Allpersonnel must be removed from the platformbefore attempting to free the platform using theground controls.Bodily Injury HazardKeep the platform floor clear of debris.Lower the platform entry mid-rail or close the entrygate before operating.Do not operate the machine with a hydraulic oil orair leak. An air or hydraulic leak can penetrateand/or burn skin.Always operate machine in a well-ventilated area toavoid carbon monoxide poisoning.4Genie S-80 & Genie S-85Part No. 43650

Second Edition · Fifth PrintingOperator's ManualSAFETY RULESDo not lower the boom unless the area below isclear of personnel and obstructions.Collision HazardsBe aware of limited sightdistance and blind spotswhen driving or operating.Be aware of boom position and tailswing whenrotating turntable.Check work area for overhead obstructions or otherpossible hazards.Limit travel speed according to condition of groundsurface, congestion, slope, location of personneland any other factors which may cause collision.Be aware of crushing hazard when grasping theplatform guard rail.It is recommended that operators wear an approvedhard hat when operating the machine.Observe and use color-coded direction arrows onthe platform controls and drive chassis for driveand steer functions.Do not operate a boom in the path of any craneunless the controls of the crane have been lockedout and/or precautions have been taken to preventany potential collision.No stunt driving or horseplay while operating amachine.Component Damage HazardsDo not use any battery or charger greater than 12Vto jump-start the engine.Do not use machine as a ground for welding.Be sure hydraulic shutoff valves (located byhydraulic tank) are open before starting engine.Part No. 43650Genie S-80 & Genie S-855

Operator's ManualSecond Edition· Fifth PrintingSAFETY RULESExplosion and Fire HazardsDecal LegendDo not start engine if you smell or detect liquidpetroleum gas (LPG), gasoline, diesel fuel or otherexplosive substances.Genie product decals use symbols, color codingand signal words to identify the following:Do not refuel machine with engine running.Refuel machine and charge battery only in an open,well-ventilated area away from sparks, flames andlighted tobacco.Do not operate the machine in hazardous locationsor locations where potentially flammable orexplosive gases or particles may be present.Damaged Machine HazardsDo not use a damaged or malfunctioning machine.Conduct a thorough pre-operation inspection of themachine and test all functions before each workshift. Immediately tag and remove from service adamaged or malfunctioning machine.Be sure all maintenance has been performed asspecified in this manual and the Genie S-80 &Genie S-85 Service Manual.Be sure all decals are in place and legible.Be sure that the operator’s, the safety and theresponsibilities manuals are complete, legible andin the storage container located on the platform.Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.Yellow without safety alertsymbol—used to indicate thepresense of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.Green—used to indicate operationor maintenance information.6Genie S-80 & Genie S-85Part No. 43650

Second Edition · Fifth PrintingOperator's d Control Panel12345678910Platform rotate switchTurntable rotate switchBoom up/down switchBoom extend/retract switchnot usedKey switch for platform/off/ground selectionAuxiliary power switchGasoline/LPG models: Water temperaturegaugeDeutz Diesel models: Oil temperature gaugeOil pressure gaugeVoltage gaugePart No. 4365011121314151617181920Emergency Stop buttonHour meterGasoline/LPG models: Check engine lightDeutz Diesel models: Glow plug switch(option)Function enable switchEngine start switch15A breaker for engine electrical circuitsGasoline/LPG select switch15A breaker for control electrical circuitsS-85 only: Jib boom up/down switchPlatform level switchGenie S-80 & Genie S-857

Operator's ManualSecond Edition· Fifth PrintingCONTROLS123413175616Platform Control Panel1 Service horn button7 Check engine light2 Platform level switch8 Engine start switch3 Platform rotate switch9 Engine idle (rpm) select switch· Rabbit & Foot Switch: foot switch activatedhigh idle· Turtle: low idle· Rabbit: high idle4 S-85 only: Jib boom up/down switch5 Auxiliary power switch6 Drive speed select switch8Genie S-80 & Genie S-85Part No. 43650

Second Edition · Fifth PrintingOperator's ManualCONTROLS71581491310121310 Gasoline/LPG models: Gasoline/LPG selectswitchDeutz Diesel models: Glow plug switch (option)1114 Drive enable indicator light15 Drive enable switch16 Proportional control handle for boomextend/retract11 Emergency Stop button12 Proportional control handle for drive function andthumb rocker for steer function17 Dual axis proportional control handle for boomup/down and turntable rotate left/right functions13 Optional equipmentPart No. 43650Genie S-80 & Genie S-859