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Operator’s Manual

with Maintenance Information

Second Edition

Fifth Printing

Part No. 43650

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Summary of Contents for 43650

Page 1: ...Operator s Manual with Maintenance Information Second Edition Fifth Printing Part No 43650 ...

Page 2: ... Genie Industries These machines comply with ANSI SIA92 5 1992 Printed on recycled paper Printed in U S A 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 a...

Page 3: ...nual 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 ...

Page 4: ... 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 Tip ...

Page 5: ...he surface area of the platform or the load Do not raise or extend the boom unless both axles areextended 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 le...

Page 6: ...atform 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 accordancewith governmentalregulations Attach lanyard to anchor provided in platform Do not sit stand or climb on the platform gua...

Page 7: ...ls and drive chassis for drive and steer functions 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...

Page 8: ... 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 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 mes...

Page 9: ...selection 7 Auxiliary power switch 8 Gasoline LPGmodels Watertemperature gauge Deutz Diesel models Oil temperature gauge 9 Oil pressure gauge 10 Voltage gauge 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 selec...

Page 10: ...tart switch 9 Engine idle rpm select switch Rabbit Foot Switch foot switch activated high idle Turtle low idle Rabbit high idle 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 17 2 3 4 5 6 16 13 ...

Page 11: ...tch option 11 Emergency Stop button 12 Proportional control handle for drive function and thumb rocker for steer function 13 Optionalequipment 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 7 8 9 10 11 13 14 15 12 13 ...

Page 12: ...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 ma...

Page 13: ...ed See Maintenancesection 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 w...

Page 14: ...es that new parts will be required to perform this procedure Indicates that a cold engine is required beforeperformingthisprocedure 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 G...

Page 15: ... 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 th...

Page 16: ... 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 aci...

Page 17: ...en 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 Maintenance Inspection Report The maintenan...

Page 18: ...ing to the manufacturer s specifications After repairs are completed the operator must perform a pre 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 Beacon if equipped ...

Page 19: ...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 an...

Page 20: ...ne Test the Hydraulic Oil Return Filter 28 Move the engine idle select switch to high idel rabbitsymbol 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 se...

Page 21: ...n the drive chassis 44 Depress the thumb rocker switch in the direction identified by the yellow triangle on the controlpanel Result Steer wheels should turn in the direction that the yellow triangles point on the drive chassis 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 d...

Page 22: ...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 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 enabl...

Page 23: ...lt All boom and steer functions should operate Drive functions should not operate with auxiliarypower FUNCTION TESTS 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 fun...

Page 24: ... 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 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 th...

Page 25: ...t operates when the Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform Emergency Stop button 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 th...

Page 26: ...ontrols 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 Simulta...

Page 27: ...tch 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 wheels will turn 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 t...

Page 28: ...anel Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle Check Engine Light if equipped Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Stopping the Engine Push in the red Emergency Stop button and turn the key switch to the OFF position After Eac...

Page 29: ...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 Observe and Obey Transport vehicle must be parked on a level surface Transport vehicle must be secured to prevent rolling while machine is being ...

Page 30: ...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 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 E...

Page 31: ...No 43650 Genie S 80 Genie S 85 29 Operator s Manual Second Edition Fifth Printing DECALS Ground Controls Side Engine Side Shading indicates decal is hidden from view i e under covers Platform Drive Chassis ...

Page 32: ... 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 widt...

Page 33: ...73 27 11 455 0355 55 11 4055 2499 55 11 4043 1661 Genie Holland Genie Scandinavia Genie France Genie Iberica Genie Germany Genie U K Genie Mexico City Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax 31 70 51 78836 31 70 51 13993 46 31 3409612 33 0 2 37 26 09 99 33 0 2 37 26 09 98 34 93 579 5042 34 93 579 5059 49 0 4202 88520 49 0 4202 8852 20 44 0 1476 584333 44 0 1476 584334...

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