Genie S-85 Operator'S Manual Download

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Operator's Manual

S-85

ANSI/CSA
North

America

South

America

Asia

with
Maintenance
Information

Seventh Edition
Third Printing
Part No. T107108

Summary of Contents for S-85

Page 1: ...Operator s Manual S 85 ANSI CSA North America South America Asia with Maintenance Information Seventh Edition Third Printing Part No T107108 ...

Page 2: ...you have any questions contact us Contact Us Internet www genielift com E mail awp techpub terex com Contents Introduction 1 Symbol and Hazard Pictorials Definitions 3 General Safety 5 Personal Safety 11 Work Area Safety 12 Legend 21 Controls 22 Inspections 30 Operating Instructions 42 Transport and Lifting Instructions 52 Maintenance 56 Specifications 60 Copyright 1995 by Terex Corporation Sevent...

Page 3: ...upervision running the machine 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 safety rules before going on to the next section 2 Always perform a pre operation i...

Page 4: ...rious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Indicates a property damage message Intended Use This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Safety Sign Maintenance Replace ...

Page 5: ...cution hazard Maintain required clearance Crush hazard Keep away from path of moving platform Fall hazard Keep off this surface Tip over hazard Platform downhill 1 Retract boom 2 Lower boom Platform uphill 1 Lower boom 2 Retract boom Tip over hazard Replace tires with tires of same specification Tip over hazard Read the operator s manual Only trained maintenance personnel should access compartment...

Page 6: ...platform Pressure rating for air line to platform Have fire extinguisher near Electrocution hazard Avoid contact Tie down instructions Read the service manual Weight of welder reduces capacity Keep open flames away Explosion Burn hazard Explosion hazard Do not use ether or other high energy starting aids on machines equipped with glow plugsll Tie down instructions Fire hazard ...

Page 7: ...Seventh Edition Third Printing Operator s Manual General Safety Part No T107108 S 85 5 General Safety ...

Page 8: ...Operator s Manual Seventh Edition Third Printing General Safety 6 S 85 Part No T107108 ...

Page 9: ...Seventh Edition Third Printing Operator s Manual General Safety Part No T107108 S 85 7 ...

Page 10: ...Operator s Manual Seventh Edition Third Printing General Safety 8 S 85 Part No T107108 ...

Page 11: ...Seventh Edition Third Printing Operator s Manual General Safety Part No T107108 S 85 9 ...

Page 12: ...Operator s Manual Seventh Edition Third Printing General Safety 10 S 85 Part No T107108 ...

Page 13: ...ccupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchor provided in the platform Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s...

Page 14: ... 10 ft 3 05 m 50 to 200KV 15 ft 4 60 m 200 to 350KV 20 ft 6 10 m 350 to 500KV 25 ft 7 62 m 500 to 750KV 35 ft 10 67 m 750 to 1000KV 45 ft 13 72 m 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 p...

Page 15: ...on a severe slope If the tilt alarm sounds when the platform is raised use extreme caution Identify the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering If the tilt alarm sounds with the platform uphill 1 Lower the boom 2 Retract the boom If the tilt alarm sounds with the platform downhi...

Page 16: ...Do not tie the boom or platform to adjacent structures Do not place loads outside the platform perimeter Do not push off or pull toward any object outside of the platform Maximum allowable side force ANSI CSA 150 lbs 667 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 speci...

Page 17: ...face or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened 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 Operation on S...

Page 18: ... enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of the boom position and tailswing when rotating the turntable Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platf...

Page 19: ...ments must remain closed and secured during operation 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 mach...

Page 20: ...chine in locations where extremely high magnetic fields may be present Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazards Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas...

Page 21: ...connector at the turntable and platform Clamp the negative lead to the ground post at the turntable and platform Pipe Cradle Safety Read understand and obey all warnings and instructions provided with the pipe cradles Do not exceed the rated platform capacity The pipe cradle assembly and the weight in the pipe cradles will reduce rated platform capacity and must be factored into total platform loa...

Page 22: ...th lifting panels Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Maximum vertical height of panels 4 ft 1 2 m Maximum wind speed 15 mph 6 7 m sec Maximum panel area 32 sq ft 3 m2 Tow Package Safety Read understand and obey all warnings and instructions provided with the tow package When vehicle is in free wheel configuration there are no ...

Page 23: ...ator s Manual Legend Part No T107108 S 85 21 Legend 1 Non steer tire 2 Steer tire 3 Ground controls 4 Boom 5 Jib boom 6 Platform controls 7 Platform 8 Lanyard anchorage point 9 Sliding mid rail 10 Manual storage container 11 Foot switch ...

Page 24: ...Operator s Manual Seventh Edition Third Printing Controls 22 S 85 Part No T107108 Controls 1 2 3 4 5 6 22 21 20 19 17 16 18 ...

Page 25: ...Seventh Edition Third Printing Operator s Manual Controls Part No T107108 S 85 23 STOP 7 8 9 9 9 9 10 15 11 14 13 12 ...

Page 26: ...oom switch down and the jib boom will lower 5 Drive speed select switch Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed 6 Emergency power switch Use emergency power if the primary power source engine fails Simultaneously hold the emergency power switch to either side and activate the desired function 7 Machine ...

Page 27: ...he right 12 Drive enable switch To drive when the drive enable light is on 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 13 Drive enable indicator light Light on indicates that the boom has moved just past either non steer wheel and drive functi...

Page 28: ... bottom of the rocker switch and the boom will extend 22 Dual axis proportional control handle for boom up down and turntable rotate left right functions Move the control handle up and the boom will raise Move the control handle down and the boom will lower Move the control handle to the right and the turntable will rotate to the right Move the control handle to the left and the turntable will rot...

Page 29: ...ve one of these two styles of ground control panel The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels unless specifically noted STOP 12 11 9 7 17 13 10 13 2 8 19 15 18 23 16 5 22 14 21 4 20 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 8 18 19 ...

Page 30: ...up down switch up and the boom will raise Move the boom up down switch down and the boom will lower 10 Machine malfunction indicator light Light on indicates all functions have stopped See the instructions in the Operating Instructions section 11 Boom extend retract switch Move the boom extend retract switch to the right and the boom will extend Move the boom extend retract switch to the left and ...

Page 31: ...tform rotate switch to the left and the platform will rotate to the left 20 Hour meter The hour meter displays the number of hours the machine has operated 21 Glow plug switch Move the glow plug switch to either side and hold for 3 to 5 seconds 22 Gasoline LPG models Fuel select switch Move the fuel select switch to the gasoline position to select gasoline Move the fuel select switch to the LPG po...

Page 32: ...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 If damage or any unauthorize...

Page 33: ...ction Check for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine ...

Page 34: ...the machine as it was intended Function Test 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 onl...

Page 35: ...form functions should operate 8 Press and hold the function enable button 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 is lowering Test the Tilt Sensor 9 Pull out the platform red Emergency Stop button to the on position Turn the key switch to platform ...

Page 36: ...he foot switch and restart the engine Result The engine should start 23 Do not press down the foot switch and test each machine function Result No functions should operate Test Machine Functions 24 Press down the foot switch 25 Activate each machine function control handle or toggle switch Result All boom and platform functions should operate through a full cycle Test the Steering 26 Press down th...

Page 37: ...5 cm block or curb Result The three remaining tires should stay in firm contact with the ground 34 Drive the left steer tire up onto a 6 in 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground 35 Drive both steer tires up onto a 6 in 15 cm block or curb Result The non steer tires should stay in firm contact with the ground Test the Drive Enable System 36...

Page 38: ...ion Result The maximum achievable drive speed with the boom extended should not exceed 1 ft 30 cm per second If the drive speed with the boom raised or extended exceeds 1 ft 30 cm per second immediately tag and remove the machine from service Test Emergency Controls 46 Shut off the engine 47 Pull out the red Emergency Stop button to the on position 48 Press down the foot switch 49 Simultaneously h...

Page 39: ...or 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 Workplace Inspection Checklist Be aware of and avoid the following hazardous situations ...

Page 40: ...2237 Danger Electrocution Hazard option 3 82366 Label Chevron Rando 1 82410 Warning Panel Cradle option 2 Part No Decal Description Qty 82862 Danger Fire Extinguisher Welder option 1 97579 Danger Tip over Welder option 1 97602 Warning Explosion Hazard 1 97815 Label Lower Mid rail 1 97875 Warning Weld Line to Platform 2 97887 Instructions Max Side Force 150 lbs 667 N ANSI 1 111896 Instructions Cont...

Page 41: ...Seventh Edition Third Printing Operator s Manual Inspections Part No T107108 S 85 39 ...

Page 42: ...x 2 1 52967 Cosmetic 4 x 4 1 62922 Cosmetic Genie S 85 1 62923 Cosmetic S 85 2 65278 Label No Step 4 82472 Label Crushing Hazard 5 Part No Decal Description Qty 82473 Label Compartment Access 1 82481 Label Battery Charger Safety 1 82487 Label Read the Manual 2 82548 Label Platform Rotate 2 82601 Label Maximum Load 227 kg 1 82602 Label Max Manual Force 667 N ANSI 1 82671 Label Weld Line to Platform...

Page 43: ...Seventh Edition Third Printing Operator s Manual Inspections Part No T107108 S 85 41 ...

Page 44: ... 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 m...

Page 45: ...the ground controls will display the glow plug symbol when the automatic glow plugs are on 6 The glow plug indicator light in the platform box will come on when the automatic glow plugs are on 7 When the automatic glow plug symbol on the ground control box or the indicator in the platform turns off move the engine start toggle switch to either side If the engine fails to start or dies the restart ...

Page 46: ...l handle or toggle switch or press the appropriate button according to the markings on the control panel To Steer 1 Press down the foot switch 2 Slowly move the drive 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 ...

Page 47: ...d level measure the vertical distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example 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 slope or side slope rating then...

Page 48: ... will turn the generator off Releasing the foot switch will turn the generator back on Plug a power tool into the power to platform GFCI outlet To stop the generator move the generator toggle switch to the off position 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 Machin...

Page 49: ...eter voltage oil pressure and coolant temperature The screen also displays fault codes and other service information Perkins Engine Machines equipped with Perkins diesel engines with an LCD screen have a regeneration mode that should run automatically when needed Left amber light on and high temperature text box present Regeneration mode is running No service required Right side amber light on or ...

Page 50: ...he bottom of the pipe cradle tube rests on the platform floor 2 Install two U bolts from the outside of the platform rails through each pipe cradle mount 3 Secure each U bolt with 2 washers and 2 nuts Pipe Cradle Operation 1 Be sure the pipe cradle assembly and installation instructions have been followed properly and that the pipe cradles are secured to the platform railings 2 Place the load so t...

Page 51: ...tion 1 Insert the hook piece through the slots in the panel cradle base 2 Hook the panel cradle to the bottom platform tube in the desired location 3 Install rubber bumper 2 through the panel cradle base and the hook piece See the illustration 4 Secure with 2 low profile lock nuts 5 If the panel cradle is installed at a platform floor support tube insert the U bolt through the floor around the tub...

Page 52: ...ne side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly end plate should be able to slide on the platform rail Panel Cradle Operation 1 Secure both panel cradles to the platform 2 Place the load so that it rests in both panel cradles 3 Center the load on t...

Page 53: ...ve torque hubs by turning over the drive disconnect caps 5 Turn the steering bypass valve counterclockwise to hydraulically release the steering Do not exceed recommended maximum towing speed or maximum towing times Maximum tow speed 8 mph 12 87 km h Maximum towing time at 8 mph 13 km h 30 minutes Maximum towing time at 6 mph 10 km h 60 minutes After Towing 1 Immediately after towing chock the whe...

Page 54: ... surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight Be sure the turntable is secured with the turntable rotation lock before transporting Be sure the unlock the turntable for operation Do not drive the machine on a slope that exceeds the uphill downhill or side slope rating See D...

Page 55: ...remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains or straps of ample load capacity Use a minimum of 5 chains Adjust the rigging to prevent damage to the chains Securing the Platform S 85 Place a block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap plac...

Page 56: ...ting Instructions 54 S 85 Part No T107108 Observe and Obey Only qualified riggers should rig and lift the machine Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial label for the machine weight ...

Page 57: ...ntable 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 All four of the lifting points are on the turntable Adjust the rigging to prevent damage to the machine and to keep the machine level Center of gravity X Axis Y Axis S 85 62 54 in 52 73 in 1...

Page 58: ...s 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 Note Check ...

Page 59: ...Deutz D2011 L04i Engine Fuel Type Low Sulfur Diesel LSD Deutz TD2 9L Engine Fuel Type Ultra Low Sulfur Diesel ULSD 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 hydraul...

Page 60: ...n the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark on the tank or visible in the sight gauge Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot o...

Page 61: ...m 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 High flotation tire pressure 70 psi 4 8 bar 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...

Page 62: ...Fuel tank capacity gasoline 30 gallons 113 6 liters Tire size 18 625 16 ply FF Tire size High Floatation 41 18LL x 22 5 14 ply Airborne noise emissions 106 dB Maximum sound level at normal operating workstations A weighted Weight 38 000 lbs 17 237 kg Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating stowed position 2WD Platform uphill...

Page 63: ...art No T107108 S 85 61 S 85 Range of Motion S 85 Part No T107108 Operator s Manual Seventh Edition Third Printing 10 ft 3 1 m 30 ft 9 1 m 70 ft 21 0 m 50 ft 15 m 0 ft 0 m 10 ft 3 1 m 10 ft 3 1 m 20 ft 6 10 m 80 ft 24 4 m 40 ft 12 2 m 60 ft 18 3 m 10 ft 3 1 m 0 ft 0 m ...

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