Terex Genie S-60 FE Operator's Manual
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Terex Genie S-60 FE Operator's Manual

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Operator's Manual
S
-60 FE
®
S
-60 DC
®
Serial Number Range
from S60EM-101
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1299606GT

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Summary of Contents for Terex Genie S-60 FE

  • Page 1 Operator's Manual Serial Number Range -60 FE ® from S60EM-101 -60 DC ® with Maintenance Information Original Instructions First Edition Second Printing Part No. 1299606GT...

  • Page 2: Table Of Contents

    Specifications ............70 Copyright © 2021 by Terex Corporation First Edition: Second Printing, July 2021 Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity -60 FE •...

  • Page 3: Introduction

    First Edition • Second Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 First Edition • Second Printing Operator's Manual Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level Platform level, jib boom up/down, boom extend/retract,and boom up/down, platform overload indicator light Platform rotate Turntable rotate and platform rotate Jib boom up/down Sequential functions and movement:...
  • Page 5 First Edition • Second Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 First Edition • Second Printing Operator's Manual Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 8 First Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Machine not level Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Burn hazard Color coded Runaway hazard Collision hazard...
  • Page 9 First Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution Avoid contact Disconnect battery Voltage rating for Pressure rating for hazard power to platform air line to platform Recovery procedure if tilt alarm sounds while elevated. Platform downhill: Platform uphill: Read the Access by trained...

  • Page 10: General Safety

    First Edition • Second Printing Operator's Manual General Safety General Safety S-60 DC -60 FE • S ® ® -60 DC Part No. 1299606GT...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety S-60 DC -60 FE • S ® ® Part No. 1299606GT -60 DC...
  • Page 12 First Edition • Second Printing Operator's Manual General Safety S-60 DC -60 FE • S ® ® -60 DC Part No. 1299606GT...
  • Page 13 First Edition • Second Printing Operator's Manual General Safety S-60 FE -60 FE • S ® ® Part No. 1299606GT -60 DC...
  • Page 14 First Edition • Second Printing Operator's Manual General Safety S-60 FE -60 FE • S ® ® -60 DC Part No. 1299606GT...
  • Page 15 First Edition • Second Printing Operator's Manual General Safety S-60 FE -60 FE • S ® ® Part No. 1299606GT -60 DC...

  • Page 16: Personal Safety

    First Edition • Second Printing Operator's Manual Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants 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.

  • Page 17: Work Area Safety

    First Edition • Second Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 18 First Edition • Second Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds with the boom unless the machine platform uphill: is on a firm, level surface. Lower the boom. Retract the boom. If the tilt alarm sounds with the platform downhill: Retract the boom.
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Use extreme care and Do not alter or disable machine components that slow speeds while driving in any way affect safety and stability. the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 20 First Edition • Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 21 First Edition • Second Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 22 First Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 23 First Edition • Second Printing Operator's Manual Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 24 First Edition • Second Printing Operator's Manual Work Area Safety Electrocution/Burn Hazards Contact Alarm Safety Connect the battery charger to a Read, understand and obey all warnings and grounded, AC 3-wire electrical instructions provided with the contact alarm. outlet only. Do not exceed the rated platform capacity.
  • Page 25 First Edition • Second Printing Operator's Manual Work Area Safety Pipe Cradle Safety Panel Cradle Safety Read, understand, and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
  • Page 26 First Edition • Second Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 27: Legend

    First Edition • Second Printing Operator's Manual Legend Legend Non-steer tire Swing gate Steer tire Platform Ground controls Lanyard anchorage points Boom 10 Sliding mid-rail Jib boom 11 Manual storage container Platform controls 12 Foot switch -60 FE • S ®...

  • Page 28: Controls

    First Edition • Second Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 29 First Edition • Second Printing Operator's Manual Controls Ground Control Panel Key switch for off/ground/platform selection Turn the key switch to the off position and the Function enable button machine will be off. Turn the key switch to the Press and hold the function enable button to ground position and the ground controls will enable the functions on the ground control operate.
  • Page 30 First Edition • Second Printing Operator's Manual Controls Hybrid mode light: FE models 12 Platform overload indicator light Light on indicates the machine is in Hybrid Light flashing indicates the platform is mode overloaded and no functions will operate. Remove weight until the light goes off. Machine mode select switch: FE Models 13 Turntable rotate switch Move the switch to the left to select DC mode...
  • Page 31 First Edition • Second Printing Operator's Manual Controls 15 Auxiliary power switch Use auxiliary power if the primary power source (engine) is not available. Simultaneously hold the auxiliary power switch to either side and activate the desired function. 16 Recovery switch Recovery switch should be used only by trained and authorized personnel.
  • Page 32 First Edition • Second Printing Operator's Manual Controls Platform Control Panel -60 FE • S ® ® -60 DC Part No. 1299606GT...
  • Page 33 First Edition • Second Printing Operator's Manual Controls Platform Control Panel -60 FE • S ® ® Part No. 1299606GT -60 DC...
  • Page 34 First Edition • Second Printing Operator's Manual Controls Platform Control Panel Boom extend/retract switch Horn button Move the boom extend/retract switch to the Press this button and the horn will sound. right and the boom will Release the button and the horn will stop. extend.
  • Page 35 First Edition • Second Printing Operator's Manual Controls 11 Dual axis proportional control handle for drive 12 Drive enable indicator light and steer functions. Light on indicates that the boom has moved just past either non-steer wheel and drive Proportional control handle for drive function function has been interrupted.
  • Page 36 First Edition • Second Printing Operator's Manual Controls 17 Platform overload indicator light Light flashing indicates the platform is overloaded. The engine will stop and no functions will operate. Remove weight until the light goes off and then restart the engine. 18 Machine mode select switch: FE Models Move the switch to the left to select DC mode Move the switch to the right to select Hybrid...

  • Page 37: Inspections

    First Edition • Second Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 38 First Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection ❑ Tires and wheels ❑ FE Models - Engine and related ❑ Verify the operator’s manual, safety manual, components responsibilities manual and any necessary ❑ Limit switches, angle sensors and horn supplements are complete, legible and in the storage container located in the platform.
  • Page 39 First Edition • Second Printing Operator's Manual Inspections 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 Do Not Operate Unless: tagged and removed from service.
  • Page 40 First Edition • Second Printing Operator's Manual Inspections At the Ground Controls Test Auxiliary Power FE Models: Select a test area that is firm, level and free of hazards. 10 Turn the key switch to ground control. Turn the key switch to ground control. 11 Pull out the red Emergency Stop button to the on position.
  • Page 41 First Edition • Second Printing Operator's Manual Inspections Test the Tilt Sensor At the Platform Controls FE Models: 17 Select a test area that is firm, level and free of 25 Turn the key switch to platform control. hazards. 26 Pull out the red Emergency Stop button to the 18 Turn the key switch to ground control.
  • Page 42 First Edition • Second Printing Operator's Manual Inspections Test the Foot Switch Test Machine Functions DC Models: 39 Press down the foot switch. 32 Do not press down the foot switch. Test each 40 Activate each machine function control handle machine function.
  • Page 43 First Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 44 Press down the foot switch. 47 Press down the foot switch and lower the boom to the stowed position. 45 Slowly move the drive control handle in the direction indicated by the blue arrow on the 48 Rotate the turntable until the boom moves past control panel until the machine begins to...
  • Page 44 First Edition • Second Printing Operator's Manual Inspections Test Limited Drive Speed Test Drive Tilt Cutout 51 Press down the foot switch. 57 Press down the foot switch. 52 Raise the boom approximately 5° above the 58 With the boom fully stowed, drive the machine horizontal.
  • Page 45 First Edition • Second Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) 66 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 75 Drive the right steer tire up onto a 6 in/15 cm greater than 4.5°.
  • Page 46 First Edition • Second Printing Operator's Manual Inspections 88 Operate each machine function. Test the Lift/Drive Select Function (if equipped) Result: All machine functions should not operate. 82 Press down the foot switch. 89 Insert the actuator into the switch socket. 83 Move the drive control handle off center and activate a boom function toggle switch.
  • Page 47 First Edition • Second Printing Operator's Manual Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 91 Extend the boom approximately 1 ft/30 cm. 92 Move the yellow bumper at the bottom of the platform 4 inches/10 cm in any direction.
  • Page 48 First Edition • Second Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations: ❑ drop-offs or holes ❑ bumps, floor obstructions, or debris ❑ sloped surfaces Do Not Operate Unless: ❑ unstable or slippery surfaces ...
  • Page 49 First Edition • Second Printing Operator's Manual Inspections Inspection for Decals with 1256425 Label – Danger, Electrocution Hazard Symbols - S-60 DC 1263542 Label – Compartment Access 1265361 Label – Battery Charger Indicator Determine whether the decals on your machine have words or symbols.
  • Page 50 First Edition • Second Printing Operator's Manual Inspections -60 FE • S ® ® -60 DC Part No. 1299606GT...
  • Page 51 First Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Label – Electrocution/Burn Hazard Symbols - S-60 FE 133205 Label – Power to Charger, Universal 133286 Determine whether the decals on your machine Label – Platform Overload 219956 have words or symbols.
  • Page 52 First Edition • Second Printing Operator's Manual Inspections -60 FE • S ® ® -60 DC Part No. 1299606GT...

  • Page 53: Operating Instructions

    First Edition • Second Printing Operator's Manual Operating Instructions Operating Instructions 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.
  • Page 54 First Edition • Second Printing Operator's Manual Operating Instructions Machine Operation Emergency Stop FE models can be operated with or without the Push in the red Emergency Stop button to the off engine running. position at the ground controls or the platform controls to stop all functions.
  • Page 55 First Edition • Second Printing Operator's Manual Operating Instructions Auxiliary Power FE Models: Starting the Engine Use auxiliary power if the primary power source From the ground control panel: fails. Turn the key switch to ground control. Turn the key switch to ground or platform Be sure both ground and platform control red control.
  • Page 56 First Edition • Second Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Note: When operating the machine from the platform, the following foot switch messages may Pull out the red Emergency Stop button to the appear on the platform control LCD screen.
  • Page 57 First Edition • Second Printing Operator's Manual Operating Instructions To Steer To Drive Press down the foot switch. Press down the foot switch. Slowly move the drive control handle in the Increase speed: Slowly move the control direction indicated by blue or yellow triangles handle off center.
  • Page 58 First Edition • Second Printing Operator's Manual Operating Instructions Driving on a slope At the downhill end, lay the level on the top edge of the piece of wood and lift the end until the piece Determine the uphill, downhill and side slope of wood is level.
  • Page 59 First Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Function Speed Control Light flashing indicates that the Move the switch to the boom has moved just past left to decrease the either non-steer wheel and the function speeds for jib drive function has been up/down, platform rotate interrupted.
  • Page 60 First Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Platform Overload Indicator Light If the tilt alarm sounds when the Light flashing indicates the platform is raised, the Machine platform is overloaded and no Not Level indicator light will come functions will operate.
  • Page 61 First Edition • Second Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) Aircraft Protection Package (if equipped) The contact alarm is designed to alert ground If the platform bumper comes personnel when an operator makes contact with into contact with an object, the the platform control panel, interrupting boom machine will shut down and no movement, sounding an alarm and flashing...
  • Page 62 First Edition • Second Printing Operator's Manual Operating Instructions FE Models: Charging Batteries with Engine Running the engine will automatically charge the batteries. The engine will automatically shut off when the battery charge cycle reaches 85%. After the charge cycle reaches 85% the platform Battery and Charger Instructions control panel LCD screen will display the following message, HYBRID CHARGE COMPLETE.
  • Page 63 First Edition • Second Printing Operator's Manual Operating Instructions Pipe Cradle Instructions Dry Battery Filling and Charging Instructions The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform This procedure applies to flooded lead acid and mounted to the guardrails with U-bolts.
  • Page 64 First Edition • Second Printing Operator's Manual Operating Instructions Panel Cradle Assembly Installation of Padding Apply the warning decal to the front of each Install the 2 pieces of padding on the platform panel cradle (if needed). rails. Position the padding to protect the panels from contact with the platform rails.
  • Page 65 First Edition • Second Printing Operator's Manual Operating Instructions Panel Cradle Operation Secure both panel cradles to the platform. Place the load so that it rests in both panel cradles. Center the load on the platform. Secure the load to the platform using the strap.

  • Page 66: Transport And Lifting Instructions

    First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 67 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 6 chains. time the machine is transported.
  • Page 68 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 69: Maintenance

    First Edition • Second Printing Operator's Manual Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 70 First Edition • Second Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Hydraulic Oil Level Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 71 First Edition • Second Printing Operator's Manual Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 72: Specifications

    First Edition • Second Printing Operator's Manual Specifications Specifications Model Ambient operating temperature -20° F to 120° F S-60 FE/DC -29° C to 49° C Height, working maximum 67 ft 2 in 20.6 m Controls 24V DC proportional Height, platform maximum 61 ft 2 in 18.6 m AC outlet in platform...
  • Page 73 First Edition • Second Printing Operator's Manual Specifications S-60 FE/DC Maximum platform capacity 660 lbs 300 kg Horizontal Values Vertical Values -10 ft -3 m 40 ft 12.2 m 0 ft 50 ft 15.2 m 10 ft 60 ft 18.3 m 20 ft 6.1 m 70 ft...
  • Page 74 First Edition • Second Printing Operator's Manual Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

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Genie s-60 dc

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