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

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Operator's Manual
S
-60 J
®
Serial Number Range
from S60JH-101
from S60JD-101
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1283765GT

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Summary of Contents for Terex Genie S-60 J

  • Page 1 Operator's Manual Serial Number Range -60 J ® from S60JH-101 from S60JD-101 with Maintenance Information Original Instructions First Edition Second Printing Part No. 1283765GT...

  • Page 2: Table Of Contents

    Specifications ............64 Copyright © 2018 by Terex Corporation First Edition: Second Printing, May, 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 ®...

  • 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 rotate Turntable rotate and platform rotate Jib boom up/down Sequential functions and movement: Boom up/down...
  • 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 Weight of welder reduces capacity Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • 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 ® -60 J Part No. 1283765GT...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety ® Part No. 1283765GT -60 J...
  • Page 12 First Edition • Second Printing Operator's Manual General Safety ® -60 J Part No. 1283765GT...

  • Page 13: 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 14: 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 15 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 16 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 17 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 18 First Edition • Second Printing Operator's Manual Work Area Safety Keep the platform floor clear of debris. Fall Hazards Lower the platform entry mid-rail or close the entry Occupants must wear a gate before operating. safety belt or harness in accordance with Do not enter or exit the platform unless the governmental...
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Collision Hazards Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Be aware of limited sight and steer functions. distance and blind spots when driving or operating.
  • Page 20 First Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Always operate the machine in a well-ventilated Do not use a damaged or malfunctioning machine. area to avoid carbon monoxide poisoning. Conduct a thorough pre-operation inspection of Do not operate the machine with a hydraulic oil or the machine and test all functions before each air leak.
  • Page 21 First Edition • Second Printing Operator's Manual Work Area Safety Battery Safety Contact Alarm Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the contact alarm. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective weight of the contact alarm assembly will reduce clothing and eye wear when...
  • Page 22 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 23 First Edition • Second Printing Operator's Manual Work Area Safety Welder Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the welding power unit. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not connect weld leads or cables unless the position.

  • Page 24: 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 J Part No. 1283765GT...

  • Page 25: 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 26 First Edition • Second Printing Operator's Manual Controls Ground Control Panel LCD readout screen Screen displays hour meter, voltage, oil Function enable button pressure and coolant temperature. Screen Press and hold the function enable button to also displays fault codes and other service enable the functions on the ground control information.
  • Page 27 First Edition • Second Printing Operator's Manual Controls 11 Key switch for off/ground/platform selection 16 Platform level down button Turn the key switch to the off position and the Press the platform level down button and the machine will be off. Turn the key switch to the level of the platform will lower.
  • Page 28 First Edition • Second Printing Operator's Manual Controls Platform Control Panel ® -60 J Part No. 1283765GT...
  • Page 29 First Edition • Second Printing Operator's Manual Controls ® Part No. 1283765GT -60 J...
  • Page 30 First Edition • Second Printing Operator's Manual Controls Platform Control Panel Fault indicator light Light on indicates a system fault. Horn button Press this button and the horn will sound. Platform overload indicator light Release the button and the horn will stop. Light flashing indicates the platform is overloaded.
  • Page 31 First Edition • Second Printing Operator's Manual Controls 13 Dual axis proportional control handle for drive 15 Drive enable switch and steer functions. To drive when the drive enable light is flashing, hold the drive enable switch to either Proportional control handle for drive function side and slowly move the drive control handle and thumb rocker for steer function.
  • Page 32 First Edition • Second Printing Operator's Manual Controls 20 Thumb rocker switch for boom extend/retract function Push the top of the rocker switch and boom will retract. Push the bottom of the rocker switch and the boom will extend. 21 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions Move the control handle up and...

  • Page 33: 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 34 First Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection ❑ Primary boom angle sensor ❑ Turntable level sensor ❑ Verify the operator’s manual, safety manual, ❑ Alarms and beacons (if equipped) responsibilities manual and any necessary supplements are complete, legible and in the ❑...
  • Page 35 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 36 First Edition • Second Printing Operator's Manual Inspections At the Ground Controls Test Machine Functions Select a test area that is firm, level and free of Do not push the function hazards. enable button. Attempt to activate each boom and Turn the key switch to ground control.
  • Page 37 First Edition • Second Printing Operator's Manual Inspections Test Auxiliary Power Test Emergency Stop 10 Turn the key switch to ground control and shut 15 Start the engine. the engine off. 16 Push in the platform red Emergency Stop 11 Pull out the red Emergency Stop button to the button to the off position.
  • Page 38 First Edition • Second Printing Operator's Manual Inspections Test Machine Functions Test Drive and Braking 24 Press down the foot switch. 29 Press down the foot switch. 25 Activate each machine function control handle 30 Slowly move the drive control handle in the or toggle switch.
  • Page 39 First Edition • Second Printing Operator's Manual Inspections Test Limited Drive Speed Test the Drive Enable System 40 Press down the foot switch. 36 Press down the foot switch and lower the boom to the stowed position. 41 Raise the boom approximately 5° above horizontal.
  • Page 40 First Edition • Second Printing Operator's Manual Inspections Test Drive Tilt Cutout 55 Press down the foot switch. 46 Press down the foot switch. 56 With the boom fully stowed, drive the machine onto a slope where the roll angle is greater 47 With the boom fully stowed, drive the machine than 5°...
  • Page 41 First Edition • Second Printing Operator's Manual Inspections 70 Operate each machine function. Test the Contact Alarm (if equipped) Result: All machine functions should operate. 64 Do not activate the foot switch and press on the contact alarm cable to release the actuator from the switch socket.
  • Page 42 First Edition • Second Printing Operator's Manual Inspections Test Auxiliary Power Test Aircraft Protection Package (if equipped) 71 Shut the engine off. Note: Two people may be required to perform this 72 Pull out the red Emergency Stop button to the test.
  • Page 43 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 44 First Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1258949 Ground Control Panel 1263540 Label – Tip-over Hazard Determine whether the decals on your machine 1263542 Label – Compartment Access have words or symbols. Use the appropriate 1272242 Label –...
  • Page 45 First Edition • Second Printing Operator's Manual Inspections ® Part No. 1283765GT -60 J...

  • Page 46: 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 47 First Edition • Second Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop Push in the red Emergency Stop button to the off Diesel models position at the ground controls or the platform controls to stop all machine functions and turn the At the ground controls, turn the key switch to engine off.
  • Page 48 First Edition • Second Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 49 First Edition • Second Printing Operator's Manual Operating Instructions To Drive To determine the slope grade: Press down the foot switch. Measure the slope with a digital inclinometer OR use the following procedure. Increase speed: Slowly move the control handle off center. You will need: Decrease speed: Slowly move the control carpenter’s level...
  • Page 50 First Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Engine RPM Select Select engine RPM using the symbols on the Light flashing indicates that the control panel. boom has moved just past either non-steer wheel and the When the foot switch is not pressed, the engine drive function has been will idle at the lowest rpm.
  • Page 51 First Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light (if Machine Malfunction Indicator Light equipped) Light on indicates a system fault. Machine On Incline indicator light is on: The light is on and the tilt alarm sounds when the machine exceeds the tilt sensor activation Push in and then pull out the red Emergency...
  • Page 52 First Edition • Second Printing Operator's Manual Operating Instructions LCD Screen When the LCD screen displays the message "Regen Required", the DPF (Diesel Particulate The LCD screen at the ground controls displays Filter) requires a Standstill Regeneration. hour meter, voltage, oil pressure and coolant temperature.
  • Page 53 First Edition • Second Printing Operator's Manual Operating Instructions Press Ok. The LCD screen will display the The system will keep the engine on at high warning "Non-flammable Environment". RPM until the coolant temperature reaches 50 C°. The LCD screen will then display the message "Standstill Regen Launch".
  • Page 54 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 bumpers come into contact with personnel when an operator makes contact with aircraft components, the machine will shut down the platform control panel, interrupting boom and no functions will operate.
  • Page 55 First Edition • Second Printing Operator's Manual Operating Instructions 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 56 First Edition • Second Printing Operator's Manual Operating Instructions Pipe Cradle Instructions Observe and Obey:  The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of cradles positioned at either side of the platform the platform.
  • Page 57 First Edition • Second Printing Operator's Manual Operating Instructions Pipe Cradle Operation Panel Cradle Assembly Be sure the pipe cradle assembly and Apply the warning decal to the front of each installation instructions have been followed panel cradle (if needed). properly and that the pipe cradles are secured Install rubber bumper 1 in the panel cradle to the platform railings.
  • Page 58 First Edition • Second Printing Operator's Manual Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.

  • Page 59: 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 60 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 61 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. 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 62: 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 63 First Edition • Second Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 64 First Edition • Second Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 65 First Edition • Second Printing Operator's Manual 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 and maintenance manuals for this machine.

  • Page 66: Specifications

    First Edition • Second Printing Operator's Manual Specifications Specifications Model Ambient operating temperature -20° F to 120° F S-60 J -29° C to 49° C Height, working maximum 66 ft 10 in 20.4 m Controls 12V DC proportional Height, platform maximum 60 ft 10 in 18.5 m AC outlet in platform...
  • Page 67 First Edition • Second Printing Operator's Manual Specifications Range of Motion Chart - S-60 J Maximum Platform Capacity 660 lbs 300 kg Vertical Values Horizontal Values 70 ft 21.34 m -10 ft -3.05 m 60 ft 19.29 m 0 ft 50 ft 15.24 m 10 ft...
  • Page 68 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>...

This manual is also suitable for:

Genie s60jh-101Genie s60jd-101

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