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

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Operator's Manual
S
-60 XC
®
S
-65 XC
®
S
-60 HF
®
S
-65 HF
®
S
-60 TRAX
®
S
-65 TRAX
®
™
™
™
™
AUS
Australia
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 1312110GT

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Summary of Contents for Terex Genie S-60 XC

  • Page 1 Operator's Manual -60 XC ® ™ Australia -65 XC ® ™ -60 HF ® -65 HF ® -60 TRAX ® ™ -65 TRAX with ® ™ Maintenance Information Original Instructions Second Edition First Printing Part No. 1312110GT...

  • Page 2: Table Of Contents

    Second Edition: First Printing, February 2022 Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" and "TraX" are trademarks of Terex South Dakota, Inc. These machines comply with AS 1418.10 ®...

  • Page 3: Introduction

    Second Edition • First 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 Operator's Manual Second Edition • First Printing 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: Drive and steer.
  • Page 5 Second Edition • First 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 Operator's Manual Second Edition • First Printing 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

    Second Edition • First 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 Operator's Manual Second Edition • First Printing 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 and tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 9 Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Crush hazard Support the platform Read the service Explosion hazard Relieve all pressure or boom during manual...

  • Page 10: General Safety

    Operator's Manual Second Edition • First Printing General Safety General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.
  • Page 11 Second Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.
  • Page 12 Operator's Manual Second Edition • First Printing General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.

  • Page 13: Personal Safety

    Second Edition • First 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

    Operator's Manual Second Edition • First Printing Work Area Safety Work Area Safety Pictures in this manual may show a boom with Keep away from the tires and wheels instead of tracks. All safety machine if it contacts information and operating instructions still apply to energized power lines.
  • Page 15 Second Edition • First Printing Operator's Manual Work Area Safety If using accessories, read, understand and obey S-60 XC, S-65 XC, S-60 TRAX, S-65 TRAX: If the the decals, instructions and manuals with the platform load is greater than 300 kg, do not move accessory.
  • Page 16 Operator's Manual Second Edition • First Printing Work Area Safety If the tilt alarm sounds when the platform is raised, Do not operate the machine in strong or gusty use extreme caution. The machine not level winds. Do not increase the surface area of the indicator light will come on and the drive function platform or the load.
  • Page 17 Second Edition • First Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Do not place or attach in any way affect safety and stability. fixed or overhanging loads to any part of this Do not replace items critical to machine stability machine.
  • Page 18 Operator's Manual Second Edition • First Printing Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating safety belt or harness in of the machine.
  • Page 19 Second Edition • First 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 Operator's Manual Second Edition • First Printing 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 Second Edition • First 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 Operator's Manual Second Edition • First Printing 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 Second Edition • First Printing Operator's Manual Work Area Safety Tow Package Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the tow package. instructions provided with the welding power unit. When vehicle is in free-wheel configuration, there Do not connect weld leads or cables unless the are no brakes and machine may move, resulting in...
  • Page 24 Operator's Manual Second Edition • First Printing 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, or non-steer tracks.

  • Page 25: Legend

    Second Edition • First Printing Operator's Manual Legend Legend Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.

  • Page 26: Controls

    Operator's Manual Second Edition • First Printing Controls Controls Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.
  • Page 27 Second Edition • First 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 28 Operator's Manual Second Edition • First Printing 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 29 Second Edition • First Printing Operator's Manual Controls Platform Control Panel Part No. 1312110GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TRAX ™...
  • Page 30 Operator's Manual Second Edition • First Printing Controls ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TRAX ™ Part No. 1312110GT...
  • Page 31 Second Edition • First 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. Restricted range of motion indicator light, Release the button and the horn will stop. weight.
  • Page 32 Operator's Manual Second Edition • First Printing Controls 11 Raise/retract boom indicator light 17 Dual axis proportional control handle for drive and steer functions. Raise/retract the boom until the light is off. Proportional control handle for drive function 12 Lower boom indicator light and thumb rocker for steer function.
  • Page 33 Second Edition • First Printing Operator's Manual Controls 19 Drive enable switch 24 Engine start switch To drive when the drive enable light is Move the engine start switch to either side to flashing, hold the drive enable switch to either start the engine.

  • Page 34: Inspections

    Operator's Manual Second Edition • First Printing Inspections Inspections Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.
  • Page 35 Second Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Primary boom angle sensor  Turntable level sensor  Be sure that the operator’s manual is  String pot length sensor complete, legible and in the storage container located in the platform. ...
  • Page 36 Operator's Manual Second Edition • First Printing 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 37 Second Edition • First Printing Operator's Manual Inspections At the Ground Controls Test Machine Functions Do not push the function Select a test area that is firm, level and free of enable button. Attempt to hazards. activate each boom and Turn the key switch to ground control.
  • Page 38 Operator's Manual Second Edition • First Printing 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 39 Second Edition • First 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 40 Operator's Manual Second Edition • First Printing Inspections Test the Drive Enable System Test Limited Drive Speed 35 Press down the foot switch and lower the 39 Press down the foot switch. boom to the stowed position. 40 Raise the boom approximately 10° above 36 Rotate the turntable until the boom moves past horizontal.
  • Page 41 Second Edition • First Printing Operator's Manual Inspections Test Drive Tilt Cutout 55 Press down the foot switch. 45 Press down the foot switch. 56 With the boom fully stowed, drive the machine onto a slope where the roll angle is greater 46 With the boom fully stowed, drive the machine than 5°...
  • Page 42 Operator's Manual Second Edition • First Printing Inspections Test Auxiliary Power 61 S-60 XC, S-65 XC, S-60 TRAX and S-65 TRAX: Drive the machine onto a slope where 65 Shut the engine off. the roll angle is greater than 5° (side to side). 66 Pull out the red Emergency Stop button to the S-60 HF and S-65 HF: Drive the machine onto on position.
  • Page 43 Second Edition • First Printing Operator's Manual Inspections 73 Operate each machine function. Test Aircraft Protection Package (if equipped) Result: All machine functions should not operate. Note: Two people may be required to perform this test. 74 Insert the actuator into the switch socket. 76 Move the yellow bumper at the bottom of the Result: The lights and horn will turn off.
  • Page 44 Operator's Manual Second Edition • First Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces ...
  • Page 45 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 82862 Danger – Fire Extinguisher, Welder Determine whether the decals on your machine (option) have words or symbols. Use the appropriate 97548 Instructions – Deutz Engine inspection to verify that all decals are legible and Specifications (F3L 2011 &...
  • Page 46 Operator's Manual Second Edition • First Printing Inspections 1281180 72169 1284981 52865 1272242 31788 72168 38149 *826345 114390 *133278 72086 1253629 *1258949 1280819 *1258950 1280820 *1281187 31060 *1281188 1267121 1281169 *1270969 *1270970 *1283560 *1287598 *1287599 72086 *1283561 31060 52475 1288408 25994 *1287489 82366...
  • Page 47 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 1281188 Label – Emergency Lowering, S-65 XC, Determine whether the decals on your machine S-65 TRAX have words or symbols. Use the appropriate 1283560 Label –...
  • Page 48 Operator's Manual Second Edition • First Printing Inspections 1281180 72169 1284981 52865 1272242 31788 72168 38149 *826345 114390 *133278 1253629 72086 *1258949 1280819 *1258950 1280820 *1281187 31060 *1281188 1267121 1281169 *1270969 *1270970 *1283560 *1287598 *1287599 72086 *1283561 31060 52475 1288408 25994 *1287489 82366...

  • Page 49: Operating Instructions

    Second Edition • First Printing Operator's Manual Operating Instructions Operating Instructions Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the picture does not show the tracks.
  • Page 50 Operator's Manual Second Edition • First Printing Operating Instructions Starting the Engine Auxiliary Power Use auxiliary power if the primary power source Diesel models fails. At the ground controls, turn the key switch to Turn the key switch to ground or platform the desired position.
  • Page 51 Second Edition • First 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 52 Operator's Manual Second Edition • First Printing Operating Instructions To Drive Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Increase speed: Slowly move the control grade.
  • Page 53 Second Edition • First Printing Operator's Manual Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light flashing indicates that the use the following procedure. boom has moved just past either non-steer wheel, or non- You will need: steer track and the drive function has been interrupted.
  • Page 54 Operator's Manual Second Edition • First Printing Operating Instructions Engine RPM Select Operating Envelope Indicator Lights Select engine RPM using the symbols on the The operating envelope indicator lights will come control panel. on to notify the operator that a function has been interrupted and/or an action is required by the When the foot switch is not pressed, the engine operator.
  • Page 55 Second Edition • First Printing Operator's Manual Operating Instructions Platform Overload Indicator Light Platform Out of Level (> ±10° error) When the platform level is > +/- 10° off target Light flashing indicates the platform angle, then the machine malfunction indicator light is overloaded.
  • Page 56 Operator's Manual Second Edition • First Printing Operating Instructions Machine Malfunction Indicator Light Platform Capacity Range Range of motion is controlled automatically based Light on indicates a system fault. on platform load. S-60 XC, S-65 XC, S-60 TRAX. S-65 TRAX Unrestricted Range of Motion: When the platform load is less than 661 lbs/300 kg.
  • Page 57 Second Edition • First Printing Operator's Manual Operating Instructions S-60 HF Tilt Sensor Activation Settings Platform Load: 600 lbs/272 kg S-60 XC, S-60 TRAX Chassis Chassis Max Height Max Reach Angle (front Angle (side Platform Load: 660 lbs/300 kg to back) to side) Chassis Chassis Angle...
  • Page 58 Operator's Manual Second Edition • First Printing Operating Instructions S-60 XC, S-65 XC, S-60 TRAX, S-65 TRAX: The range of motion light is on when the platform load exceeds 660 lbs/300 kg. S-60 HF, S-65 HF: The range of motion light is on when the platform load exceeds 600 lbs/272 kg.
  • Page 59 Second Edition • First Printing Operator's Manual Operating Instructions LCD Screen Aircraft Protection Package Operation (if equipped) The LCD screen at the ground controls displays hour meter, voltage, oil pressure and coolant If the platform bumper comes into contact with an temperature.
  • Page 60 Operator's Manual Second Edition • First Printing 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 61 Second Edition • First 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 62 Operator's Manual Second Edition • First Printing 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 63: Towing Instructions

    Second Edition • First Printing Operator's Manual Towing Instructions Towing Instructions Using the Tow Package Before Towing: Position the machine on a level surface. Chock the wheels to prevent the machine from rolling. Attach the tow bar securely to the machine. Attach the tow bar securely to the towing vehicle.

  • Page 64: Transport And Lifting Instructions

    Operator's Manual Second Edition • First Printing Transport and Lifting Instructions Transport and Lifting Instructions Pictures in this manual may show a boom with  Be sure the turntable is secured with the tires and wheels instead of tracks. All safety turntable rotation lock before transporting.
  • Page 65 Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform – S-60 XC, S-60 HF and S-60 TRAX Transit Make sure the platform is in the stowed position. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 66 Operator's Manual Second Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. (if equipped) 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 67: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance Check the Engine Oil Level Maintenance Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 68 Operator's Manual Second Edition • First Printing 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 69 Second Edition • First 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 70 Operator's Manual Second Edition • First Printing Maintenance Scheduled Maintenance Maintenance performed commissioning, 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 71: Specifications

    Second Edition • First Printing Operator's Manual Specifications Specifications Model S-60 XC Maximum slope rating, stowed position, 4WD Height, working maximum 66 ft 20.29 m Platform uphill 30% (17°) Height, platform maximum 60 ft 18.29 m Platform downhill 45% (24°) Horizontal reach, platform 48 ft 6 in 14.8 m...
  • Page 72 Operator's Manual Second Edition • First Printing Specifications Model S-65 XC Maximum slope rating, stowed position, 4WD Height, working maximum 71 ft 21.81 m Platform uphill 30% (17°) Height, platform maximum 65 ft 19.81 m Platform downhill 45% (24°) Horizontal reach, platform 54 ft 2 in 16.51 m Side slope...
  • Page 73 Second Edition • First Printing Operator's Manual Specifications Model S-60 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 66 ft 20.29 m Platform uphill 30% (17°) Height, platform maximum 60 ft 18.29 m Platform downhill 45% (24°) Horizontal reach, platform 48 ft 7 in 14.8 m Side slope...
  • Page 74 Operator's Manual Second Edition • First Printing Specifications Model S-65 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 71 ft 21.81 m Platform uphill 30% (17°) Height, platform maximum 65 ft 19.81 m Platform downhill 45% (24°) Horizontal reach, platform 54 ft 2 in 16.51 m Side slope...
  • Page 75 Second Edition • First Printing Operator's Manual Specifications Model S-60 HF Maximum slope rating, stowed position, 4WD Height, working maximum 66 ft 2 in 20.33 m Platform uphill 25% (14°) Height, platform maximum 60 ft 2 in 18.33 m Platform downhill 45% (24°) Horizontal reach, platform 46 ft 7 in...
  • Page 76 Operator's Manual Second Edition • First Printing Specifications Model S-65 HF Maximum slope rating, stowed position, 4WD Height, working maximum 71 ft 2 in 21.86 m Platform uphill 25% (14°) Height, platform maximum 65 ft 2 in 19.86 m Platform downhill 45% (24°) Horizontal reach, platform 51 ft 2 in...
  • Page 77 Second Edition • First Printing Operator's Manual Specifications S-60 XC and S-60 Trax Range of Motion Chart Maximum platform capacity 1000 lbs 454 kg 660 lbs 300 kg Vertical Values Horizontal Values -10 ft -3.05 m -10 ft -3.05 m 0 ft 0 ft 10 ft...
  • Page 78 Operator's Manual Second Edition • First Printing Specifications S-65 XC and S-65 Trax Range of Motion Chart Maximum platform capacity 1000 lbs 454 kg 660 lbs 300 kg Vertical Values Horizontal Values -20 ft -6.1 m -10 ft -3.05 m -10 ft -3.05 m 0 ft...
  • Page 79 Second Edition • First Printing Operator's Manual Specifications S-60 HF Range of Motion Chart Maximum platform capacity 1000 lbs 454 kg 600 lbs 272 kg Vertical Values Horizontal Values -10 ft -3.05 m -10 ft -3.05 m 0 ft 0 ft 10 ft 3.05 m 10 ft...
  • Page 80 Operator's Manual Second Edition • First Printing Specifications S-65 HF Range of Motion Chart Maximum platform capacity 1000 lbs 454 kg 600 lbs 272 kg Vertical Values Horizontal Values -10 ft -3.05 m -10 ft -3.05 m 0 ft 0 ft 10 ft 3.05 m 10 ft...

This manual is also suitable for:

Genie s-65 xcGenie s-60 hfGenie s-65 hfGenie s-60 traxGenie s-65 trax

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