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Operator's Manual Serial Number Range S-60 ® ™ from S60XCH-45001 to 48333 from S65XCM-101 to 1999 from S65XCD-1251 S-65 ® ™ S-60 ® S-65 ® S-60 TRAX ® ™ S-65 TRAX with ® ™ Maintenance Information Original Instructions First Edition Fifth Printing Part No.
First Edition: Fifth Printing, December 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. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity...
First Edition • Fifth Printing Operator's Manual Introduction Intr oducti on 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.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
First Edition • Fifth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. Stop engine. starting aids on machines equipped with glow plugs.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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...
Operator's Manual First Edition • Fifth Printing General Safety Gener al 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
First Edition • Fifth Printing Operator's Manual Personal Safety Pers onal 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.
Operator's Manual First Edition • Fifth Printing Work Area Safety Work Ar ea 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.
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First Edition • Fifth Printing Operator's Manual Work Area Safety S-60 XC, S-65 XC, S-60 TRAX, S-65 TRAX: If the If using accessories, read, understand and obey platform load is greater than 300 kg, do not move the decals, instructions and manuals with the the platform into the unrestricted range of motion accessory.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Do not place or attach fixed or overhanging loads in any way affect safety and stability. to any part of this Do not replace items critical to machine stability machine.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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...
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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.
Operator's Manual First Edition • Fifth Printing 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.
First Edition • Fifth Printing Operator's Manual 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.
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Operator's Manual First Edition • Fifth Printing 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth Printing Controls Platform Control Panel -60/65 XC -60/65 HF S -60/65 TRAX Part No. 1286582GT ® ™ ® ® ™...
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First Edition • Fifth Printing Operator's Manual Controls Part No. 1286582GT -60/65 XC -60/65 HF S -60/65 TRAX ® ™ ® ® ™...
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Operator's Manual First Edition • Fifth Printing 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.
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First Edition • Fifth Printing Operator's Manual 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.
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Operator's Manual First Edition • Fifth Printing 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.
First Edition • Fifth Printing Operator's Manual Inspections Ins pections Pictures in this manual may show a boom with Pre-operation Inspection tires and wheels instead of tracks. All safety Fundamentals information and operating instructions still apply to the S-60 TRAX and the S-65 TRAX, even if the It is the responsibility of the operator to perform a picture does not show the tracks.
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Operator's Manual First Edition • Fifth Printing Inspections Pre-operation Inspection Primary boom angle sensor Turntable level sensor Be sure that the operator’s, safety, and String pot length sensor responsibilities manuals are complete, legible and in the storage container located in the ...
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth Printing 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.
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First Edition • Fifth Printing Operator's Manual Inspections At the Platform Controls Test Auxiliary Power 10 Turn the key switch to ground control and shut Test the Tilt Sensor Alarm the engine off. 14 Enter the platform and pull out the red 11 Pull out the red Emergency Stop button to the Emergency Stop button.
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Operator's Manual First Edition • Fifth Printing 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.
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First Edition • Fifth Printing Operator's Manual Inspections Test Limited Drive Speed Test the Drive Enable System 39 Press down the foot switch. 35 Press down the foot switch and lower the boom to the stowed position. 40 Raise the boom approximately 10° above horizontal.
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Operator's Manual First Edition • Fifth Printing 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°...
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First Edition • Fifth Printing Operator's Manual Inspections Test Auxiliary Power 61 S-60 XC, S-65 XC, S-60 TRAX and S-65 TRAX: Drive the machine onto a slope 65 Shut the engine off. where the roll angle is greater than 5° (side to 66 Pull out the red Emergency Stop button to the side).
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Operator's Manual First Edition • Fifth Printing Inspections Test the Lift/Drive Select Function 76 Operate each machine function. 69 Start the engine. Result: All machine functions should not operate. 70 Press down the foot switch. 77 Insert the actuator into the switch socket. 71 Move the drive control handle off center and activate a boom function control handle.
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First Edition • Fifth Printing Operator's Manual Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. Move the yellow bumper at the bottom of the platform 10 cm in any direction. Activate each function control handle or toggle switch.
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Operator's Manual First Edition • Fifth Printing 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 You learn and practice the principles of safe ...
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First Edition • Fifth Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1270969 Label – Relay Fuse Panel, Deutz 2.9 TD 1270970 Label – Relay Fuse Panel, Deutz TD2011L04i Use the pictures on the next page to verify that all 1272242 Label –...
First Edition • Fifth Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons Pictures in this manual may show a boom with Fundamentals tires and wheels instead of tracks. All safety The Operating Instructions section provides information and operating instructions still apply to instructions for each aspect of machine operation.
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Operator's Manual First Edition • Fifth Printing 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.
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First Edition • Fifth Printing Operator's Manual Operating Instructions Auxiliary Power Operation from Ground Use auxiliary power if the primary power source Turn the key switch to ground control. fails. Pull out the red Emergency Stop button to the on position. Turn the key switch to ground or platform control.
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Operator's Manual First Edition • Fifth Printing Operating Instructions Platform Overload Indicator Light Operation from Platform Light flashing indicates the platform is overloaded. Turn the key switch to platform control. The engine will stop and no functions will operate. Pull out both ground and platform red Remove weight from the platform until the light Emergency Stop buttons to the on position.
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First Edition • Fifth Printing Operator's Manual Operating Instructions To Position Platform Driving on a slope Determine the uphill, downhill and side slope Press down the foot switch. ratings for the machine and determine the slope Slowly move the appropriate function control grade.
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Operator's Manual First Edition • Fifth Printing 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.
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First Edition • Fifth Printing Operator's Manual Operating Instructions Engine RPM Select Operating Envelope Indicator Lights Select engine RPM using the symbols on the The operating envelope indicator lights will come on to notify the operator that a function has been control panel.
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Operator's Manual First Edition • Fifth Printing Operating Instructions Platform Overload Indicator Light Platform Capacity Range Range of motion is controlled automatically based Light flashing indicates the platform on platform load. is overloaded. The engine will stop and no functions will operate. S-60 XC, S-65 XC, S-60 TRAX.
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First Edition • Fifth Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings S-60 HF, S-65 HF Tilt/Slope Platform Load/Maximum Boom Model S-60 XC, S-65 XC, S-60 TRAX, S-65 TRAX (front to back) Angle 272 kg 454 kg Model Tilt/Slope Platform Load/Maximum Boom (front to back) Angle...
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Operator's Manual First Edition • Fifth Printing Operating Instructions LCD Screen S-60 XC, S-65 XC, S-60 TRAX, S-65 TRAX: The range of motion The LCD screen at the ground controls displays light is on when the platform load hour meter, voltage, oil pressure and coolant exceeds 300 kg.
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First Edition • Fifth Printing Operator's Manual Operating Instructions Standstill Regeneration When the LCD screen displays the message "Regen Required", the DPF (Diesel Particulate During the DPF standstill generation process, Filter) requires a Standstill Regeneration. all boom functions are disabled. Keep clear of the engine exhaust and muffler.
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Operator's Manual First Edition • Fifth Printing 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 35 C°. The LCD screen will then display the message "Standstill Regen Launch".
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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, or non-steer tracks.
Operator's Manual First Edition • Fifth Printing Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
First Edition • Fifth Printing Operator's Manual Maintenance Maintenanc e 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.
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Operator's Manual First Edition • Fifth 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.
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First Edition • Fifth 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.
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Operator's Manual First Edition • Fifth 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.
First Edition • Fifth Printing Operator's Manual Specifications Specific ati ons Model S-60 XC Airborne noise emissions Height, working maximum 20.29 m Sound pressure level at ground 83 dBA workstation Height, platform maximum 18.29 m Sound pressure level at platform 79 dBA Horizontal reach, platform maximum 14.8 m...
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Operator's Manual First Edition • Fifth Printing Specifications Model S-65 XC Airborne noise emissions Height, working maximum 21.81 m Sound pressure level at ground workstation 83 dBA Height, platform maximum 19.81 m Sound pressure level at platform workstation 79 dBA Horizontal reach, platform 16.51 m Guaranteed sound power level...
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First Edition • Fifth Printing Operator's Manual Specifications Airborne noise emissions Model S-60 TRAX Sound pressure level at ground 83 dBA Height, working maximum 20.29 m workstation Height, platform maximum 18.29 m Sound pressure level at platform 79 dBA Horizontal reach, platform 14.8 m workstation maximum...
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Operator's Manual First Edition • Fifth Printing Specifications Model S-65 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 21.81 m Platform uphill 30% (17°) Height, platform maximum 19.81 m Platform downhill 45% (24°) Horizontal reach, platform 16.51 m Side slope 25% (14°) maximum...
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First Edition • Fifth Printing Operator's Manual Specifications Model S-60 HF Airborne noise emissions Height, working maximum 20.33 m Sound pressure level at ground 83 dBA workstation Height, platform maximum 18.33 m Sound pressure level at platform 79 dBA Horizontal reach, platform 14.21 m workstation maximum...
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Operator's Manual First Edition • Fifth Printing Specifications Model S-65 HF Airborne noise emissions Height, working maximum 21.86 m Sound pressure level at ground 83 dBA workstation Height, platform maximum 19.86 m Sound pressure level at platform 79 dBA Horizontal reach, platform 15.6 m workstation maximum...
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First Edition • Fifth Printing Operator's Manual Specifications S-60 XC and S-60 TRAX Range of Motion S-60 HF Range of Motion Chart Chart S-65 XC and S-65 TRAX Range of Motion S-65 HF Range of Motion Chart Chart Part No. 1286582GT -60/65 XC -60/65 HF S -60/65 TRAX...
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Operator's Manual First Edition • Fifth Printing Specifications Contents of EC Declaration of Conformity - 1 <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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First Edition • Fifth Printing Operator's Manual Specifications Contents of EC Declaration of Conformity - 2 <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, Conformity assessment procedure: art.12 (3) (a), with the application of European Harmonized Standard EN 280:2013+A1:2015.
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Operator's Manual First Edition • Fifth Printing Specifications Contents of UK Declaration of Conformity - 1 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...
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First Edition • Fifth Printing Operator's Manual Specifications Contents of UK Declaration of Conformity - 2 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) conformity assessment procedure according to Part 3, 11.