Terex Genie S-65 TRAX Operator's Manual
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Terex Genie S-65 TRAX Operator's Manual

Terex Genie S-65 TRAX Operator's Manual

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Operator's Manual
S-65 T
RAX
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Third Edition
First Printing
Part No. 1261731

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Summary of Contents for Terex Genie S-65 TRAX

  • Page 1 Operator's Manual S-65 T ANSI/CSA North America South America Asia with Maintenance Information Third Edition First Printing Part No. 1261731...

  • Page 2: Table Of Contents

    Specifications ............61 Copyright © 2010 by Terex Corporation Third Edition: First Printing, January 2015 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI/SIA A92.5 CAN B.354.4 S-65 Trax Part No.

  • Page 3: Introduction

    Third Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • First Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Danger Accident reporting...
  • Page 5 Third Edition • First Printing Operator's Manual Introduction Safety Sign Maintenance Hazard Classification Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual Third Edition • First Printing 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 7 Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Corrosive acid. Color Coded Runaway Hazard Collision hazard Collision hazard Direction Arrows Electrocution hazard Avoid contact Disconnect battery Voltage rating for...

  • Page 8: General Safety

    Operator's Manual Third Edition • First Printing General Safety General Safety 28175 31788 52865 114258 97865 31060 114390 82237 133250 133250 82237 97865 31788 133250 DANGER DANGER WARNING DANGER Electrocution/Burn Hazard Explosion / Burn Hazard Ignition of explosive gases or contact with corrosive Failure to disconnect all acid will cause death, burns or blindness Tip-over Hazard...
  • Page 9 Third Edition • First Printing Operator's Manual General Safety 114390 DANGER 218559 DANGER WARNING WARNING Drive Direction Hazard Machine can move in opposite direction of joystick movement. Movement in an unplanned Tip-over Hazard Crush Hazard direction can result in death or serious injury. Tipping over this machine will result in death or serious injury.
  • Page 10 Operator's Manual Third Edition • First Printing General Safety 82237 31788 133250 97865 DANGER DANGER DANGER WARNING Explosion / Burn Hazard Electrocution/Burn Hazard Ignition of explosive gases or contact with corrosive Failure to disconnect all acid will cause death, burns or blindness Tip-over Hazard the batteries before Lug NutTorque:...
  • Page 11 Third Edition • First Printing Operator's Manual General Safety 82487 82473 114251 133205 114252 133067 1256425 133263 133263 114252 82487 133263 82487 B 114252 A 133263 A 114251 133067 82473 0 to 50KV 3.0 m 114251 A 50 to 200KV 4.6 m 200 to 350KV 6.1 m...
  • Page 12 Operator's Manual Third Edition • First Printing General Safety 82487 82487 B 114473 114473 A 133067 114473 0 to 50KV 3.0 m 50 to 200KV 4.6 m 200 to 350KV 6.1 m 219953 350 to 500KV 7.6 m 219953 500 to 750KV 10.6 m 750 to 1000KV 13.7 m...
  • Page 13 Third Edition • First Printing Operator's Manual General Safety 82487 114252 133263 82487 B 114252 A 133263 A 114251 133067 82473 1256425 0 to 50KV 3.0 m 114251 A 50 to 200KV 4.6 m 200 to 350KV 6.1 m 82473 B 350 to 500KV 7.6 m 500 to 750KV...

  • Page 14: Personal Safety

    Operator's Manual Third Edition • First Printing 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 15: Work Area Safety

    Third Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will Occupants, equipment and materials shall not not provide protection from contact with or exceed the maximum platform capacity. proximity to electrical current.
  • Page 16 Operator's Manual Third Edition • First Printing Work Area Safety Do not depend on the tilt alarm as a level indicator. Use extreme care and slow The tilt alarm sounds in the platform only when the speeds while driving the machine is on a severe slope.
  • Page 17 Third Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not replace tracks with tires. Do not modify or alter an aerial work platform Do not drive the machine on a slope that exceeds without prior written permission from the the maximum uphill, downhill or side slope rating of manufacturer.
  • Page 18 Operator's Manual Third Edition • First Printing 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 19 Third Edition • First 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 20 Operator's Manual Third Edition • First Printing 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 the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 21 Third Edition • First Printing Operator's Manual Work Area Safety Welder Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the welding power unit. instructions provided with the pipe cradles. Do not connect weld leads or cables unless the Do not exceed the rated platform capacity.
  • Page 22 Operator's Manual Third Edition • First Printing Work Area Safety Panel Cradle Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the panel cradles. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not exceed the rated platform capacity.

  • Page 23: Legend

    Third Edition • First Printing Operator's Manual Legend Legend Non-steer track Platform Steer track Lanyard anchorage points Ground controls Sliding mid-rail Boom 10 Manual storage container Jib boom 11 Foot switch Platform controls Part No. 1261731 S-65 Trax...

  • Page 24: Controls

    Operator's Manual Third Edition • First Printing Controls Controls S-65 Trax Part No. 1261731...
  • Page 25 Third Edition • First Printing Operator's Manual Controls STOP 14 13 Part No. 1261731 S-65 Trax...
  • Page 26 Operator's Manual Third Edition • First Printing Controls Drive speed select switch Platform Control Panel Machine on incline symbol: Low range Pictures in this manual may show a boom with operation for inclines. tires and wheels instead of tracks. All safety Machine on level surface symbol: High range information and operating instructions still apply to operation for maximum drive speed.
  • Page 27 Third Edition • First Printing Operator's Manual Controls 11 Dual axis proportional control handle for drive 12 Drive enable switch and steer functions To drive when the drive enable light is on, hold OR Proportional control handle for drive the drive enable switch to either side and function and thumb rocker for steer function.
  • Page 28 Operator's Manual Third Edition • First Printing Controls 22 Dual axis proportional control handle for boom 17 Gasoline/LPG models: Fuel select switch up/down and turntable rotate left/right Move the fuel select switch to the gasoline functions position to select gasoline. Move the fuel select switch to the LPG position to select Move the control handle up LPG.
  • Page 29 Third Edition • First Printing Operator's Manual Controls The S-65 machines will have one of these two styles of ground control panel. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted.
  • Page 30 Operator's Manual Third Edition • First Printing Controls Ground Control Panel Turntable rotate switch Move the turntable rotate switch to the right LCD readout screen and the turntable will rotate to the right. Move Screen displays hour meter, voltage, oil the turntable rotate switch to the left and the pressure and coolant temperature.
  • Page 31 Third Edition • First Printing Operator's Manual Controls 14 Key switch for off/ground/platform selection 19 Platform rotate switch Turn the key switch to the off position and the Move the platform rotate switch to the right machine will be off. Turn the key switch to the and the platform will rotate to the right.

  • Page 32: Inspections

    Operator's Manual Third Edition • First Printing 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 33 Third Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Limit switches and horn  Alarms and beacons (if equipped)  Be sure that the operator’s, safety and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 34 Operator's Manual Third 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 35 Third Edition • First Printing Operator's Manual Inspections Test the Tilt Sensor At the Ground Controls Pull out the platform red Emergency Stop Select a test area that is firm, level and free of button to the on position. Turn the key switch obstruction.
  • Page 36 Operator's Manual Third Edition • First Printing Inspections Test Machine Functions At the Platform Controls 24 Press down the foot switch. Test Emergency Stop 25 Activate each machine function control handle 15 Enter the platform and pull out the red or toggle switch.
  • Page 37 Third Edition • First Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 29 Press down the foot switch. 36 Press down the foot switch and lower the boom to the stowed position. 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the 37 Rotate the turntable until the boom moves past control panel until the machine begins to move,...
  • Page 38 Operator's Manual Third Edition • First Printing Inspections Test Limited Drive Speed Test Emergency Controls 40 Press down the foot switch. 46 Shut off the engine. 41 Raise the boom to just above horizontal. 47 Pull out the red Emergency Stop button to the on position.
  • Page 39 Third Edition • First 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 40 Danger – Track Specifications 27206 Triangle – Blue 133252 Label – Track Load, S-65 TRAX 27207 Triangle – Yellow 133254 Cosmetic – Genie S-65 TRAX 28158 Label – Unleaded 133260 Cosmetic – S-65 TRAX 28159 Label – Diesel 133278 Label – Low Sulfur Fuel (diesel models) 28160 Label –...
  • Page 41 Third Edition • First Printing Operator's Manual Inspections 28158 1262347 1255581 28175 31788 72169 or 28159 72168 52865 28160 114258 97865 31060 826345 or 133278 825579 72086 114390 114465 or 219723 82366 82237 52607 133252 133250 133250 52475 133252 1260107 52475 133260 147603...
  • Page 42 Below is a numerical list with quantities and 133067 Label – Electrocution Hazard descriptions. 133252 Label – Track Load, S-65 TRAX Part No. Decal Description 133254 Cosmetic – Genie S-65 TRAX 27204 Arrow – Blue 133260 Cosmetic – S-65 TRAX 27205 Arrow – Yellow 133263 Label –...

  • Page 43: Operating Instructions

    Third Edition • First Printing Operator's Manual Operating Instructions 28158 82487 1255581 82473 82481 or 28159 28160 114251 133205 82487 114252 82487 72086 133067 114465 or 219723 1256425 133252 133263 133263 52475 133252 1260107 52475 133260 147603 or 823761 133387 114473 219953 219953...
  • Page 44 Operator's Manual Third Edition • First Printing Operating Instructions 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. the S-65 TRAX, even if the picture does not show the tracks.
  • Page 45 Third Edition • First Printing Operator's Manual Operating Instructions Models with glow plug toggle switch: Starting the Engine Move the glow plug switch to either side and At the ground controls, turn the key switch to hold for 3 to 5 seconds. the desired position.
  • Page 46 Operator's Manual Third Edition • First Printing Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all machine functions and turn the on position.
  • Page 47 Third Edition • First Printing Operator's Manual Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 48 Operator's Manual Third Edition • First Printing Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 49 Third Edition • First Printing Operator's Manual Operating Instructions Drive Enable Engine Idle Select (rpm) Select engine idle (rpm) using the symbols on the Light on indicates that the boom control panel. has moved just past either non-steer track and the drive When the foot switch is not pressed, the engine function has been interrupted.
  • Page 50 Operator's Manual Third Edition • First Printing Operating Instructions Machine Not Level Indicator Light Engine Shut-down indicator light (if equipped) (if equipped) Light on indicates machine is not Light on: Tag and remove the machine level. The tilt alarm will be sounding from service.
  • Page 51 Third Edition • First Printing Operator's Manual Operating Instructions LCD Screen (if equipped) Aircraft Protection Package (if equipped) If the platform bumpers come into contact with The LCD screen displays hour aircraft components, the machine will shut down meter, voltage, oil pressure and and no functions will operate.
  • Page 52 Operator's Manual Third 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 53 Third 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 54 Operator's Manual Third Edition • First Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rubber rails. Position the padding to protect the panels bumper 2 from contact with the platform rails. Installation of Strap rubber bumper 1 U-bolt...
  • Page 55 Third Edition • First 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 tracks.

  • Page 56: Transport And Lifting Instructions

    Operator's Manual Third Edition • First Printing 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 57 Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform - S-65 Trax Securing to Truck or Trailer for Transit Place a block under the platform rotator. Do not allow the block to contact the platform cylinder. Always use the turntable rotation lock pin each Secure the platform with a nylon strap placed time the machine is transported.
  • Page 58 Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Move the jib boom parallel with the ground.Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable.

  • Page 59: Maintenance

    Third Edition • First 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 60 Operator's Manual Third 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 61 Third 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 62 Operator's Manual Third Edition • First Printing 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 manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 63: Specifications

    Third Edition • First Printing Operator's Manual Specifications Specifications Model S-65 Maximum slope rating, stowed position, 4WD Height, working maximum 71 ft 21.8 m Platform downhill 24° Height, platform maximum 65 ft 19.8 m Platform uphill 17° Height, stowed maximum 9 ft 2.74 m Side slope...
  • Page 64 Operator's Manual Third Edition • First Printing Specifications S-65 TRAX Range of Motion 60 ft 18.3 m 40 ft 12.2 m 20 ft 6.1 m 0 ft 20 ft 6.0 m 0 ft 20 ft 40 ft 60 ft 6.0 m 12.2 m 18.3 m S-65 Trax...

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