Terex S6010-21001 Operator's Manual
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Terex S6010-21001 Operator's Manual

Terex S6010-21001 Operator's Manual

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Operator's Manual
S-65 TRAX
Serial Number Range
from S6010-21001
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Second Edition
Sixth Printing
Part No. T107107

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Summary of Contents for Terex S6010-21001

  • Page 1 Operator's Manual Serial Number Range S-65 TRAX from S6010-21001 ANSI/CSA North America South America Asia with Maintenance Information Second Edition Sixth Printing Part No. T107107...

  • Page 2: Table Of Contents

    Maintenance ............60 Specifications ............64 Copyright © 2010 by Terex Corporation Second Edition: Sixth Printing, June 2014 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...

  • Page 3: Introduction

    Second Edition • Sixth Printing Operator's Manual Introduction Introduction Owners, Users and Operators: Thank you for choosing our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: Danger 1 Comply with employer, job site and...
  • Page 4 Operator's Manual Second Edition • Sixth Printing Introduction Hazard Classification Intended Use This machine is intended to be used only to lift Decals on this machine use symbols, color coding personnel, along with their tools and materials to and signal words to identify the following: an aerial work site.

  • Page 5: Symbol And Hazard Pictorials Definitions

    Second Edition • Sixth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Explosion hazard No smoking. Electrocution hazard moving parts No flame. Stop engine Maintain required Crush hazard Keep away from path Fall hazard Keep off this surface.
  • Page 6 Operator's Manual Second Edition • Sixth Printing Symbol and Hazard Pictorials Definitions Lanyard attachment Tracks load Voltage rating for Pressure rating for air Have fire point power to platform line to platform extinguisher near. Electrocution hazard Avoid contact Tie-down instructions Read the service manual Tie-down instructions...

  • Page 7: General Safety

    Second Edition • Sixth Printing Operator's Manual General Safety General Safety 31788 114390 28161 114389 114258 31060 82237 28177 133250 114389 DANGER 28177 133250 WARNING Crush Hazard Death or serious injury may result from platform crushing personnel against boom. Keep away from path of moving platform.
  • Page 8 Operator's Manual Second Edition • Sixth Printing General Safety 114389 1000262 82862 DANGER DANGER DANGER Tip-over Hazard Failure to match rated loads could result in an overloaded platform, which could result in machine tipping over. When replacing platform, be sure rated load on replacement platform matches rated load on machine serial number label.
  • Page 9 Second Edition • Sixth Printing Operator's Manual General Safety Part No. T107107 S-65 Trax...
  • Page 10 Operator's Manual Second Edition • Sixth Printing General Safety S-65 Trax Part No. T107107...
  • Page 11 Second Edition • Sixth Printing Operator's Manual General Safety 82487 82487 B 114473 114473 A 114473 82601 82671 227 kg < = 82487 227 kg 82601 B 82547 82601 or 82547 340 kg 82602 < = 340 kg 82547 B 82602 12.5 m/sec 82602 B...
  • Page 12 Operator's Manual Second Edition • Sixth Printing General Safety 82472 82671 82548 114247 82671 C 82472 B 82473 133263 133067 82473 B 0 to 50KV3.0 m 50 to 200KV4.6 m 200 to 350KV6.1 m 350 to 500KV7.6 m 500 to 750KV10.6 m 750 to 1000KV13.7 m 133067 A 114252...

  • Page 13: Personal Safety

    Second Edition • Sixth 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 • Sixth Printing Work Area Safety Work Area Safety Electrocution Hazards Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds. This machine is not electrically insulated and will not provide protection from contact with or Keep away from the proximity to electrical current.
  • Page 15 Second Edition • Sixth 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 Operator's Manual Second Edition • Sixth Printing Work Area Safety Do not replace items critical to machine stability Use extreme care and with items of different weight or specification. slow speeds while driving the machine in the Do not replace tracks with tires. stowed position across uneven terrain, debris, Do not modify or alter an aerial work platform...
  • Page 17 Second Edition • Sixth Printing Operator's Manual Work Area Safety Do not use the machine on a moving or mobile Fall Hazards surface or vehicle. Occupants must wear a Be sure all track lug nuts are properly tightened. safety belt or harness in accordance with Do not use the platform controls to free a platform governmental regulations.
  • Page 18 Operator's Manual Second Edition • Sixth Printing Work Area Safety Observe and use the color-coded direction arrows Collision Hazards on the platform controls and drive chassis for drive and steer functions. Be aware of limited sight distance and blind spots Do not lower the boom when driving or operating.
  • Page 19 Second Edition • Sixth 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 the Do not operate the machine with a hydraulic oil or machine and test all functions before each work air leak.
  • Page 20 Operator's Manual Second Edition • Sixth Printing Work Area Safety Battery Safety Welder Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the welding power unit. Batteries contain acid. Do not connect weld leads or cables unless the Always wear protective welding power unit is turned off at the platform clothing and eye wear when...
  • Page 21 Second Edition • Sixth 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 22 Operator's Manual Second Edition • Sixth 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.

  • Page 23: Legend

    Second Edition • Sixth Printing Operator's Manual Legend Legend Platform Non-steer track Lanyard anchorage point Steer track Sliding mid-rail Ground controls 10 Manual storage container Boom 11 Foot switch Jib boom Platform controls Part No. T107107 S-65 Trax...

  • Page 24: Controls

    Operator's Manual Second Edition • Sixth Printing Controls Controls S-65 Trax Part No. T107107...
  • Page 25 Second Edition • Sixth Printing Operator's Manual Controls STOP 14 13 Part No. T107107 S-65 Trax...
  • Page 26 Operator's Manual Second Edition • Sixth Printing Controls Drive speed select switch Platform Control Panel Machine on incline symbol: Low range Horn button operation for inclines. Press this button and the horn will sound. Machine on level surface symbol: High range Release the button and the horn will stop.
  • Page 27 Second Edition • Sixth 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 Second Edition • Sixth Printing Controls 17 Gasoline/LPG models: Fuel select switch 22 Dual axis proportional control handle for boom 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 Second Edition • Sixth 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 Second Edition • Sixth Printing Controls Turntable rotate switch Ground Control Panel 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 Second Edition • Sixth 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 Second Edition • Sixth 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 Second Edition • Sixth Printing Operator's Manual Inspections  Tracks, sprocket, idler, bogey, Pre-operation Inspection undercarriage/frame, tensioner  Be sure that the operator’s, safety and  Engine and related components responsibilities manuals are complete, legible  Limit switches and horn and in the storage container located in the platform.
  • Page 34 Operator's Manual Second Edition • Sixth Printing Inspections Pictures in this manual may show a boom with Function Test Fundamentals tires and wheels instead of tracks. All safety The function tests are designed to discover any information and operating instructions still apply to malfunctions before the machine is put into service.
  • Page 35 Second Edition • Sixth Printing Operator's Manual Inspections Test Emergency Stop 10 Open the tank side turntable cover and locate the tilt Push in the red Emergency Stop button to the sensor next to the fuel tank. off position. 11 Press down one side of the Result: The engine should shut off and no tilt sensor.
  • Page 36 Operator's Manual Second Edition • Sixth Printing Inspections 22 Do not press down the foot switch and restart At the Platform Controls the engine. Test Emergency Stop Result: The engine should start. 23 Do not press down the foot switch and test 15 Enter the platform and pull out the red each machine function.
  • Page 37 Second Edition • Sixth Printing Operator's Manual Inspections 28 Press the thumb rocker switch in the direction Test the Oscillating Axle (if equipped) indicated by the yellow triangle on the control 32 Start the engine from the platform controls. panel OR slowly move the control handle in the direction indicated by the yellow triangle.
  • Page 38 Operator's Manual Second Edition • Sixth Printing Inspections 39 Move and hold the drive enable toggle switch 43 Lower the boom to the stowed position. to either side and slowly move the drive control 44 Extend the boom 18 inches / 46 cm. handle off center.
  • Page 39 Second Edition • Sixth Printing Operator's Manual Inspections Test Aircraft Protection Package (if equipped) 50 Move the yellow bumper at the bottom of the platform 4 inches / 10 cm in any direction. 51 Activate each function control handle or toggle switch.
  • Page 40 Operator's Manual Second Edition • Sixth Printing Inspections Workplace Inspection Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace.
  • Page 41 Second Edition • Sixth 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  unstable or slippery surfaces  overhead obstructions and high voltage conductors ...
  • Page 42 Operator's Manual Second Edition • Sixth Printing 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 in Specifications (F3L 2011 &...
  • Page 43 Second Edition • Sixth Printing Operator's Manual Inspections Part No. T107107 S-65 Trax...
  • Page 44 Operator's Manual Second Edition • Sixth Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 133252 Label – Track Load, S-65 TRAX 133254 Cosmetic – Genie S-65 TRAX Determine whether the decals on your machine 133260 Cosmetic – S-65 TRAX have words or symbols.
  • Page 45 Second Edition • Sixth Printing Operator's Manual Inspections 82481 82487 Serial 82472 28158 Label or 28159 114252 114251 28160 133067 114252 147790 147794 or 823656 40434 114252 114099 133263 82548 133252 147790 133387 133252 147601 or 823762 133263 114473 114252 28174 133260 or 28235...

  • Page 46: Operating Instructions

    Operator's Manual Second Edition • Sixth Printing 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 Second Edition • Sixth 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 48 Operator's Manual Second Edition • Sixth 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 49 Second Edition • Sixth 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 50 Operator's Manual Second Edition • Sixth 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 51 Second Edition • Sixth 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 52 Operator's Manual Second Edition • Sixth Printing Operating Instructions Machine Not Level Indicator Light (if Machine Malfunction Indicator Light equipped) Light on indicates all functions have stopped. Light on indicates machine is not level. The tilt alarm will be sounding when this light is on.
  • Page 53 Second Edition • Sixth Printing Operator's Manual Operating Instructions Restart the engine. The regeneration mode Pipe Cradle Instructions should run automatically. The pipe cradle assembly consists of 2 pipe Left amber light on and no high temperature text cradles positioned at either side of the platform box present: Regeneration mode is turned off.
  • Page 54 Operator's Manual Second Edition • Sixth Printing Operating Instructions Observe and Obey: Pipe Cradle Operation  Be sure the pipe cradle assembly and Pipe cradles must be installed on the inside of installation instructions have been followed the platform. properly and that the pipe cradles are secured ...
  • Page 55 Second Edition • Sixth Printing Operator's Manual Operating Instructions Panel Cradle Assembly Installation of Padding Apply the warning decal to the front of each Install the 2 pieces of padding on the platform panel cradle (if needed). rails. Position the padding to protect the panels from contact with the platform rails.
  • Page 56 Operator's Manual Second Edition • Sixth Printing Operating Instructions Panel Cradle Operation Secure both panel cradles to the platform. rubber Place the load so that it rests in both panel bumper 2 cradles. Center the load on the platform. Secure the load to the platform using the strap. rubber bumper 1 Tighten the strap.
  • Page 57 Second Edition • Sixth 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 58: Transport And Lifting Instructions

    Operator's Manual Second Edition • Sixth Printing Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the vehicle capacity, loading surfaces and chains or straps are sufficient to withstand the machine weight. Genie lifts are very heavy relative to their size. See the serial label for the machine weight.
  • Page 59 Second Edition • Sixth Printing Operator's Manual Transport and Lifting Instructions Free-wheel Configuration for Securing to Truck or Trailer for Winching Transit Chock the tracks to prevent the machine from Always use the turntable rotation lock pin each rolling. time the machine is transported. Release the track brakes by turning over all four drive hub...
  • Page 60 Operator's Manual Second Edition • Sixth Printing Transport and Lifting Instructions Securing the Chassis Securing the Platform - S-65 Trax Place a block under the platform rotator. Do not Use chains or straps of ample load capacity. allow the block to contact the platform cylinder. Use a minimum of 5 chains.
  • Page 61 Second Edition • Sixth Printing Operator's Manual 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 62: Maintenance

    Operator's Manual Second Edition • Sixth Printing 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 Second Edition • Sixth 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 Operator's Manual Second Edition • Sixth Printing 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 Second Edition • Sixth 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 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 66: Specifications

    Operator's Manual Second Edition • Sixth Printing 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 67 Second Edition • Sixth Printing Operator's Manual 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...
  • Page 68 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. www.genielift.com...

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