Genie S-60 HC Operator's Manual

Operator’s Manual

with Maintenance Information

Second Edition

Fifth Printing

Part No. 43648

Operator's Manual Second Edition • Fifth Printing

®

®

S-60

S-65

Important

Read, understand and obey these safety rules and operating instructions before operating this machine.

Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries.

Contents

Page

Safety Rules .............................................................. 1

Controls ..................................................................... 7

Pre-operation Inspection ........................................... 10

Maintenance ............................................................. 12

Function Tests .......................................................... 16

Work Place Inspection .............................................. 21

Operating Instructions ............................................... 22

Transport .................................................................. 25

Decals ...................................................................... 26

Specifications ........................................................... 28

Contact us:

Internet: http://www.genielift.com

e-mail: [email protected]

Genie S-60 & Genie S-65

®

Copyright © 1995 by Genie Industries

First Edition: First Printing, January 1995

Second Printing, January 1996

Third Printing, October 1996

Second Edition: First Printing, November 1996

Second Printing, March 1997

Third Printing, March 1998

Fourth Printing, February 2000

Fifth Printing, July 2000

"Genie" is a registered trademark of

Genie Industries in the U.S.A. and many other countries. "S" is a trademark of Genie Industries.

These machines comply with

ANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Part No. 43648

Second Edition • Fifth Printing Operator's Manual

Safety Rules

Part No. 43648

Danger

Failure to obey the instructions and safety rules in this manual will result in death or serious injury.

Do Not Operate Unless:

You learn and practice the principles of safe machine operation contained in this operator's manual.

1 Avoid hazardous situations.

Know and understand the above principle before going on to the next section.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the work place.

5 Only use the machine as it was intended.

You read, understand and obey:

Manufacturer's instructions and safety rules—safety and operator's manuals and machine decals employer's safety rules and worksite regulations applicable governmental regulations

You are properly trained to safely operate the machine.

Genie S-60 & Genie S-65 1


SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and will

not provide protection from contact with or proximity to electrical current.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Voltage

Phase to Phase

0 to 300V

300V to 50KV

50KV to 200KV

200KV to 350KV

350KV to 500KV

500KV to 750KV

750KV to 1000KV

Minimum Safe

Approach Distance

Feet Meters

Avoid Contact

10 3.05

15

20

25

35

45

4.60

6.10

7.62

10.67

13.72

Allow for platform movement, electrical line sway or sag and beware of strong or gusty winds.

Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off.

Do not operate the machine during lightning or storms.

Do not use the machine as a ground for welding.

Tip-over Hazards

Occupants and equipment shall not exceed the maximum platform capacity.

Maximum platform capacity

S-65


S-60 with 8 Ft Platform

500 lbs

500 lbs


S-60 with 6 Ft Platform

600 lbs


S-60 with 6 Ft Platform with foam-filled tires and proper counterweight configuration

750 lbs

Maximum occupants

227 kg

227 kg

272 kg

340 kg

2

2 Genie S-60 & Genie S-65 Part No. 43648


SAFETY RULES

Do not raise or extend the boom unless the machine is on a firm, level surface.

Do not depend on the tilt alarm as a level indicator.

Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended.

Do not push off or pull toward any object outside of the platform.

Maximum allowable side force - ANSI & CSA

150 lbs

667 N

Maximum allowable manual force - CE

90 lbs

400 N

The tilt alarm sounds in the platform only when the machine is on a severe slope.

If the tilt alarm sounds:

Do not extend, rotate or raise the boom above horizontal. Move the machine to a firm, level surface before raising the platform. If the tilt alarm sounds when the platform is raised, use extreme caution to retract the boom and lower the platform.

Do not rotate the boom while lowering. Move the machine to a firm, level surface before raising the platform.

Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.

Do not alter or disable machine components that in any way affect safety and stability.

Do not replace items critical to machine stability with items of different weight or specification.

Do not modify or alter an aerial work platform.

Mounting attachments for holding tools or other materials onto the platform, toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load.

Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

Part No. 43648 Genie S-60 & Genie S-65 3


SAFETY RULES

Do not place or attach overhanging loads to any part of this machine.

Fall Hazards

Occupants must wear a safety belt or harness in accordance with governmental regulations.

Attach lanyard to anchor provided in platform.

Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

Do not place ladders or scaffolds in platform or against any part of this machine.

Do not use the machine on a moving or mobile surface or vehicle.

Be sure all tires are in good condition, air-filled tires are properly inflated and lug nuts are properly tightened.

Models with 750 lb (340 kg) Capacity: Do not use air-filled tires. Models are equipped with foam-filled tires. The wheel weight and the proper counterweight configuration are critical for machine stability.

Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.

Do not climb down from the platform when raised.

Keep the platform floor clear of debris.

Lower the platform entry mid-rail or close the entry gate before operating.

Bodily Injury Hazard

Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin.

Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.



SAFETY RULES

Collision Hazards

Be aware of limited sight distance and blind spots when driving or operating.

Be aware of boom position and tailswing when rotating the turntable.

Check work area for overhead obstructions or other possible hazards.

Do not lower the boom unless the area below is clear of personnel and obstructions.

Be aware of crushing hazard when grasping the platform guard rail.

It is recommended that operators wear an approved hard hat when operating the machine.

Observe and use color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.

Limit travel speed according to condition of ground surface, congestion, slope, location of personnel, and any other factors which may cause collision.

Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision.

No stunt driving or horseplay while operating a machine.

Component Damage Hazards

Do not use any battery or charger greater than 12V to jump-start the engine.

Do not use the machine as a ground for welding.

Be sure the hydraulic shutoff valves (located by hydraulic tank) are open before starting engine.



SAFETY RULES

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other explosive substances.

Do not refuel the machine with the engine running.

Refuel the machine and charge the battery only in an open, well-ventilated area away from sparks, flames and lighted tobacco.

Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine.

Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine.

Be sure all maintenance has been performed as specified in this manual and the

Genie S-60 &

Genie S-65 Service Manual.

Be sure all decals are in place and legible.

Be sure the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located on the platform.

Decal Legend

Genie product decals use symbols, color coding and signal words to identify the following:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Green—used to indicate operation or maintenance information.


Second Edition • Fifth Printing

8 9 10

Operator's Manual

Controls

11

7

6

5

4

3

2

1

20 19

Ground Control Panel

1 Platform rotate switch

2 Turntable rotate switch

3 Boom up/down switch

4 Boom extend/retract switch

5 not used

6 Key switch for platform/off/ground selection

7 Auxiliary power switch

8 Gasoline/LPG models: Water temperature gauge

Deutz Diesel models: Oil temperature gauge

9 Oil pressure gauge

10 Voltage gauge

18

17

16

15

11 Emergency Stop button

12 Hour meter

13 Gasoline/LPG models: Check engine light

Deutz Diesel models: Glow plug switch

(option)

14 Function enable switch

15 Engine start switch

16 15A breaker for engine electrical circuits

17 Gasoline/LPG select switch

18 15A breaker for control electrical circuits

19 S-65 only: Jib boom up/down switch

20 Platform level switch


12

13

14

Operator's Manual

CONTROLS

1


2 3 4 5 6

17 13 16

Platform Control Panel

1 Service horn button

2 Platform level switch

3

Platform rotate switch

4 S-65 only: Jib boom up/down switch

5 Auxiliary power switch

6 Drive speed select switch

8

7 Check engine light

8 Engine start switch

9 Engine idle (rpm) select switch

· Rabbit & Foot Switch: foot switch activated high idle

· Turtle: low idle

· Rabbit: high idle

10 Gasoline/LPG models: Gasoline/LPG select switch

Deutz Diesel models: Glow plug switch (option)

Genie S-60 & Genie S-65 Part No. 43648


7 8 9 10

Operator's Manual

CONTROLS

11

15 14 13 13 12

11 Emergency Stop button

12 Proportional control handle for drive function and thumb rocker for steer function

13 used for optional equipment

14 Drive enable indicator light

15 Drive enable switch

16 Proportional control handle for boom extend/retract

13 used for optional equipment

17 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions


Operator's Manual

Pre-operation Inspection




1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

Know and understand the above principles before going on to the next section.




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.

The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests.

The Pre-operation inspection also serves to determine if routine maintenance procedures are required. Only routine maintenance items specified in this manual may be performed by the operator.

Refer to the list on the next page and check each of the items and locations for modifications, damage or loose or missing parts.

A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. After repairs are completed, the operator must perform a pre-operation inspection again before going on to the function tests.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.



PRE-OPERATION INSPECTION

Pre-operation Inspection

o

Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform.

o

Be sure that all decals are legible and in place.

See Decals section.

o

Check for engine oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

o

Check for hydraulic oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

o

Check for engine coolant leaks and proper level of coolant. Add coolant if needed. See

Maintenance section.

o

Check for battery fluid leaks and proper fluid level. Add distilled water if needed. See

Maintenance section.

o Check for proper tire pressure. Add air if needed.

See Maintenance section.

Check the following components or areas for damage and improperly installed, loose or missing parts: o Electrical components, wiring and electrical cables o

Hydraulic hoses, fittings, cylinders and manifolds o

Fuel and hydraulic tanks o o

Drive and turntable motors and drive hubs

Boom wear pads o

Tires and wheels o

Engine and related components o

Limit switches and horn o Alarms and beacons (if equipped) o

Nuts, bolts and other fasteners o

Platform entry mid-rail or gate

Check entire machine for: o Crack in welds or structural components o Dents or damage to machine o

Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened.

o

After you complete your inspection, be sure that all compartment covers are in place and latched.


Operator's Manual

Maintenance


Check the Engine Oil Level

Observe and Obey:

Only routine maintenance items specified in this manual shall be performed by the operator.

Scheduled maintenance inspections shall be completed by qualified service technicians, according to the manufacturer's specifications and the requirements specified in the responsibilities manual.

Maintenance Symbols Legend

The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

Indicates that tools will be required to perform this procedure.

Maintaining the proper engine oil level is essential to good engine performance and service life.

Operating the machine with an improper oil level can damage engine components.

Check the oil level with the engine off.

1 Check the oil dipstick.

Gasoline/LPG Engine: located above the bellhousing on the bulkhead side of the engine.

Diesel Engine: located on the engine block near the engine oil filter.

Result: The oil level should be at the full mark on the dipstick. Add oil as needed.

Ford LRG-425 EFI Engine

Oil capacity (including filter)

4.5 quarts 4.3 liters

Oil viscosity requirements

below 60°F / 15.5°C

-10° to 90°F / -23° to 32°C above -10°F / -23°C above 25°F / -4°C

5W-30

5W-30

5W-30

10W-30

Use oils meeting API classification SH or SG grade.

Units ship with 10-40 CC/SG.

Indicates that new parts will be required to perform this procedure.

Indicates that a cold engine is required before performing this procedure.



MAINTENANCE

Deutz F4L 1011F Engine



below 60°F / 15.5°C (synthetic)

-10°F to 90°F / -23°C to 32°C

11 quarts

10.5 liters

5W-30

10W-40 above -4°F / -34°C 15W-40

Engine oil should have properties of API classification

CC/SE or CC/SF grades.


Perkins 704-30 Engine


9.6 quarts 9 liters


below 60°F / 15.5°C 15W-40

10W-30 -10°F to 90°F / -23°C to 32°C above -4°F / -34°C 15W-40

Engine oil should have properties of API classification

CF4 grade.


Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems.

1 Be sure that the boom is in the stowed position, then visually inspect the sight gauge located on the side of the hydraulic oil tank. Add oil as needed.

Result: The hydraulic oil level should be within the top 2 inches (5 cm) of the sight gauge.

Hydraulic oil specifications

Hydraulic oil type

Tank capacity

Hydraulic system

(including tank)

Dexron equivalent

45 gallons

170 liters

53 gallons

201 liters



MAINTENANCE

Check the Engine Coolant

Level - Liquid Cooled Models

Maintaining the engine coolant at the proper level is essential to engine service life. Improper coolant level will affect the engine's cooling capability and damage engine components. Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems.

Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may cause severe burns.

1 Check the fluid level in the coolant recovery tank. Add fluid as needed.

Result: The fluid level should be at the

FULL

mark.

Do not remove the radiator cap.

Check the Batteries

Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions.

Electrocution hazard. Contact with hot or live circuits may result in death or serious injury. Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections are free of corrosion.

3 Be sure that the battery hold downs and cable connections are tight.

4 Remove the battery vent caps.

5 Check the battery acid level. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill.

6 Install the vent caps.

Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.



MAINTENANCE

Check the Tire Pressure

This procedure does not need to be performed on machines equipped with the foam-filled tire option.

Bodily injury hazard. An overinflated tire can explode and could cause death or serious injury.

Tip-over hazard. Do not use temporary flat tire repair products.

To safeguard maximum stability, achieve optimum machine handling and minimize tire wear, it is essential to maintain proper pressure in all air-filled tires.

1 Check each tire with an air pressure gauge. Add air as needed.

Tire specifications

Tire size

Pressure

15-19.5NHS

85 psi

5.86 bar

The Schedule

There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, two year. To account for repeated procedures, the Scheduled

Maintenance Procedures Section and the

Maintenance Inspection Report have been divided into five subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.

Inspection

Daily or every 8 hours

Quarterly or every 250 hours

Six months or every 500 hours

Table or Checklist

A

A + B

A + B + C

Annual or every 1000 hours

Two year or every 2000 hours

A + B + C + D

A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report contains checklists for each type of scheduled inspection.

Make copies of the

Maintenance Inspection Report to use for each inspection. Store completed forms for three years.

Scheduled Maintenance

The scheduled maintenance items 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.

Inspections and maintenance described below require the qualified entity to record and retain records of all inspections and maintenance items for four years.

Machines that have been out of service for more than three months must receive the quarterly inspection before placing the machine back into service.


Operator's Manual

Function Tests






3 Always perform function tests prior to use.




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 tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service.

1 Select a test area that is firm, level and free of obstruction.

At the Ground Controls

2 Turn the key switch to ground control.

3 Pull out the red Emergency Stop button to the

ON

position.

Result: The beacon (if equipped) should flash.

4 Start the engine (see Operating Instructions section).

Test Emergency Stop

5 Push in the red Emergency Stop button to the

OFF

position.

Result: The engine should turn off and all functions should not operate.


ON

position and restart the engine.

Test the Machine Functions

7 Do not hold the function enable switch to either side. Attempt to activate each boom and platform function toggle switch.

Result: All boom and platform functions should

not operate.

8 Hold the function enable switch to either side and activate each boom and platform function toggle switch.

Result: All boom and platform functions should operate through a full cycle. The descent alarm

(if equipped) should sound while the boom is lowering.

Machines equipped with Platform Level Control

Disable Function: The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches.



FUNCTION TESTS

Test the Tilt Sensor

9 Pull out the platform red Emergency Stop button to the

ON

position. Turn the key switch to platform control.

10 Open the tank side turntable cover and locate the tilt sensor next to the control box.

11 Press down one side of the tilt sensor.

Result: The alarm, located in the platform, should sound.

Test Auxiliary Controls

12 Turn the key switch to ground control and shut the engine off.


ON

position.

14 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch.

Note: To conserve battery power, test each function through a partial cycle.

Result: All boom functions should operate.

At the Platform Controls

Test Emergency Stop

15 Turn the key switch to platform control and restart the engine.

16 Push in the platform red Emergency Stop button to the

OFF

position.

Result: The engine should turn off and all functions should not operate.

17 Pull out the red Emergency Stop button and restart the engine.

Test the Hydraulic Oil Return Filter

18 Move the engine idle select switch to high idel

(rabbit symbol).

19 Locate and check the hydraulic filter condition indicator.

Result: The filter should be operating with the plunger in the green area.

20 Move the engine idle select switch to foot switch activated high idle (rabbit and foot switch symbol).

Test the Service Horn

19 Push the horn button.

Result: The service horn should sound.



FUNCTION TESTS

Test the Foot Switch

20 Push in the platform Emergency Stop button to the

OFF

position.

21 Pull out the Emergency Stop button to the

ON

position but do not start the engine.

22 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side.

Result: The engine should not start.

23 Do not press down the foot switch and restart the engine.

24 Move the lift/drive select switch to the lift position (if equipped).

25 Do not press down the foot switch. Test each machine function.

Result: The machine functions should not operate.

Test Machine Functions


27 Press down the foot switch.

28 Activate each machine function control handle or toggle switch.

Result: All boom/platform functions should operate through a full cycle.



Test the Steering

29 Move the lift/drive select switch to the drive position (if equipped).


31 Depress the thumb rocker switch on top of the drive control handle in the direction identified by the blue triangle on the control panel.

Result: The steer wheels should turn in the direction that the blue triangles point on the drive chassis.

32 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel.

Result: The steer wheels should turn in the direction that the yellow triangles point on the drive chassis.

Test Drive and Braking



35 Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move, then return the handle to the center position.

Result: The machine should move in the direction that the blue arrow points on the drive chassis, then come to an abrupt stop.

36 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move, then return the handle to the center position.

Result: The machine should move in the direction that the yellow arrow points on the drive chassis, then come to an abrupt stop.

Note: The brakes must be able to hold the machine on any slope it is able to climb.



FUNCTION TESTS

Test the Oscillating Axle

(if equipped)


38 Start the engine from the platform controls.

39 Drive the right steer tire up onto a 6 inch (15.2

cm) block or curb.

Result: The three remaining tires should stay in firm contact with the ground.

40 Drive the left steer tire up onto a 6 inch (15.2

cm) block or curb.

Result: The three remaining tires should stay in firm contact with the ground.

41 Drive both steer tires up onto a 6 inch (15.2 cm) block or curb.

Result: The non-steer tires should stay in firm contact with the ground.

Test the Drive Enable System


43 Press down the foot switch and lower the boom to the stowed position.

44 Rotate the turntable until the boom moves past one of the non-steering wheels.

Result: The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown.


46 Move the drive control handle off center.

Result: The drive function should not operate.

47 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center.

Result: The drive function should operate.

Note: When the drive enable system is in use, the machine may drive in the opposite direction that the drive and steer control handle is moved.

Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction of travel.

Blue

Test Limited Drive Speed



50 Raise the boom to just above horizontal.

Yellow


52 Slowly move the drive control handle to the full drive position.

Result: The maximum achievable drive speed with the boom raised should not exceed 1 foot per second (0.3 meters per second).



FUNCTION TESTS


54 Lower the boom to the stowed position.

55 Extend the boom 1 foot (30 cm).


57 Slowly move the drive control handle to the full drive position.

Result: The maximum achievable drive speed with the boom extended should not exceed 1 foot per second (0.3 meters per second).

If the drive speed with the boom raised or extended exceeds 1 foot per second (0.3 meters per second), immediately tag and remove the machine from service.

Test Auxiliary Controls

58 Shut off the engine.


ON

position.



62 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch.

Note: To conserve battery power, test each function through a partial cycle.

Result: All boom and steer functions should operate. Drive functions should not operate with auxiliary power.

Test the Lift/Drive Select Switch (if equipped)

63 Move the lift/drive select switch to the lift position.



Result: No drive functions should operate.

66 Activate each boom function toggle switch.

Result: All boom functions should operate.

67 Move the lift/drive select switch to the drive position.


69 Activate each boom function toggle switch.

Result: No boom functions should operate.


Result: The drive functions should operate.

71 Repair any malfunctions before operating the machine.



Work Place Inspection






4 Inspect the work place.



Work Place Inspection

Be aware of and avoid the following hazardous situations:

· drop-offs or holes

· bumps, floor obstructions or debris

· overhead obstructions and high voltage conductors

· hazardous locations

· inadequate surface support to withstand all load forces imposed by the machine

· wind and weather conditions

· the presence of unauthorized personnel

· other possible unsafe conditions

Fundamentals

The Work Place Inspection helps the operator determine if the work place is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the work place.

It is the operator's responsibility to read and remember the work place hazards, then watch for and avoid them while moving, setting up and operating the machine.


Operator's Manual

Operating Instructions








5 Only use the machine as it was intended.

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.

Using the machine for anything other than lifting personnel and tools to an aerial work site is unsafe and dangerous.

Only trained and authorized personnel should be permitted to operate a machine. If more than one operator is expected to use a machine at different times in the same work shift, they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator's, safety and responsibilities manuals. That means every new operator should perform a preoperation inspection, function tests, and a work place inspection before using the machine.

Starting the Engine

1 At the ground controls, turn the key switch to the desired position.

2 Be sure both ground and platform control red

Emergency Stop buttons are pulled out to the

ON position.

3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position.

4 Move the engine start toggle switch to either side. If the engine fails to start or dies, the restart delay will disable the start switch for

3 seconds.

If the engine fails to start after 15 seconds of cranking, determine the cause and repair any malfunction. Wait 60 seconds before trying to start again.

All models: In extreme cold conditions, 20°F (-6°C) and below, warm the engine for 5 minutes to prevent hydraulic system damage.

Gasoline/LPG models:In extreme cold conditions,

20°F (-6°C) and below, the machine should be started on gasoline, then switched to LPG.

Emergency Stop

Push in either the ground or platform red

Emergency Stop button to the

OFF

position to stop all functions and turn the engine off.

Repair any function that operates when the

Emergency Stop button is pushed in.

Selecting and operating the ground controls will override the platform Emergency Stop button.



OPERATING INSTRUCTIONS

Auxiliary Controls

Use auxiliary power if the primary power source

(engine) fails.

1 Turn the key switch to ground or platform control.


ON

position.

3 Move the lift/drive select switch to the lift position (if equipped) when operating the auxiliary controls from the platform.

4 Press down the foot switch when operating the auxiliary controls from the platform.

5 Simultaneously hold the auxiliary power switch

ON

and activate desired function.

The drive function will not operate with auxiliary power.

Operation from Ground

1 Turn the key switch to ground control.


ON

position.

3 Gasoline/LPG models: Choose fuel by moving fuel select switch to desired position.

4 Start the engine.

To Position Platform

1 Hold the function enable switch to either side.

2 Move the appropriate toggle switch according to the markings on the control panel.

Drive and steer functions are not available from the ground controls.



Operation from Platform

1 Turn the key switch to platform control.

2 Pull out both ground and platform red

Emergency Stop buttons to the

ON

position.

3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position.

4 Start the engine. Do not press down the foot switch when starting the engine.

To Position Platform



3 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel.



To Steer



3 Turn the steering wheels with the thumb rocker switch located on top of the drive control handle.

Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn.



OPERATING INSTRUCTIONS

To Drive



3 Increase speed: Slowly move the drive control handle off center.

Decrease speed: Slowly move the drive control handle toward center.

Stop: Return the drive control handle to center or release the foot switch.

Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel.

Machine travel speed is restricted when the boom is raised or extended.

Drive Enable

Light

ON

indicates that the boom has moved just past either non-steering wheel and drive function has been interrupted.

To drive, hold the drive enable switch to either side and slowly move the drive control handle off center.

Be aware that the machine may move in the opposite direction that the drive and steer controls are moved.

Always use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel.

Generator

To operate the generator, move the generator toggle switch to the generator position. The engine will continue to run but no drive or platform functions will operate.

Plug power tool into the power to platform GFCI outlet.

To resume machine functions, move the generator toggle switch to machine functions position. All functions will operate.

24

Engine Idle Select (rpm)

Select engine idle (rpm) using the symbols on the control panel.

· Rabbit and foot switch symbol: foot switch activated high idle

· Turtle symbol: low idle

· Rabbit symbol: high idle

Check Engine Light (if equipped)

Light on and engine stopped: Tag the machine and remove from service.

Light on and engine still running: Contact service personnel within 24 hours.

Stopping the Engine

Push in the red Emergency Stop button and turn the key switch to the

OFF

position.

After Each Use

1 Select a safe parking location—firm level surface, clear of obstruction and traffic.

2 Retract and lower the boom to the stowed position.

3 Rotate the turntable so that the boom is between the non-steering wheels.

4 Turn the key switch to the

OFF

position and remove the key to secure from unauthorized use.

5 Chock the wheels.

Genie S-60 & Genie S-65 Part No. 43648


Transport Instructions

Observe and Obey:

Transport vehicle must be parked on a level surface.

Transport vehicle must be secured to prevent rolling while machine is being loaded.

Be sure vehicle capacity, loading surfaces and straps or lines are sufficient to withstand machine weight. See Specifications section.

Securing to Truck or Trailer for

Transit

Always use the turntable rotation lock pin each time the machine is transported.

Always chock machine wheels in preparation for transport.

Use tie points on drive chassis for anchoring down to transport surface.

Use the lower platform mount between the boom end and the platform to secure the boom from sideto-side movement. Do not use excessive downward force when securing the boom section.

Use chains or straps of ample load capacity.

Turn the key switch to the

OFF

position and remove the key before transporting.

Inspect the entire machine for loose or unsecured items.

Free-wheel Configuration for

Winching

Chock the wheels to prevent the machine from rolling.

2WD models: Release non-steer wheel brakes by turning over the torque hub disconnect caps (see below).

4WD models: Release wheel brakes by turning over all four torque hub disconnect caps (see below).

Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions.

Reverse procedures described to re-engage brakes.

Note: The pump free-wheel valve should always remain closed.

Disengage

Position

Engage

Position


Operator's Manual

Decals


Decal Inspection

Use the picture on the next page to verify that all decals are legible and in place.

Below is a numerical list with quantities and descriptions.

27564

28157

28158

28159

28160

28161

28163

28164

28165

28171

28174

28175

28176

Part No. Decal Description

25994

Quantity

Caution - Component Damage Hazard 1

27204

27205

27206

27207

Arrow - Blue

Arrow - Yellow

Triangle- Blue

Triangle - Yellow

1

1

2

2

Danger - Electrocution Hazard

Label - Dexron

Label - Unleaded

Label - Diesel

Label - Liquid Petroleum Gas

Danger - Crushing Hazard

Notice - Maximum Side Force - 150 lbs

Notice - Hazardous Materials

Notice - Foot Switch

Label - No Smoking

Label - Power to Platform, 230V

Caution - Compartment Access

Notice - Missing Manuals

2

1

1

1

1

2

7

1

2

1

3

1

2

28177

28181

28235

Warning - Platform Rotate

Warning - No Step or Ride

Label - Power to Platform, 115V

28236 Warning - Failure To Read . . .

30080* Notice - Maximum Load 500 lbs

31060

32700

32726

32728

Danger - Tip-over Hazard, Interlock

Danger - Safety Rules

Label - Glow Plug (option)

Label - Generator (option)

1

2

1

1

1

1

2

1

2

26 Genie S-60 & Genie S-65

Part No. Decal Description

33885 Serial Plate - S-65

33952 Danger - Tilt-Alarm

33973

35599

40434

Notice - Tire Pressure

Notice - Align Air Hoses

Label - Lanyard Anchorage

43594* Notice - Maximum Load 750 lbs

43595 Danger - Tip-over, Tires (foam-filled)

43647

43649

Notice - Operating Instructions

Ground Control Panel

43663

44769

44981

Notice - Function Enable

Lift/Drive Select

Airline to Platform

Quantity

1

1

2

1

4

2

1

1

1

1

1

2

44986

49741

49926

52156

52966

52967

53037

62076

62077

62078

Notice - Maximum Manual Force - 90 lbs

Notice - Ford Engine Specs-LRG-425 EFI 1


Platform Control Panel

Cosmetic - 4 x 2

Cosmetic - 4 x 4

Notice - Deutz Diesel Engine Specs

Cosmetic - Genie S-60

Cosmetic - S-60

Cosmetic - Genie S-65

1

62079

64361

72160

Cosmetic - S-65

Notice - Perkins Diesel Engine Specs


72162 Platform Control Panel

*Please reference the Specifications section or the chart on page 2 to determine the capacity of your machine.

1

1

1

1

1

1

1

1

1

1

1

1

Part No. 43648


DECALS

Ground

Controls

Side

Engine

Side


Operator's Manual

Specifications


Model

Height, working maximum

Height, platform maximum

S - 6 0

66 ft

20.1 m

60 ft

18.3 m

9 ft 9 ft

S - 6 5

71 ft

21.6 m

65 ft

19.8 m

Height, stowed maximum

2.74 m 2.74 m

Horizontal reach maximum

Width

Drive speed, stowed

Deutz Diesel models

Drive speed, raised or extended

- all models

51 ft 3 in

15.6 m

8 ft

2.43 m

56 ft 4 in

17.2 m

8 ft

2.43 m

Length, stowed

Maximum load capacity

6 foot platform


8 foot platform

27 ft 2 in

8.3 m

600 lb

272 kg


6 foot platform with foam-filled tires and proper counterweight configuration

750 lb

340 kg

Wheelbase

500 lb

227 kg

Turning radius (outside)

9 ft 0 in

2.7 m

22 ft 2 in

6.75 m

30 ft 10 in

9.4 m

500 lb

227 kg

500 lb

227 kg

N/A

N/A

9 ft 0 in

2.7 m

Turning radius (inside) 12 ft 1 in

3.7 m

22 ft 2 in

6.75 m

12 ft 1 in

3.7 m

Turntable rotation (degrees)

Turntable tailswing 3 ft 3

1

/

2

in

100 cm continuous

3 ft 3

1

/

2

in

100 cm

Power source Ford 63 Hp Gasoline/LPG LRG-423

(choice) or LRG-425 EFI

Deutz 56 Hp Diesel F4L 1011

Drive speeds

Drive speed, stowed

Gasoline/LPG models

2WD 4WD

4.4 mph 3.0 mph

7.1 km/h 4.8 km/h

40 ft/6.2 sec 40 ft/9.1 sec

12.2 m/6.2 sec 12.2 m/9.1 sec

4.0 mph 2.8 mph

6.4 km/h 4.5 km/h

40 ft/6.8 sec 40 ft/9.7 sec

12.2 m/6.8 sec 12.2 m/9.7 sec

0.6 mph 0.6 mph

1.0 km/h 1.0 km/h

40 ft/40 sec 40 ft/40 sec

12.2 m/40 sec 12.2 m/40 sec

Model S - 6 0 S - 6 5

Controls 12V DC proportional

Platform dimensions, 6 foot 72 in x 30 in 72 in x 30 in

(length x width) 1.8 m x 76 cm 1.8 m x 76 cm

Platform dimensions, 8 foot 96 in x 36 in 96 in x 36 in

(length x width) 2.4 m x 91 cm 2.4 m x 91 cm

Platform leveling self-leveling self-leveling

Platform rotation

AC outlet in platform

160° standard

Hydraulic pressure (maximum) 2600 psi

(boom functions) 179 bar

Weight

160° standard

2900 psi

200 bar

Tire size 15-19.5 NHS 15-19.5 NHS

Gradeability, stowed (2WD/4WD) 28% / 40 %

Ground clearance

Hydraulic tank capacity

12 in

30 cm

45 gallons

170 liters

12 in

30 cm

45 gallons

170 liters

Fuel tank capacity 30 gallons

114 liters

26,060 lbs

11,821 kg

30 gallons

114 liters

28,400 lbs

12,882 kg

Airborne noise emissions 80 dB

Maximum sound level at normal operating workstations

(A-weighted)

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice or obligation.

60 ft

18.3 m

40 ft

12.2 m

20 ft

6.1 m

0 ft

0 m

20 ft

6.0 m

0 ft

0 m

S-60 S-65

20 ft

6.0 m

40 ft

12.2 m

60 ft

18.3 m


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.

Genie Holland

Phone +

31 70 51 78836

Fax +

31 70 51 13993

Genie Scandinavia

Phone +

46 31 3409612

Fax +

46 31 3409613

Genie France

Phone +

Fax +

33 (0)2 37 26 09 99

33 (0)2 37 26 09 98

Genie Iberica

Phone +

34 93 579 5042

Fax +

34 93 579 5059

Genie Germany

Phone +

49 (0)4202 88520

Fax +

49 (0)4202 8852-20

Genie U.K.

Phone +

Fax +

44 (0)1476 584333

44 (0)1476 584334

Genie Mexico City

Phone +

52 5 653 03 84

Fax +

52 5 664 40 16

Genie North America

Phone

425.881.1800

Toll Free

Fax

USA and Canada

800.536.1800

425.883.3475

Genie Australia Pty Ltd.

Phone +

Fax +

61 7 3375 1660

61 7 3375 1002

Genie China

Phone +

86 21 53852570

Fax +

86 21 53852569

Genie Malaysia

Phone +

Fax +

60 4 228 1235

60 4 226 6872

Genie Japan

Phone +

81 3 3453 6082

Fax +

81 3 3453 6083

Genie Korea

Phone +

82 2 558 7267

Fax +

82 2 558 3910

Genie Africa

Phone +

Fax +

27 11 455 0373

27 11 455 0355

Genie Latin America

Phone +

55 11 4055 2499

Fax +

55 11 4043 1661

Genie S-60 HC Operator's Manual

Assistant Bot

Operator’s Manual

with Maintenance Information

Important

Contents

Contact us:

Safety Rules

Danger

Failure to obey the instructions and safety rules in this manual will result in death or serious injury.

Do Not Operate Unless:

Electrocution Hazards

Tip-over Hazards

Fall Hazards

Bodily Injury Hazard

Collision Hazards

Component Damage Hazards

Explosion and Fire Hazards

Damaged Machine Hazards

Decal Legend

Controls

Pre-operation Inspection

Do Not Operate Unless:

Fundamentals

Pre-operation Inspection

Maintenance

Check the Engine Oil Level

Observe and Obey:

Check the Hydraulic Oil Level

Check the Engine Coolant

Level - Liquid Cooled Models

Check the Batteries

Check the Tire Pressure

Scheduled Maintenance

Function Tests

Do Not Operate Unless:

Fundamentals

At the Ground Controls

At the Platform Controls

Work Place Inspection

Do Not Operate Unless:

Work Place Inspection

Fundamentals

Operating Instructions

Do Not Operate Unless:

Fundamentals

Starting the Engine

Emergency Stop

Auxiliary Controls

Operation from Ground

Operation from Platform

Engine Idle Select (rpm)

Check Engine Light (if equipped)

Stopping the Engine

After Each Use

Transport Instructions

Observe and Obey:

Securing to Truck or Trailer for

Transit

Free-wheel Configuration for

Winching

Decals

Decal Inspection

Ground

Controls

Side

Engine

Side

Specifications

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.

Related manuals

Genie

S-80

Genie

Z-45 22

Genie

S 85

Genie