Genie S-65 User manual

Operator's Manual Third Edition • Second Printing
S-60 TRAX • S-65 TRAX Part No.227285
Copyright © 1995 by Terex Corporation
Third Edition: Second Printing, September 2011
"Genie" is a registered trademark of
Terex South Dakota in the U.S.A. and many
other countries. "S" is a trademark of Terex
South Dakota.
These machines comply with AS1418.10
Printed on recycled paper
Printed in U.S.A.
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, please call Genie Industries.
Contents
Page
Introduction................................................................ 1
Symbols and Hazard Pictorials Definitions ................ 3
General Safety .......................................................... 5
Personal Safety ......................................................... 8
Work Area Safety ...................................................... 9
Legend ..................................................................... 20
Controls .................................................................... 21
Inspections ............................................................... 29
Operating Instructions .............................................. 40
Transport and Lifting Instructions.............................. 50
Maintenance............................................................. 53
Specifications ........................................................... 56
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 1
Introduction
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understand andobeythe
manufacturer'sinstructions andsafety rules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperly trainedtosafely operatethe
machine.
Owners, Users and Operators:
Genieappreciatesyour choice ofourmachine for
yourapplication.Our numberonepriority isuser
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:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyou believeshouldbe added,please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

Operator's Manual Third Edition • Second Printing
2 S-60TRAX • S-65TRAX PartNo.227285
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
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-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotential personalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesahazardous situation
which, if not avoided, will result in
deathorserious injury.
Indicatesahazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesahazardous situation
which, if not avoided, could result
inminor ormoderateinjury.
Indicatesahazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 3
Symbol and Hazard Pictorials Definitions
CrushHazard ExplosionHazard
FallHazard
CrushHazard
Tip-overHazard
Tip-overHazard
Tip-overHazard
Tip-overHazard
Electrocution
Hazard
Keep off this
surface.
Keepawayfrom
movingparts.
Maintainrequired
clearance. Keepawayfrom
path of moving
platform.
Readthe
operator’s
manual.
Nosmoking.
Noflame.
Stopengine.
Replacetracks
with same tracks. See serial label for
rated capacity.
Recovery procedure if tilt alarm sounds
whileelevated.
Onlytrained
maintenance
personnelshould
access
compartments.
Counterweight
uphill:
1 Retract boom.
2 Lowerboom.
Counterweight
downhill:
1 Lowerboom.
2 Retract boom.

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4 S-60TRAX • S-65TRAX PartNo.227285
Lanyard
attachmentpoint
Symbol and Hazard Pictorials Definitions
Trackload Voltageratingfor
powertoplatform Pressureratingfor air line to platform
Avoid contact.
Havefire
extinguishernear.
Tie-down
instructions Tie-down instructions
Electrocution
Hazard
ExplosionHazard Do not use ether
orotherhigh
energystarting
aids on machines
equippedwith
glowplugs.
X1

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 5
Safety signs and locations
General Safety
28177
31060
114258 28161
28161 C
Crush Hazard
Contact with moving parts can
result in death or serious
injury.
WARNING
Keep away from moving parts.
Tip-over Hazard
Altering or disabling limit switches
can result in machine tip-over.
Machine tip-over will result in
death or serious injury.
DANGER
Do not alter or disable limit switch(s).
31060 B
Crush Hazard
Death or serious
injury may result
from platform
crushing
personnel
against boom.
WARNING
28177 C
Keep away from
path of moving
platform.
Burn Hazard
Fuel and fumes
can explode
and burn.
DANGER
No smoking. No
flame. Stop
engine.
114258 A
28177
31060
114389 114258 114390 28161
133250
114390
DANGER
133250
DANGER
114389
82237
DANGER
82237
31788
31788

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6 S-60TRAX • S-65TRAX PartNo.227285
General Safety
Safety signs and locations
28236
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.
Do not attach this platform to a
machine with any other rated
load.
1000262 B
DANGER
Read and understand Operator's
Manual, Responsibilities Manual and
Safety Manual and all safety signs
before using or maintaining machine.
If you do not understand the
information in the manuals, consult
your supervisor, the owner or the
manufacturer. 28236 D
WARNING
Improper operation or
maintenance can result in
serious injury or death.
1000262
114416
114389
1000262
28236
DANGER
114389
Tip-over Hazard
If tilt-alarm
sounds, unit is
on a severe
slope. Death or
serious injury
will result.
114416 A
DANGER
Platform uphill:
1Lower boom.
2Retract boom.
Platform downhill:
1Retract boom.
2Lower boom.
•Read operator's
manual before
attempting to move
machine.
Stop all movement.
114416
97875
or 97579
82862
DANGER
82862
Tip-over Hazard
Welder power supply
reduces rated platform
capacity and
must be factored into total
platform load.
97579 D
DANGER
Do not overload
platform.
Welder power supply
weighs 75 lbs / 34 kg.
Electrocution Hazard
Failure to properly connect
and use the weld line to
platform could result in death
or serious injury.
Read, understand and obey all
warnings and instructions
provided with welding power unit.
Turn welding power unit off
before connecting leads.
Be sure weld cables are properly
connected.
DC weld only: 40V, 300 amp
maximum.
Component Damage
Hazard
Failure to properly
connect weld leads
may result in machine
or component
damage.
Turn welding power unit
off before connecting
leads.
Connect leads to twist-
lock connectors at
turntable and platform.
97875 A
WARNING
97579 97875

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 7
Safety signs and locations
General Safety
28175
28181
97602
Keep off this surface.
WARNING
Fall Hazard
Death or serious injury may result
from climbing or riding on boom.
28181 C
Explosion Hazard
Death or serious injury can
result from the use of ether or
other high energy starting
aids. 97602 B
WARNING
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
Compartment access
is restricted.
Contact with
components under
any cover may result
in serious injury.
Only trained maintenance personnel
should access compartments. Access
by operator is only advised when
performing Pre-operation Inspection. All
compartments must remain closed and
secured during operation.
28175 G
WARNING
28177
31060 28161
28161 C
Crush Hazard
Contact with moving parts can
result in death or serious
injury.
WARNING
Keep away from moving parts.
Tip-over Hazard
Altering or disabling limit switches
can result in machine tip-over.
Machine tip-over will result in
death or serious injury.
DANGER
Do not alter or disable limit switch(s).
31060 B
Crush Hazard
Death or serious
injury may result
from platform
crushing
personnel
against boom.
WARNING
28177 C
Keep away from
path of moving
platform.
114390
28175
28161
28177
28181 31060
133250
97602
114390
DANGER
133250

Operator's Manual Third Edition • Second Printing
8 S-60TRAX • S-65TRAX PartNo.227285
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
requiredwhenoperatingthismachine.
Occupants must wear a safety belt or harness in
accordancewithgovernmentalregulations.Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
All PFPE must comply with applicable
governmentalregulations,andmustbeinspected
and used in accordance with the PFPE
manufacturer’sinstructions.

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 9
Electrocution Hazards
This machine is not
electricallyinsulated
andwillnotprovide
protection from contact
with or proximity to
electricalcurrent.
Maintain safe distances
fromelectricalpower
linesand apparatusin
accordancewith
applicablegovernmentalregulationsandthe
followingchart.
LineVoltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the
machine if it contacts
energizedpowerlines.
Personnelonthe
groundorinthe
platform must not touch
oroperatethe machine
untilenergizedpower
lines are shut off.
Donotoperatethemachineduring lightningor
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants,equipmentand materials shallnot
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
Work Area Safety
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 S-65 TRAX, even if the picture
does not show the tracks.

Operator's Manual Third Edition • Second Printing
10 S-60TRAX • S-65TRAX PartNo.227285
The weight of options and accessories, such as
pipecradles, panelcradles andwelders, willreduce
the rated platform capacity and must be factored
into the total platform load. See the decals with the
options and accessories.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
Do not raise or extend
the boom unless the
machine is on a firm,
level surface.
Donot dependon the
tilt alarm as a level
indicator. The tilt alarm
sounds in the platform
onlywhen themachine
is on a severe slope.
If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surfacebefore raisingtheplatform.
If the tilt alarm sounds when the platform is raised:
Use extreme caution. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with
theplatformuphill:
First lower the boom, then
retracttheboom.
If the tilt alarm sounds with
theplatformdownhill:
First retract the boom, then
lowertheboom.
Do not raise the boom when wind speeds may
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the boom is raised, lower
the boom and do not continue to operate the
machine.
Work Area Safety

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 11
Work Area Safety
Do not contact adjacent structures with the boom.
Do not tie the boom or
platformto adjacent
structures.
Do not place loads
outsidethe platform
perimeter.
Do not push off or pull
towardanyobject
outside
of the platform.
Maximum allowable
manual force 90 lbs / 400 N
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 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.
Useextreme careand
slowspeedswhile
driving the machine in
thestowed position
acrossuneventerrain,
debris,unstableor
slipperysurfacesand
nearholesanddrop-
offs.
Do not drive the
machineonornear
uneventerrain,
unstablesurfaces or
otherhazardous
conditions with the
boomraisedor
extended.
Do not use the machine
as a crane.
Do not push the machine or other objects with the
boom.

Operator's Manual Third Edition • Second Printing
12 S-60TRAX • S-65TRAX PartNo.227285
Be sure all track lug nuts are properly tightened.
Do not use the platform controls to free a platform
thatis caught,snaggedorotherwiseprevented
from normal motion by an adjacent structure. All
personnelmustberemovedfrom theplatform
before attempting to free the platform using the
groundcontrols.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 4WD
Platform downhill 45% (24°)
Platform uphill 30% (17°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Do not replace tracks with tires.
Do not modify or alter an aerial work platform
withoutprior writtenpermissionfromthe
manufacturer.Mountingattachmentsforholding
toolsorother materials ontotheplatform, toeboards
or guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.
Do not place or attach
overhangingloadsto
any part of this
machine.
Donotplace laddersor
scaffolds in the
platformoragainst any
part of this machine.
Do not transport tools
andmaterials unless
they are evenly
distributedand canbe
safely handled by
person(s)inthe
platform.
Do not use the machine
on a moving or mobile
surface or vehicle.
Work Area Safety

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 13
Fall Hazards
Occupants must wear a
safety belt or harness
inaccordancewith
governmental
regulations. Attach the
lanyardto theanchor
providedinthe
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 climb down
fromtheplatformwhen
raised.
Keeptheplatform floor
clear of debris.
Lowertheplatform
entry mid-rail or close
theentry gatebefore
operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited
sight distance and blind
spotswhendriving or
operating.
Be aware of the boom
positionandtailswing
whenrotatingthe
turntable.
Checkthework area for
overheadobstructions
orotherpossible
hazards.
Beaware ofcrushing
hazardswhengrasping
theplatformguardrail.
Operatorsmustcomply
with employer, job site
andgovernmentalrules
regardingtheuse of
personalprotective
equipment.
Observeandusethecolor-codeddirectionarrows
on the platform controls and drive chassis for drive
and steer functions.
Work Area Safety

Operator's Manual Third Edition • Second Printing
14 S-60TRAX • S-65TRAX PartNo.227285
Work Area Safety
Stay clear of all Trax rotating or moving parts such
as sprockets and rollers.
Donot lowerthe boom
unlesstheareabelow
is clear of personnel
andobstructions.
Limit travel speed
accordingtothe
conditionoftheground
surface,congestion,
slope, location of
personnel,andany
otherfactorswhich
may cause collision.
Donot operateaboom
in the path of any crane
unless the controls of
thecranehavebeen
lockedoutand/or
precautionshavebeen
taken to prevent any
potentialcollision.
Nostuntdrivingorhorseplaywhileoperating a
machine.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Do not allow any object to come near moving parts.
The object could be thrown out of the Trax
undercarriage.
Alwaysoperatethe machineina well-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontact withcomponentsunderanycover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 15
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleumgas(LPG),gasoline,diesel fuelor other
explosive substances.
Donotrefuelthemachine withthe enginerunning.
Refuel the machine and charge the battery only in
anopen, well-ventilatedarea awayfrom sparks,
flames and lighted tobacco.
Donotoperate themachine inhazardouslocations
orlocationswherepotentiallyflammable or
explosive gases or particles may be present.
Donot sprayetherintoenginesequippedwithglow
plugs.
Damaged Machine Hazards
Donotuse adamaged ormalfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureall maintenancehas beenperformedas
specifiedinthismanualandtheappropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legibleandin thestorage
containerlocatedontheplatform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-startthe engine.
Do not use the machine as a ground for welding.
Maintain the cleanliness of the machine to ensure
properandsafeoperation. Removedirt,debris,
and any tools used for maintenance from the Trax
undercarriagesystem.
Work Area Safety

Operator's Manual Third Edition • Second Printing
16 S-60TRAX • S-65TRAX PartNo.227285
Work Area Safety
Welder Safety
Read,understandandobeyallwarningsand
instructionsprovided withtheweldingpowerunit.
Theweightof the welderwill reduce therated
platform capacity and must be factored into the
totalplatform load.Thewelderpowersupply weighs
75 lbs / 34 kg.
Donotoperate thewelderunless afire extinguisher
is immediately available for instant use, per OSHA
regulation1926.352(d).
Battery Safety
Burn Hazards
Batteries contain acid.
Alwayswearprotective
clothingandeyewear
whenworkingwith
batteries.
Avoid spilling or
contacting battery acid.
Neutralizebatteryacid
spills with baking soda
andwater.
Explosion Hazard
Keep sparks, flames
andlightedtobacco
awayfrom batteries.
Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.

Operator's Manual
Third Edition • Second Printing
PartNo.227285 S-60TRAX • S-65TRAX 17
Work Area Safety
Weld Line to Platform Safety
Read,understandandobeyallwarningsand
instructionsprovided withtheweldingpowerunit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Donotoperate unlessthe weldcablesareproperly
connected.
Connect the positive lead to the twist-lock
connectoratthe turntableand platform.
Clamp the negative lead to the ground post at the
turntableandplatform.

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18 S-60TRAX • S-65TRAX PartNo.227285
Work Area Safety
Pipe Cradle Safety
Read,understandandobeyallwarningsand
instructions provided with the pipe cradles.
Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles will reduce rated platform capacity and
must be factored into total platform load.
The pipe cradle assembly weighs 21 lbs / 9.5 kg.
The maximum capacity of the pipe cradle assembly
is 200 lbs / 91 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum
number of occupants in platform.
Center the load within the perimeter of the platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the
platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Donot operateunlessyouareadequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhangingload.
Do not cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhangingload.
ElectrocutionHazard: Keeppipes awayfromall
energizedelectricalconductors.
Panel Cradle Safety
Read,understandandobeyallwarningsand
instructionsprovidedwith the panelcradles.
Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, occupants,
tools and any other equipment must not exceed
rated capacity.
The panel cradle assembly weighs 30 lbs / 13.6 kg.
The maximum capacity of the panel cradles is
250 lbs / 113 kg.
The weight of the panel cradles and the load in the
panel cradles may limit the maximum number of
occupants in platform to one person.
Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.
Donot operateunlessyouareadequately
instructed and are aware of all hazards associated
with lifting panels.
Do not cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhangingload.
Maximum vertical height of panels: 4 ft / 1.2 m
Maximum wind speed: 15 mph / 6.7 m/sec
Maximum panel area: 32 sq. ft / 3 m2