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.

Operator's Manual Third Edition • Second Printing
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

Operator's Manual Third Edition • Second Printing
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.