Genie S-60 HC User manual

Operator's Manual
S-60HC PartNo.T107112
Second Edition • Second Printing
Important
Read,understandandobeythesesafetyrulesand
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
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 8
Work Area Safety....................................................... 9
Legend ...................................................................... 17
Controls .................................................................... 18
Inspections ............................................................... 25
OperatingInstructions............................................... 36
TransportandLiftingInstructions .............................. 42
Maintenance ............................................................. 45
Specifications ........................................................... 49
Contact us:
Internet:www.genielift.com
E-mail:[email protected]
Copyright © 1995 by Terex Corporation
Second 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.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Printed on recycled paper
Printed in U.S.A.

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 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,understandandobeythe
manufacturer'sinstructionsand safety rules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis 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:
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
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

Operator'sManual Second Edition • Second Printing
2 S-60HC PartNo.T107112
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-basedcleaners becausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesanimminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicatesapotentiallyhazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicatesapotentiallyhazardous
situation which, if not avoided,
maycauseminor or moderate
injury.
Indicatesapotentiallyhazardous
situation which, if not avoided,
mayresultinpropertydamage.
Red
Orange
Yellow
Blue

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 3
CrushHazard ExplosionHazard FireHazard ExplosionHazard Electrocution
Hazard
FallHazard CrushHazard Tip-overHazard
MaximumManual
Force MaximumWind Speed
Symbol and Hazard Pictorials Definitions
Tip-overHazard Tip-overHazard
Tip-overHazard Tip-overHazard Electrocution
Hazard
Maintainrequired
clearance.
Readthe
operator’s
manual.
Keep off this
surface. Keepawayfrom movingparts. Keepawayfrom path of moving
platform.
Onlytrained
maintenance
personnelshould
access
compartments.
Nosmoking.
Noflame.
Stopengine.
Counterweight
downhill:
1 Lowerboom.
2 Retract boom.
Counterweight
uphill:
1 Retract boom.
2 Lowerboom.

Operator'sManual Second Edition • Second Printing
4 S-60HC PartNo.T107112
Lanyard
attachmentpoint
Symbol and Hazard Pictorials Definitions
Wheelload Voltageratingfor
powertoplatform Pressureratingfor air line to platform
Replacetireswith
same tire. Avoid contact.
Havefire
extinguishernear.
Replaceplatform
withsamerated
platform.
Tie-down
instructions Tie-down instructions

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 5
General Safety
Safety signs and locations

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6 S-60HC PartNo.T107112
Safety signs and locations
General Safety

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 7
General Safety
Safety signs and locations

Operator'sManual Second Edition • Second Printing
8 S-60HC PartNo.T107112
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'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 9
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obeyalllocalandgovernmentalregulations
regardingrequiredclearancefromelectricalpower
lines. At a minimum, the required clearance
contained in the chart below must be followed.
LineVoltage Required Clearance
0 to 50KV 3.0 m
50 to 200KV 4.6 m
200 to 350KV 6.1 m
350 to 500KV 7.6 m
500 to 750KV 10.6 m
750 to 1000KV 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.Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperatethemachineduringlightningor
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants,equipment and materials shall not
exceed the maximum platform capacity for the
restrictedorunrestrictedrangeof motion.
Maximum platform capacity
Unrestricted range of motion 340 kg
Restricted range of motion 567 kg
Maximum occupants 3
S-60 HC: Do not attach a platform rated at 340 kg
(unrestrictedrangeofmotion)and567 kg(restricted
range of motion) to machines with any other rated
load. See the serial label for the maximum rated
load.
The weight of options and accessories, such as
pipecradles,panel cradles 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.
Work Area Safety

Operator'sManual Second Edition • Second Printing
10 S-60HC PartNo.T107112
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.
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.
Donot rotate the boom while lowering. Move the
machine to a firm, level surface before raising the
platform.
If the tilt alarm sounds with the
platformuphill:
First lower the boom, then retract the
boom.
If the tilt alarm sounds with the
platformdownhill:
First retract the boom, then lower the
boom.
Do not raise the boom when wind speeds may
exceed 12.5 m/s. If wind speeds exceed 12.5 m/s
when the boom is raised, lower the boom and do
notcontinue to operate the machine.
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.
Use extreme care and slow speeds while driving
the machine in the stowed position across uneven
terrain,debris,unstableor slippery surfaces and
nearholesanddrop-offs.
Donotdrivethe machine on or near uneven terrain,
unstablesurfacesorotherhazardousconditions
withtheboomraisedorextended.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Work Area Safety

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 11
Work Area Safety
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s)intheplatform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, air-filled tires
areproperly inflatedandlugnutsare properly
tightened.
Do not use the platform controls to free a platform
thatiscaught, snagged or otherwiseprevented
from normal motion by an adjacent structure. All
personnelmustberemovedfromthe platform
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, 2WD
Counterweight uphill 30% (17°)
Counterweight downhill 10% (6°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Counterweight uphill 45% (24°)
Counterweight downhill 30% (17°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Do not push off or pull
towardanyobject outside
of the platform.
Maximum allowable
manual force - CE 400 N
Do not alter or disable
machinecomponentsthat
in any way affect safety
and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Do not replace factory-installed foam-filled tires with
air-filled tires. Wheel weight is critical to stability.
Do not modify or alter an aerial work platform
withoutpriorwritten permissionfromthe
manufacturer.Mountingattachmentsforholding
toolsor 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.
Do not place or attach overhanging loads to any
part of this machine.
Do not place ladders or scaffolds in the platform or
against any part of this machine.

Operator'sManual Second Edition • Second Printing
12 S-60HC PartNo.T107112
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the boom position and tailswing when
rotatingtheturntable.
Checktheworkarea for overhead obstructions or
otherpossiblehazards.
Beaware ofcrushinghazardswhengraspingthe
platformguardrail.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Observeandusethecolor-codeddirectionarrows
on the platform controls and drive chassis for drive
and steer functions.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmentalregulations.
Attach the lanyard to the
anchorprovidedinthe
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 from the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gatebeforeoperating.
Work Area Safety

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 13
Do not lower the boom unless the area below is
clearofpersonnel and obstructions.
Limit travel speed according to the condition of the
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
outand/orprecautionshavebeen taken to prevent
any potential collision.
Nostuntdrivingor horseplay while operating 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.
Alwaysoperatethemachineinawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontactwith components under anycover
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.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleumgas(LPG),gasoline,dieselfuel or other
explosive substances.
Donotrefuelthemachinewith the engine running.
Refuel the machine and charge the battery only in
anopen,well-ventilated area awayfromsparks,
flames and lighted tobacco.
Donotoperatethemachineinhazardouslocations
orlocations wherepotentiallyflammable or
explosive gases or particles may be present.
Donotsprayether into enginesequippedwithglow
plugs.
Damaged Machine Hazards
Donotuseadamagedormalfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenancehasbeenperformedas
specifiedinthismanual and the appropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
containerlocatedontheplatform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
Do not use the machine as a ground for welding.
Work Area Safety

Operator'sManual Second Edition • Second Printing
14 S-60HC PartNo.T107112
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 9.5 kg.
The maximum capacity of the pipe cradle assembly
is 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.
Donotoperate unlessyouareadequately
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:Keep pipesawayfromall
energizedelectricalconductors.
Weld Line to Platform Safety
Read,understandandobeyallwarningsand
instructionsprovidedwiththeweldingpower unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Donotoperateunlesstheweldcablesare properly
connected.
Connect the positive lead to the twist-lock
connectorattheturntableandplatform.
Clamp the negative lead to the ground post at the
turntableandplatform.
Work Area Safety

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 15
Panel Cradle Safety
Read,understandandobeyallwarningsand
instructionsprovided with the panel cradles.
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 13.6 kg.
The maximum capacity of the panel cradles is
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.
Donotoperate unlessyouareadequately
instructed and are aware of all hazards associated
with lifting panels.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhangingload.
Maximum vertical height of panels: 1.2 m
Maximum wind speed: 6.7 m/sec
Maximum panel area: 3 m2
Work Area Safety

Operator'sManual Second Edition • Second Printing
16 S-60HC PartNo.T107112
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworkingwithbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Work Area Safety
Lockout 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
thenon-steerwheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chockthewheels.

Operator'sManual
Second Edition • Second Printing
PartNo.T107112 S-60HC 17
1 Non-steertire
2 Steertire
3 Groundcontrols
4 Boom
5 Platformcontrols
6 Platform
7 Lanyardanchoragepoint
8 Sliding mid rail
9 Manualstoragecontainer
10 Foot switch
Legend

Operator'sManual Second Edition • Second Printing
18 S-60HC PartNo.T107112
Controls
9 Notused
10 RedEmergency Stopbutton
11 Dualaxisproportionalcontrolhandlefordrive
and steer functions
ORProportionalcontrolhandlefordrivefunction
and thumb rocker for steer function
12 Driveenableswitch
13 Driveenableindicatorlight
14 Glowplugswitch(ifequipped)
PlatformControlPanel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 Restrictedrangeof motion indicator light
5 Drive speed select switch
6 Emergencypowerswitch
7 Machinenotlevelindicatorlight(ifequipped)
8 Generator switch(ifequipped)