Genie S-65 User manual

Operator’s Manual
with Maintenance Information
Third Edition
Second Printing
Part No. 82407

GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
Copyright © 1995 by Genie Industries
First Edition: Third Printing, October 1996
Second Edition: Fifth Printing, July 2000
Third Edition: Second Printing, May 2004
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "S" is a trademark of Genie Industries.
Thesemachinescomplywith
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
Important
Read,understand and obey these safetyrulesand
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 ..................................................................... 9
Pre-operationInspection ........................................... 12
Maintenance ............................................................. 14
Function Tests.......................................................... 18
WorkplaceInspection................................................ 23
OperatingInstructions............................................... 24
TransportandLiftingInstructions .............................. 29
Decals ...................................................................... 32
Specifications ........................................................... 36
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

PartNo.82407 GenieS-60&GenieS-65 1
Operator's Manual
Third Edition • Second Printing
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:
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'sinstructionsandsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youare properly trained tosafelyoperate the
machine.

2 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
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
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
Voltage Minimum Safe
Phase to Phase Approach Distance
Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 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
energizedpowerlines.Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperate themachineduringlightningor
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants,equipment and materialsshall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum platform capacity
S-60 with 6 Ft Platform
withpropercounterweight
configuration 750 lbs 340 kg
Maximum occupants 2

PartNo.82407 GenieS-60&GenieS-65 3
Operator's Manual
Third Edition • Second Printing
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.
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.
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, unstable or slipperysurfaces and
nearholesanddrop-offs.
Donot drive the machineon or near uneventerrain,
unstablesurfacesor otherhazardousconditions
withtheboom 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
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 replace factory-installed tires with tires of
different specification or ply rating.
High flotation tires must be factory-installed. Do not
replacestandardfactory-installedtireswith high
flotation tires.
Do not modify or alter an aerial work platform
withoutpriorwrittenpermissionfromthe
manufacturer.Mountingattachmentsforholding
toolsor other materialsonto the platform,toeboards
or guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.

4 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
SAFETY RULES
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.
Do not place or attach overhanging loads to any
part of this machine.
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s)intheplatform.
Do not place ladders or scaffolds in the 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
areproperlyinflatedandlugnutsareproperly
tightened.
Models with 750 lb / 340 kg Capacity: Do not
attach a platform rated at 750 lbs / 340 kg to
machines with any other rated load. See the serial
plate for the maximum rated load.
Do not use the platform controls to free a platform
thatiscaught,snaggedorotherwiseprevented
from normal motion by an adjacent structure. All
personnelmustberemoved from the platform
before attempting to free the platform using the
groundcontrols.

PartNo.82407 GenieS-60&GenieS-65 5
Operator's Manual
Third Edition • Second Printing
SAFETY RULES
Do not lower the boom unless the area below is
clearofpersonnelandobstructions.
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.
Nostuntdrivingorhorseplaywhileoperating a
machine.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of theboom position and tailswingwhen
rotatingtheturntable.
Checktheworkareaforoverheadobstructions or
otherpossiblehazards.
Beawareofcrushing hazardswhengraspingthe
platformguardrail.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Observeandusecolor-codeddirectionarrowson
the platform controls and drive chassis for drive
and steer functions.

6 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
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.
Alwaysoperate the machine inawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontactwithcomponentsunderanycover
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, diesel fuel or other
explosive substances.
Donotrefuelthe machine with the engine running.
Refuel the machine and charge the battery only in
anopen,well-ventilatedareaawayfromsparks,
flames and lighted tobacco.
Donotoperate the machine in hazardouslocations
orlocationswherepotentially flammableor
explosive gases or particles may be present.
Donotsprayeitherintoengineequippedwithglow
plugs.
SAFETY RULES
Damaged Machine Hazards
Donotuse a damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureall maintenance has been performedas
specified in this manual and the Genie S-60 &
GenieS-65ServiceManual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsare complete, legible andin the storage
containerlocatedonthe platform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-start the engine.
Do not use the machine as a ground for welding.

PartNo.82407 GenieS-60&GenieS-65 7
Operator's Manual
Third Edition • Second Printing
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhen workingwithbatteries.
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.
SAFETY RULES

8 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
Decal Legend
Genie product decals use 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.
Red—usedtoindicatethe
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
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—usedtoindicateoperation
ormaintenanceinformation.
SAFETY RULES

PartNo.82407 GenieS-60&GenieS-65 9
Operator's Manual
Third Edition • Second Printing
Controls
GroundControlPanel
1 Platform rotate switch
2 Turntablerotateswitch
3 Boomup/downswitch
4 Boomextend/retract switch
5 Platformoverloadindicatorlight(ifequipped)
6 Machinemalfunctionindicatorlight
7 Checkenginelight
8 Auxiliarypowerswitch
9 Key switch for platform/off/ground selection
10 RedEmergencyStopbutton
11 Hourmeter
12 Gasoline/LPG models: Fuel select switch
13 Functionenableswitch
14 Diesel models: Glow plug switch
15 15A breaker for engine electrical circuits
16 Engine start switch
17 15A breaker for control electrical circuits
18 20A breaker for oilcooler and options
19 Platform level switch
20 S-65 only: Jib boom up/down switch

10 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
CONTROLS
1 3
7 Glowplugswitch
8 Engine start switch
9 Engine idle (rpm) select switch
· Turtle: foot switch activated low idle
· Rabbit: foot switch activated high idle
10 Gasoline/LPG models: Fuel select switch
11 RedEmergencyStopbutton
Platform Control Panel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 S-65 only: Jib boom up/down switch
5 Auxiliarypowerswitch
6 Drive speed select switch
2 4 5 6
18
20 17
19

PartNo.82407 GenieS-60&GenieS-65 11
Operator's Manual
Third Edition • Second Printing
CONTROLS
12 Dualaxisproportional controlhandlefordrive
and steer functions
ORProportionalcontrolhandlefordrivefunction
and thumb rocker for steer function
13 Platformoverloadindicatorlight(ifequipped)
14 Machinenot level indicator light(ifequipped)
15 Driveenableindicatorlight
78 9 10 11
121415
16 Driveenableswitch
17 Proportionalcontrolhandleforboom
extend/retract
18 Machinemalfunctionindicatorlight
19 usedforoptionalequipment
20 Dualaxisproportionalcontrolhandleforboom
up/down and turntable rotate left/right functions
1316

12 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
2 Alwaysperformapre-operation
inspection.
Knowandunderstandthepre-operation
inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
It is the responsibility of the operator to perform a
pre-operationinspectionandroutinemaintenance.
Thepre-operation inspection isavisual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
isapparentlywrongwith a machine before the
operator performs the function tests.
Thepre-operationinspectionalso servesto
determineifroutinemaintenanceproceduresare
required.Onlyroutinemaintenanceitemsspecified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
Ifdamageoranyunauthorizedvariationfrom
factory delivered condition is discovered, the
machinemustbetaggedand removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications.Afterrepairsare
completed,theoperatormustperforma
pre-operationinspectionagainbeforegoingonto
the function tests.
Scheduledmaintenanceinspectionsshallbe
performedbyqualified service technicians,
accordingtothemanufacturer'sspecifications and
the requirements listed in the responsibilities
manual.

PartNo.82407 GenieS-60&GenieS-65 13
Operator's Manual
Third Edition • Second Printing
PRE-OPERATIONINSPECTION
Pre-operation Inspection
oBe sure that the operator’s, safety and
responsibilitiesmanualsarecomplete,legible
and in the storage container located in the
platform.
oBe sure that all decals are legible and in place.
See Decals section.
oCheck for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheckfor engine coolant leaksand proper level
of coolant. Add coolant if needed. See
Maintenancesection.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
oCheckfor proper tirepressure. Add airif needed.
SeeMaintenancesection.
Checkthefollowing components or areas for
damage,improperlyinstalledormissingpartsand
unauthorizedmodifications:
oElectricalcomponents,wiring and
electrical cables
oHydraulic hoses, fittings, cylinders and
manifolds
oFuel and hydraulic tanks
oDriveandturntablemotorsanddrivehubs
oBoomwearpads
oTiresandwheels
oEngineandrelatedcomponents
oLimit switches and horn
oAlarmsandbeacons(ifequipped)
oNuts, bolts and other fasteners
oPlatformentry mid-rail or gate
Checkentiremachine for:
oCracks in welds or structural components
oDentsordamagetomachine
oBe sure that all structural and other critical
componentsarepresentandallassociated
fastenersand pins arein place and properly
tightened.
oAfter you complete your inspection, be sure that
all compartment covers are in place and
latched.

14 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
Maintenance
Observe and Obey:
Only routine maintenance items specified in this
manualshallbe performedbytheoperator.
Scheduledmaintenanceinspectionsshallbe
completed by qualified service technicians,
accordingtothemanufacturer'sspecifications
andthe requirements specified inthe
responsibilitiesmanual.
MaintenanceSymbolsLegend
Thefollowingsymbolshave been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginningofamaintenance
procedure,it conveys the meaning
below.
Indicates that tools will be required to
performthisprocedure.
Indicates that new parts will be required to
performthisprocedure.
Indicates that a cold engine is required
beforeperformingthisprocedure.
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
togoodengineperformanceandservicelife.
Operatingthemachinewithanimproperoillevel
candamageenginecomponents.
Check the oil level with the
engineoff.
1 Check the oil dipstick. Add oil as needed.
GMModels:
Result: The oil level should be within the ADD and
FULL marks on the dipstick.
DeutzModels:
Result: The oil level should be within the two
marks on the dipstick.
PerkinsModels:
Result: The oil level should be within the two
notches on the dipstick.
FordModels:
Result: The oil level should be within the SAFE
zone.

PartNo.82407 GenieS-60&GenieS-65 15
Operator's Manual
Third Edition • Second Printing
MAINTENANCE
GM3.0L EFIEngine
Oil type 10W-30
Oil type - cold conditions 5W-30
Only use engine oils labeled "For Gasoline Engines"
by the American Petroleum Institute (API).
Units ship with 10W-30.
Deutz F3L 2011F Engine
Oil type 15W-40
Oil type - cold conditions 5W-30 (synthetic)
Engine oil should have properties of API classification
CC/SE or CC/SF grades.
Units ship with 10-40 CC/SG.
Perkins 404-22 Engine
Oil type 15W-40
Oil type - cold conditions 5W-40
Engine oil should have properties of API classification
CH-4 grade.
Units ship with 10-40 CC/SG.
Ford LRG-425 EFI Engine (EPA Compliant)
Oil type 10W-40
Oil type - cold conditions 5W-30
Deutz F3L 2011F Engine (Tier II)
Oil type 15W-40
Oil type - cold conditions 5W-30
Engine oil should have properties of API classification
CC/SE or CC/SF grades.
Units ship with 10-40 CC/SG.
Check the Hydraulic Oil Level
Maintaining the hydraulic oil at the proper level is
essentialtomachineoperation.Improperhydraulic
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 Chevron Rykon
Premium MV equivalent

16 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
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
damageengine components. Dailychecks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
Burnhazard.Bewareofhotengine
parts and coolant. Contact with hot
enginepartsand/orcoolant may
causesevereburns.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed.
Result: The fluid level should be at the
FULLmark.
Donot remove theradiator cap.
Check the Batteries
Proper battery condition is essential to good engine
performanceandoperationalsafety.Improperfluid
levels or damaged cables and connections can
resultinenginecomponentdamageandhazardous
conditions.
Electrocutionhazard.Contactwith
hot or live circuits may result in
death or serious injury. Remove all
rings,watchesandotherjewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contactingbattery acid. Neutralize
battery acid spills with baking soda
andwater.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Be sure that the battery hold-down brackets are
in place and secure.
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.
Addingterminalprotectors anda
corrosionpreventativesealantwill
helpeliminatecorrosionon the
battery terminals and cables.
MAINTENANCE

PartNo.82407 GenieS-60&GenieS-65 17
Operator's Manual
Third Edition • Second Printing
Check the Tire Pressure
Thisproceduredoesnotneed
tobeperformedon machines
equippedwithfoam-filledtires.
Bodily injury hazard. An over-
inflated tire can explode and could
cause death or serious injury.
Tip-overhazard.Donotuse
temporaryflattirerepairproducts.
To safeguard maximum stability, achieve
optimummachinehandlingandminimizetire
wear, it is essential to maintain proper pressure
in all air-filled tires.
1 Check each tire with an air pressure gauge. Add
airasneeded.
Tire pressure 70 psi 4.92 bar
High flotation tire pressure 60 psi 4.21 bar
MAINTENANCE
Scheduled Maintenance
Maintenanceperformedquarterly,annuallyand
every two years must be completed by a person
trainedandqualifiedtoperformmaintenanceon this
machineaccordingto the procedures foundinthe
service manual for this machine.
Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.

18 GenieS-60&GenieS-65 PartNo.82407
Operator's Manual Third Edition • Second Printing
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:Thebeacon(if equipped) should flash.
4 Starttheengine(seeOperating Instructions
section).
TestEmergencyStop
5 Push in the red Emergency Stop button to the
off position.
Result: The engine should turn off and all
functionsshouldnotoperate.
6 Pull out the red Emergency Stop button to
the on position and restart the engine.
Function Tests
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
2 Alwaysperformapre-operation
inspection.
3 Alwaysperformfunctiontestspriorto
use.
Knowandunderstandthefunctiontests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into service.
Theoperatormustfollowthestep-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,accordingtothemanufacturer's
specifications.
Afterrepairsarecompleted, the operator must
performapre-operationinspectionandfunction
tests again before putting the machine into service.