Terex Genie S-65 TraX User manual

Operator's Manual
S
-
65
T
RAX ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Third Edition
First Printing
Part No. 1261731

Operator's Manual Third Edition • First Printing
S-65 Trax Part No. 1261731
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 4
General Safety ...................................................... 6
Personal Safety................................................... 12
Work Area Safety................................................ 13
Legend ................................................................ 21
Controls............................................................... 22
Inspections.......................................................... 30
Operating Instructions......................................... 41
Transport and Lifting Instructions ....................... 54
Maintenance ....................................................... 57
Specifications...................................................... 61
Copyright © 2010 by Terex Corporation
Third Edition: First Printing, January 2015
Genie is a registered trademark of
Terex South Dakota, Inc. in the U.S.A. and many
other countries.
These machines comply with
ANSI/SIA A92.5
CAN B.354.4

Third Edition • First Printing Operator's Manual
Introduction
Part No. 1261731 S-65 Trax 1
Introducti on
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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,
contact Genie.
Sequence number
stamped on chassis
Serial label located
under cover
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register your
machine and keep your contact information up to
date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.

Operator's Manual Third Edition • First Printing
Introduction
2 S-65 Trax Part No. 1261731
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.
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 safety rules
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 workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Third Edition • First Printing Operator's Manual
Introduction
Part No. 1261731 S-65 Trax 3
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-based cleaners because they may damage
the safety sign material.
Hazard Classification
Decals on this machine use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
DANGER
WARNING
CAUTION
NOTICE

Operator's Manual Third Edition • First Printing
Symbol and Hazard Pictorials Definitions
4 S-65 Trax Part No. 1261731
Symbol and Hazard P ictorials Definiti ons
Fire hazard Explosion hazard Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
No smoking.
No flame.
Stop engine.
Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Replace tracks with
same tracks.
Wheel load Wind speed Maximum capacity Side force Weight of welder
reduces capacity
+
+

Third Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1261731 S-65 Trax 5
Tie-down point Lifting point Platform tie-down
instructions
Lifting & tie down
instructions
Lanyard anchorage
points
Corrosive acid. Color Coded
Direction Arrows
Runaway Hazard Collision hazard Collision hazard
Electrocution hazard Avoid contact Disconnect battery Voltage rating for
power to platform
Pressure rating for air
line to platform
Recovery procedure if tilt alarm sounds while
elevated.
Platform downhill:
1Retract boom.
2Lower boom.
Platform uphill:
1Lower boom.
2Retract boom.
Read the operator’s
manual
Read the service
manual

Operator's Manual Third Edition • First Printing
General Safety
6 S-65 Trax Part No. 1261731
General Safety
114390
3178828175
114258 97865 52865
31060
133250
133250
82237
31060
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
Burn Hazard
Fuel and fumes
can explode
and burn.
DANGER
No smoking. No
flame. Stop
engine.
114258 A
114390
DANGER
DANGER
82237
114258
28175
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
DANGER
Explosion / Burn Hazard
Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness
31788 C
Keep all open flames and sparks away. Wear
personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to operation.
DO NOT OPERATE equipment if you do not
understand the information in the manuals.
Consult your supervisor, the owner or the
manufacturer.
WARNING
Electrocution/Burn Hazard
Failure to disconnect all
the batteries before
performing service on this
machine may result in
death or serious injury.
Disconnect all the batteries
before performing service on
this machine.
WARNING
97865 B
52865
31788
97865
Lug Nut Torque:
Dry bolts:
240 ft-lbs /
325 Nm
Lubricated bolts:
180 ft-lbs /
244 Nm
Tip-over Hazard
Failure to replace tracks with
Genie approved tracks will
result in death or serious
injury.
Tracks are critical to machine
stability.
Do not replace with tires.
Refer to Genie parts manual
for approved tracks.
133250 A
DANGER
133250

Third Edition • First Printing Operator's Manual
General Safety
Part No. 1261731 S-65 Trax 7
218549
1262342
114416
WARNING
Runaway Hazard
Machine movement can occur
when a machine is operated
on a slope that exceeds rated
uphill, downhill or side slope
rating.
A runaway machine could result
in death or serious injury.
2WD: 30% (17°)
4WD: 45% (24°)
TRAX: 45% (24°)
2WD: 10% (6°)
4WD: 30% (17°)
TRAX: 30% (17°)
1262342 A
Do not drive machine on a slope that exceeds
maximum uphill, downhill or side slope rating.
Determine slope and side slope ratings for
machine and determine slope grade.
Maximum slope rating,
platform downhill
(gradeability):
Maximum slope rating,
platform uphill
Note: Slope rating is subject to ground conditions
and adequate traction. Gradeability applies to
platform downhill configuration only.
Be sure boom is below horizontal
and platform is between non-steer
wheels or tracks.
Move drive speed select switch to
machine on incline symbol.
Driving On a Slope
Maximum
side slope rating
25% (14°)
28236
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.
DANGER
82862
Tip-over Hazard
Welder power supply
reduces rated platform
capacity and
must be factored into total
platform load.
DANGER
Do not overload
platform.
Welder power supply
weighs 75 lbs / 34 kg.
97579
114390
DANGER
218559
218559 A
Keep away from overhead obstructions
or other possible hazards.
Crush Hazard
Contact with overhead obstructions
could result in death or serious injury.
WARNING
Drive Direction Hazard
Machine can move in opposite direction of
joystick movement. Movement in an unplanned
direction can result in death or serious injury.
Always match the color-coded direction arrows
on platform controls and drive chassis to
determine direction of machine travel. Read
and understand operator's manual.
WARNING
Only raise the platform when the
machine is on a frm, level
surface.
Tip-over Hazard
Tipping over this machine will
result in death or serious injury.
DANGER
114416
Tip-over Hazard
If tilt-alarm
sounds, unit is
on a severe
slope. Death or
serious injury
will result.
114416 A
DANGER
Platform uphill:
1 Lower boom.
2 Retract boom.
Platform downhill:
1 Retract boom.
2 Lower boom.
• Read operator’s
manual before
attempting to move
machine.
• Stop all movement.
1262342
218549
218549 A
DANGER
Tip-over Hazard
Tipping over the machine will result
in death or serious injury.
Maximum
allowable wind
speed:
28 mph /
12.5 m/sec
Maximum
Allowable
Manual Force:
150 ft lbs / 667
N
Maximum Capacity:
500 lbs / 227 kg
Occupants and
equipment must not
exceed
500 lbs / 227 kg
Maximum
Occupants: 2

Operator's Manual Third Edition • First Printing
General Safety
8 S-65 Trax Part No. 1261731
97875
82237
97875
114390
133250
133250
114258
28175
31060
97602
97602
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.
31060
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
Burn Hazard
Fuel and fumes
can explode
and burn.
DANGER
No smoking. No
flame. Stop
engine.
114258 A
114390
DANGER
DANGER
82237
114258
28175
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
DANGER
Explosion / Burn Hazard
Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness
31788 C
Keep all open flames and sparks away. Wear
personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to operation.
DO NOT OPERATE equipment if you do not
understand the information in the manuals.
Consult your supervisor, the owner or the
manufacturer.
31788
Lug Nut Torque:
Dry bolts:
240 ft-lbs /
325 Nm
Lubricated bolts:
180 ft-lbs /
244 Nm
Tip-over Hazard
Failure to replace tracks with
Genie approved tracks will
result in death or serious
injury.
Tracks are critical to machine
stability.
Do not replace with tires.
Refer to Genie parts manual
for approved tracks.
133250 A
DANGER
133250
Electrocution/Burn Hazard
Failure to disconnect all
the batteries before
performing service on this
machine may result in
death or serious injury.
Disconnect all the batteries
before performing service on
this machine.
WARNING
97865 B
97865

Third Edition • First Printing Operator's Manual
General Safety
Part No. 1261731 S-65 Trax 9
133067
82487 82473
114251 133205
114252
133263
1256425
133263
114252 82487
114251 133067
114252 A
82487 B
114251 A
133067 A
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
82473
82473 B
133205 82481
1256425
133263 A
133263

Operator's Manual Third Edition • First Printing
General Safety
10 S-65 Trax Part No. 1261731
219953
1262343
114473
133067
82487
219953
114473
82487
82487 B
114473 A
133067
133067 A
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
1262343
219958
219953
667 N
227 kg
12.5 m/sec

Third Edition • First Printing Operator's Manual
General Safety
Part No. 1261731 S-65 Trax 11
133067
133263
133263
114251
82473
114252
1256425
114252 82487
114251 133067
114252 A
82487 B
114251 A
133067 A
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
82473
82473 B
1256425
133263 A
133263

Operator's Manual Third Edition • First Printing
Personal Safety
12 S-65 Trax Part No. 1261731
Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1261731 S-65 Trax 13
WorkArea Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 10.67 m
750 to 1000KV 45 ft 13.72 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
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, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not raise or extend the
boom unless the machine
is on a firm, level surface.

Operator's Manual Third Edition • First Printing
Work Area Safety
14 S-65 Trax Part No. 1261731
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 while the boom is lowered:
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. 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 the
platform uphill:
1Lower the boom.
2Retract the boom.
If the tilt alarm sounds with the
platform downhill:
1Retract the boom.
2Lower the boom.
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.
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
slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.
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.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
side force – ANSI & CSA
150 lbs / 667 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.

Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1261731 S-65 Trax 15
Do not replace tracks with tires.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. 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.
Do not place or attach fixed
or overhanging loads to
any part of this machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all track lug nuts are properly tightened.
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.
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
and adequate traction. See Driving on a Slope in
the Operating Instructions section.

Operator's Manual Third Edition • First Printing
Work Area Safety
16 S-65 Trax Part No. 1261731
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
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
gate before 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 spots
when driving or operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.

Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1261731 S-65 Trax 17
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any othe
r
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.
Bodily Injury Hazard
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
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 or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.

Operator's Manual Third Edition • First Printing
Work Area Safety
18 S-65 Trax Part No. 1261731
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 appropriate Genie
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 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.
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.