S65 Operators Manual
Contents
1. AA af E Operator s Manual with Maintenance Information S 60 S 65 Second Edition Fifth Printing Part No 43648 Operators Manual Second Edition e Fifth Printing S 60 S 65 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 call Genie Industries Genie Genie Important Contents Page Safety Rules iese ER EE ee EE ee EE ee ee Ee ee EE ee 1 Se ie ER OE EE N N EE N 7 Pre operation inspection ee ee ee ee 10 Genie Industries Maintenance cccsecceecceeeceeeceeceeeceeeeauesaueceeseeesaes 12 iaht 1 l Function TESIS i s RE ER ek RE GE N GE Ke 16 SOR gn oo ENE Neto Work Place Inspection ee ee ee ee ee ee 21 First Edition First Printing January 1995 Second Printing January 1996 Operating Instructions ee ee ee ape RE EE 22 Third Printing October 1996 WAU eo EE RE ET EE EE EE EN 25 Second Edition First Printing November 1996 Boe EE AE E 26 Second Printing March 1997 te ae Third Printing March 1998 Specifications ie ee ee ee Ee RR Ee RE Ee ee ee ee ee ee 28 Fourth Printing February 2000 Fifth Printing July 2000 Genie is a registered trademark of Genie Industries in the U S A and2. F a OT 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 Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Part No 438648 Second Edition e Fifth Printing Operator s Manual SAFETY RULES Collision Hazards Do not lower the boom unless the area below is clear of personnel and obstructions Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position and tailswing when bee WEE wl rotating the turntable ees Qe Check work area for overhead obstructions or other possible hazards Limit travel soeed according to condition of 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 out and or precautions have been taken to prevent any potential collision Be aware of crushing hazard when grasping the No stunt driving or horseplay while operating a platform guard rail machine It is recommended that operators wear an approved Component Damage Hazards hard hat when operating the machine Do n
3. Genie Ib rica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Mexico City Phone 52 5 653 03 84 Fax 52 5 664 40 16 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 60 4 228 1235 Fax 60 4 226 6872 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie Africa Phone 27 11 455 0373 Fax 27 11 455 0355 Genie Latin America Phone 55 11 4055 2499 Fax 55 11 4043 1661
4. b Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart 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 2 Genie S 60 amp Genie S 65 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 and equipment shall not exceed the maximum platform capacity Maximum platform capacity S 65 500 Ibs 227 kg Maximum platform capacity S 60 with 8 Ft Platform 500 Ibs 227 kg Maximum platform capacity S 60 with 6 Ft Platform 600 Ibs 272 kg Maximum platform capacity S 60 with 6 Ft Platform with foam filled tires and proper counterweight configuration 750 Ibs 340 kg Maximum occupants 2 Part No 43648 Second Edition e Fifth Printing Operator s Manual 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 it
5. 64361 72160 72162 Notice Maximum Load 750 Ibs Danger Tip over Tires foam filled Notice Operating Instructions Ground Control Panel Notice Function Enable Lift Drive Select Airline to Platform Notice Maximum Manual Force 90 Ibs Notice Ford Engine Specs LRG 425 EFI Ground Control Panel Platform Control Panel Cosmetic 4 x 2 Cosmetic 4 x 4 Notice Deutz Diesel Engine Specs Cosmetic Genie S 60 Cosmetic S 60 Cosmetic Genie S 65 Cosmetic S 65 Notice Perkins Diesel Engine Specs Ground Control Panel Platform Control Panel page 2 to determine the capacity of your machine Please reference the Specifications section or the chart on Part No 43648 Second Edition e Fifth Printing Operator s Manual DECALS 28171 28158 or 43649 or 27564 33884 or Ground 28159 43647 49926 or 25994 28161 33885 idee Controls Side 28158 or H 28159 ia 28157 an me 28177 LH 32700 40434 43663 33952 28161 32726 33937 32728 44769 28161 52156 Sagal or 72162 62079 40434 27204 43647 27206 F I 32700 27207 EE 40434 II 28236 Kr 40434 aa 43595 27207 H 28176 2 206 AH a Ao or ee 27205 ee T or 43594 52966 or 28165 52967 44981 28163 or 44986 28174 or 28235 28181 l Ad fle d 62077 or 62079 28177 pp WA SS 31060 soe BA as x 27564 62078 Ch or 53037 2 J 2
6. 4 Limit switches and horn 4 Alarms and beacons if equipped 4 Nuts bolts and other fasteners 4 Platform entry mid rail or gate Check entire machine for 4 Crack in welds or structural components 4 Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened 4 After you complete your inspection be sure that all compartment covers are in place and latched Genie S 60 amp Genie S 65 11 Operators Manual Second Edition e Fifth Printing Maintenance Observe and Obey MI Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of amaintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be Q required to perform this procedure Indicates that a cold engine is required before performing this procedure 12 Genie S 60 amp Genie S 65 Check the Engine Oil Level Mai
7. 4 Start the engine To Position Platform 1 Hold the function enable switch to either side 2 Move the appropriate toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches Part No 43648 OPERATINGINSTRUCTIONS Operation from Platform 1 Turn the key switch to platform control 2 Pullout both ground and platform red Emergency Stop buttons to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Move the lift drive select switch to the lift position if equipped 2 Press down the foot switch 3 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches To Steer 1 Move the lift drive select switch to the drive position if equipped 2 Press down the foot switch 3 Turn the steering wheels with the thumb rocker switch located on top of the drive con
8. An over AWARNING inflated tire can explode and could cause death or serious injury Tip over hazard Do not use AWARNING temporary flat tire repair products To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge Add air as needed Tire specifications Tire size 15 19 5NHS Pressure 85 psi 5 86 bar Scheduled Maintenance The scheduled maintenance items must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Inspections and maintenance described below require the qualified entity to record and retain records of all inspections and maintenance items for four years Machines that have been out of service for more than three months must receive the quarterly inspection before placing the machine back into service Part No 43648 MAINTENANCE The Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual two year To account for repeated procedures the Scheduled Maintenance Procedures Section and the Maintenance Inspection Reporthave been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a s
9. 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 Do not 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 P A dis EVADA NE 9 A 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 Part No 43648 Genie S 60 amp Genie S 65 SAFETY RULES Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended Do not push off or pull toward any object outside of the platform Maximum allowable side force ANSI amp CSA 150 Ibs 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
10. drive and steer control handle is moved Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of travel Blue lt t Yellow Test Limited Drive Speed 48 Move the lift drive select switch to the lift position if equipped 49 Press down the foot switch 50 Raise the boom to just above horizontal 51 Move the lift drive select switch to the drive position if equipped 52 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom raised should not exceed 1 foot per second 0 3 meters per second Genie S 60 amp Genie S 65 19 Operators Manual Second Edition e Fifth Printing FUNCTIONTESTS 53 Move the lift drive select switch to the lift position if equipped 54 Lower the boom to the stowed position 55 Extend the boom 1 foot 30 cm 56 Move the lift drive select switch to the drive position if equipped 57 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom extended should not exceed 1 foot per second 0 3 meters per second If the drive speed with the boom raised or extended exceeds 1 foot per second 0 3 meters per second immediately tag and remove the machine from service Test Auxiliary Controls 58 Shut off the engine 59 Pull out the red Emergency Stop button to the on pos
11. idle Turtle low idle Rabbit high idle 10 Gasoline LPG models Gasoline LPG select switch Deutz Diesel models Glow plug switch option Part No 43648 Second Edition e Fifth Printing Operator s Manual oul 1 11 ENGINE START d 1 O 4 DRIVE ENABLE OPERATION Light on indicates that boom has moved past a non steer tire and drive reon is turned off To drive hold drive enable switch to side and slowly move drive control handle Machine may drive in opposite direction that drive and steer controls are moved this panel and drive chassis to identify the direction machine will travel ONE Emergency Stop button Use color coded direction arrows on C CONTROLS 9 10 D ENGINE RPM FUEL SELECT EMERGENCY STOP g m y SIm TO START TO STOP 02 15 Drive enable switch 12 Proportional control handle for drive function and 16 Proportional control handle for boom 13 14 Pa thumb rocker for steer function used for optional equipment Drive enable indicator light rt No 43648 Genie S 60 amp Genie S 65 extend retract 13 used for optional equipment 17 Dual axis proportional control handle for boom up down and turntable rotate left right functions Operators Manual Second Edition e Fifth Printing Pre operation Inspection Do Not Operate Uniess You learn and practice the principles of safe
12. many other Contact us countries S is a trademark of Genie Industries These machines comply with Internet http www genielift com ANSI SIA 92 5 1992 e mail techpub genieind com Z Printed on recycled paper Printed in U S A Genie S 60 amp Genie S 65 Part No 43648 Second Edition e Fifth Printing Operator s Manual 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 M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the above principle 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 work place 5 Only use the machine as it was intended M You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You are properly trained to safely operate the machine Part No 43648 Genie S 60 amp Genie S 65 1 Operators Manual Second Edition e Fifth Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current l SW N T
13. Do not modify or alter an aerial work platform 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 Operators Manual Second Edition e Fifth Printing SAFETY RULES Do not place or attach overhanging loads to any part of this machine AY Re mm Do not place ladders or scaffolds in 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 are properly inflated and lug nuts are properly tightened Models with 750 Ib 340 kg Capacity Do not use air filled tires Models are equipped with foam filled tires The wheel weight and the proper counterweight configuration are critical for machine stability 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 4 Genie S 60 amp Genie S 65 Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations Attach lanyard to anchor provided in platform Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times ls
14. PI classification CF4 grade Units ship with 10 40 CC SG Part No 43648 MAINTENANCE Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic 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 Dexron equivalent Tank capacity 45 gallons 170 liters Hydraulic system 53 gallons including tank 201 liters Genie S 60 amp Genie S 65 13 Operators Manual Second Edition e Fifth Printing MAINTENANCE 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 damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems Burn hazard Beware of hot engine ACAUTION parts and coolant Contact with hot engine parts and or coolant may Cause severe burns 1 Check the fluid level in the co
15. ated high idle rabbit and foot switch symbol Test the Service Horn 19 Push the horn button Result The service horn should sound Genie S 60 amp Genie S 65 17 Operators Manual Second Edition e Fifth Printing FUNCTIONTESTS Test the Foot Switch 20 Push in the platform Emergency Stop button to the oFF position 21 Pull out the Emergency Stop button to the on position but do not start the engine 22 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 23 Do not press down the foot switch and restart the engine 24 Move the lift drive select switch to the lift position if equipped 25 Do not press down the foot switch Test each machine function Result The machine functions should not operate Test Machine Functions 26 Move the lift drive select switch to the lift position if equipped 27 Press down the foot switch 28 Activate each machine function control handle or toggle switch Result All boom platform functions should operate through a full cycle Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches 18 Genie S 60 amp Genie S 65 Test the Steering 29 Move the lift drive select switch to the drive position if equipped 30 Press down the foo
16. atform dimensions 8 foot 96 in x 36 in 96 in x 36 in length x width 2 4 m x 91 cm 2 4 m x 91 cm Platform leveling self leveling self leveling Platform rotation 160 160 AC outlet in platform standard standard Hydraulic pressure maximum 2600 psi 2900 psi boom functions 179 bar 200 bar Tire size 15 19 5 NHS 15 19 5 NHS Gradeability stowed 2WD 4WD 28 40 Ground clearance 12 in 12 in 30 cm 30 cm Hydraulic tank capacity 45 gallons 45 gallons 170 liters 170 liters Fuel tank capacity 30 gallons 30 gallons 114 liters 114 liters Weight 26 060 Ibs 28 400 Ibs 11 821 kg 12 882 kg Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 40 ft 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec 4 0 mph 2 8 mph 6 4 km h 4 5 km h 40 ft 6 8 sec 40 ft 9 7 sec 12 2 m 6 8 sec 12 2 m 9 7 sec Drive speed stowed Deutz Diesel models Drive speed 0 6 mph 0 6 mph raised or extended 1 0 km h 1 0 km h all models 40 ft 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec 28 Genie S 60 amp Genie S 65 6 0m Of 20 ft AO ft 60 ft Part No 43648 Genie Holland Phone 31 70 51 78836 Fax 31 7051 13993 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98
17. cheduled inspection Inspection Table or Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Genie S 60 amp Genie S 65 15 Operators Manual Second Edition e Fifth Printing Function Tests Do Not Operate Uniess You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the above principles before going on to the next section 4 Inspect the work place 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 The operator must follow the step 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 according to the manufacturer s specifications After repair
18. ctions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel and tools to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a work place inspection before using the machine 22 Genie S 60 amp Genie S 65 Starting the Engine 1 At the ground controls turn the key switch to the desired position 2 Besure both ground and platform control red Emergency Stop buttons are pulled out to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start agai
19. d 37 Move the lift drive select switch to the drive position if equipped 38 Start the engine from the platform controls 39 Drive the right steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground 40 Drive the left steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground 41 Drive both steer tires up onto a 6 inch 15 2 cm block or curb Result The non steer tires should stay in firm contact with the ground Test the Drive Enable System 42 Move the lift drive select switch to the lift position if equipped 43 Press down the foot switch and lower the boom to the stowed position 44 Rotate the turntable until the boom moves past one of the non steering wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown Part No 43648 FUNCTION TESTS 45 Move the lift drive select switch to the drive position if equipped 46 Move the drive control handle off center Result The drive function should not operate 47 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center Result The drive function should operate Note When the drive enable system is in use the machine may drive in the opposite direction that the
20. ient to withstand machine weight See Specifications section Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Always chock machine wheels in preparation for transport Use tie points on drive chassis for anchoring down to transport surface Disengage Position Engage Position Use the lower platform mount between the boom end and the platform to secure the boom from side to side movement Do not use excessive downward force when securing the boom section Use chains or straps of ample load capacity Turn the key switch to the orF position and remove the key before transporting Inspect the entire machine for loose or unsecured items Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling 2WD models Release non steer wheel brakes by turning over the torque hub disconnect caps see below 4WD models Release wheel brakes by turning over all four torque hub disconnect caps see below Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions Reverse procedures described to re engage brakes Note The pump free wheel valve should always remain closed Part No 43648 Genie S 60 amp Genie S 65 25 Operators Manual Decals Decal Inspection Use the picture on the next page to ver
21. ify that all decals are legible and in place Below is a numerical list with guantities and descriptions Part No Decal Description 25994 27204 27205 27206 27207 27564 28157 28158 28159 28160 28161 28163 28164 28165 28171 28174 28175 28176 28177 28181 28235 28236 30080 31060 32700 32726 32728 26 Caution Component Damage Hazard Arrow Blue Arrow Yellow Triangle Blue Triangle Yellow Danger Electrocution Hazard Label Dexron Label Unleaded Label Diesel Label Liquid Petroleum Gas Danger Crushing Hazard Notice Maximum Side Force 150 Ibs Notice Hazardous Materials Notice Foot Switch Label No Smoking Label Power to Platform 230V Caution Compartment Access Notice Missing Manuals Warning Platform Rotate Warning No Step or Ride Label Power to Platform 115V Warning Failure To Read Notice Maximum Load 500 Ibs Danger Tip over Hazard Interlock Danger Safety Rules Label Glow Plug option Label Generator option Genie S 60 amp Genie S 65 Quantity 1 1 ININ NIN 33885 33952 33973 35599 Second Edition e Fifth Printing Part No Decal Description Quantity Serial Plate S 65 1 Danger Tilt Alarm 1 Notice Tire Pressure 2 Notice Align Air Hoses 1 Label Lanyard Anchorage 4 40434 43594 43595 43647 43649 43663 44769 44981 44986 49741 49926 52156 52966 52967 53037 62076 62077 62078 62079
22. ion tests prior to use 4 Inspect the work place Know and understand the above principles before going on to the next section 5 Only use the machine as it was intended Fundamentals The Work Place Inspection helps the operator determine if the work place is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the work place It is the operator s responsibility to read and remember the work place hazards then watch for and avoid them while moving setting up and operating the machine Part No 43648 Work Place Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Genie S 60 amp Genie S 65 21 Operators Manual Second Edition e Fifth Printing Operating Instructions Do Not Operate Uniess MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the work place 5 Only use the machine as it was intended Fundamentals The Operating Instru
23. ition 60 Press down the foot switch 61 Move the lift drive select switch to the lift position if equipped 62 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power 20 Genie S 60 amp Genie S 65 Test the Lift Drive Select Switch if equipped 63 Move the lift drive select switch to the lift position 64 Press down the foot switch 65 Move the drive control handle off center Result No drive functions should operate 66 Activate each boom function toggle switch Result All boom functions should operate 67 Move the lift drive select switch to the drive position 68 Press down the foot switch 69 Activate each boom function toggle switch Result No boom functions should operate 70 Move the drive control handle off center Result The drive functions should operate 71 Repair any malfunctions before operating the machine Part No 43648 Second Edition e Fifth Printing Operator s Manual Work Place Inspection Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform funct
24. machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the above principles before going on to the next section 3 Always perform function tests prior to use 4 Inspect the work place 5 Only use the machine as it was intended 10 Genie S 60 amp Genie S 65 Fundamentals It is the responsibility of the operator to perform a Pre operation Inspection and routine maintenance The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made bya qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to
25. n All models In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes to prevent hydraulic system damage Gasoline LPG models In extreme cold conditions 20 F 6 C and below the machine should be started on gasoline then switched to LPG Emergency Stop Push in either the ground or platform red Emergency Stop button to the oFF position to stop all functions and turn the engine off Repair any function that operates when the Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform Emergency Stop button Part No 43648 Second Edition e Fifth Printing Operator s Manual Auxiliary Controls Use auxiliary power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the ON position 3 Move the lift drive select switch to the lift position if equipped when operating the auxiliary controls from the platform 4 Press down the foot switch when operating the auxiliary controls from the platform 5 Simultaneously hold the auxiliary power switch ON and activate desired function The drive function will not operate with auxiliary power Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Gasoline LPG models Choose fuel by moving fuel select switch to desired position
26. ntaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the oil dipstick Gasoline LPG Engine located above the bellhousing on the bulkhead side of the engine Diesel Engine located on the engine block near the engine oil filter Result The oil level should be at the full mark on the dipstick Add oil as needed Ford LRG 425 EFI Engine Oil capacity including filter 4 5 quarts 4 3 liters Oil viscosity requirements below 60 F 15 5 C SW 30 10 to 90 F 23 to 32 C SW 30 above 10 F 23 C SW 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG grade Units ship with 10 40 CC SG Part No 43648 Second Edition e Fifth Printing Operator s Manual Deutz F4L 1011F Engine 11 quarts Oil capacity including filter 10 5 liters Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades Units ship with 10 40 CC SG Perkins 704 30 Engine Oil capacity including filter 9 6 quarts 9 liters Oil viscosity requirements below 60 F 15 5 C 15W 40 10 F to 90 F 23 C to 32 C 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of A
27. olant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap 14 Genie S 60 amp Genie S 65 Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight 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 Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Part No 43648 Second Edition e Fifth Printing Operator s Manual Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option Bodily injury hazard
28. or 64361 Engine N La Side 28161 28161 28174 28160 27564 28164 28175 44981 or 28235 28171 33973 28161 35999 Part No 43648 Genie S 60 amp Genie S 65 27 Operators Manual Second Edition e Fifth Printing Specifications Model S 60 Height working maximum 66 ft 20 1 m Height platform maximum 60 ft 18 3 m Height stowed maximum 9 ft 2 74 m 2 7 4 m Horizontal reach maximum 51ft3in 15 6 m Width 8 ft 2 43 m Length stowed 27 ft 2 in 8 3 m Maximum load capacity 600 ID 6 foot platform 272 ko Maximum load capacity 500 ID 8 foot platform 227 ko Maximum load capacity 6 foot platform with foam filled tires and proper counterweight 750 ID configuration 340 kg Wheelbase 9 ft O in 2 7 m Turning radius outside 22 ft 2 in 6 75 m Turning radius inside 12 ft 1 in 3 7 m Turntable rotation degrees Turntable tailswing 3 ft 31 2 in 100 cm Power source Ford 63 Hp Gasoline LPG LRG 423 choice or LRG 425 EFI S 65 71 ft 21 6 m 65 ft 19 8 m 9 ft 56 ft 4 in 17 2 m 8 ft 2 43 m 30 ft 10 in 9 4 m 500 ID 227 kg 500 Ib 227 kg N A N A 9 ft O in 2 m 22 ft 2 in 6 75 m 12 ft 1 in 3 7 m continuous 3 ft 31 2 in 100 cm Deutz 56 Hp Diesel F4L 1011 2WD 4 4 mph 7 1 km h Drive speeds Drive speed stowed Gasoline LPG models 4WD 3 0 mph 4 8 km h Model S 60 S 65 Controls 12V DC proportional Platform dimensions 6 foot 72 in x 30 in 72in x 30in length x width 1 8mx 76cm 1 8mx 76cm Pl
29. orm rotate switch Turntable rotate switch Boom up down switch Boom extend retract switch not used Key switch for platform off ground selection Auxiliary power switch Gasoline LPG models Water temperature gauge Deutz Diesel models Oil temperature gauge Oil pressure gauge Voltage gauge 11 12 13 14 15 16 17 18 19 20 Emergency Stop button Hour meter Gasoline LPG models Check engine light Deutz Diesel models Glow plug switch option Function enable switch Engine start switch 15A breaker for engine electrical circuits Gasoline LPG select switch 15A breaker for control electrical circuits S 65 only Jib boom up down switch Platform level switch Genie S 60 amp Genie S 65 7 Operators Manual Second Edition e Fifth Printing CONTROLS HORN PLATFORM LEVEL TURNTABLE ROTATE Platform Control Panel 1 Service horn button 2 Platform level switch 3 Platform rotate switch 4 S 65 only Jib boom up down switch 5 Auxiliary power switch 6 Drive speed select switch Genie S 60 amp Genie S 65 PLATFORM ROTATE JIB BOOM AUXILIARY DRIVE SPEED POWER DRIVE ENABLI OPERA Light on that hoo moved p non stee drive fun turned o To drive and slow Machine that driv s7 TURNTABLE ROTATE Use colo A BOOM hi lt EXTEND Wel 43 7 Check engine light 8 Engine start switch 9 Engine idle rom select switch Rabbit amp Foot Switch foot switch activated high
30. ot use any battery or charger greater than 12V Observe and use color coded direction arrows on to jump start the engine the platform controls and drive chassis for drive and steer functions Do not use the machine as a ground for welding Be sure the hydraulic shutoff valves located by hydraulic tank are open before starting engine Part No 43648 Genie S 60 amp Genie S 65 5 Operators Manual Second Edition e Fifth Printing SAFETY RULES 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 in hazardous locations or locations where potentially flammable or explosive gases or particles may be present 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 Genie S 60 amp Genie S 65 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
31. s are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service 16 Genie S 60 amp Genie S 65 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 The beacon if equipped should flash 4 Start the engine see Operating Instructions section Test Emergency Stop 5 Push in the red Emergency Stop button to the OFF position Result The engine should turn off and all functions should not operate 6 Pull out the red Emergency Stop button to the on position and restart the engine Test the Machine Functions 7 Donot hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 8 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm if equipped should sound while the boom is lowering Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches Part No 43648 Second Edition e Fifth Printing Opera
32. storage container located on the platform Decal Legend Genie product decals use symbols color coding and signal words to identify the following A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER AWARNING ACAUTION CAUTION 6 Genie S 60 amp Genie S 65 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury 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 used to indicate operation ormaintenance information Part No 43648 Second Edition e Fifth Printing Operator s Manual Controls 19 AUXILIARY POWER Ox Ox lk OE ON Q CONTROLS 15 AMP EMERGENCY STOP 00009 9 O t 4 9 FUNCTION ENABLE Or ENGINE 15 AMP 20 ig 7 is a Ground Control Panel OO N OU BOON OO Part No 43648 Platf
33. t switch 31 Depress the thumb rocker switch on top of the drive control handle in the direction identified by the blue triangle on the control panel Result The steer wheels should turn in the direction that the blue triangles point on the drive chassis 32 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangles point on the drive chassis Test Drive and Braking 33 Move the lift drive select switch to the drive position if equipped 34 Press down the foot switch 35 Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 36 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the yellow arrow points on the drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Part No 43648 Second Edition e Fifth Printing Operator s Manual Test the Oscillating Axle if equippe
34. the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Part No 438648 Second Edition e Fifth Printing 5 ee ee Pre operation Inspection E Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Be sure that all decals are legible and in place See Decals section Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage and improperly installed loose or missing parts Part No 43648 4 Electrical components wiring and electrical cables 4 Hydraulic hoses fittings cylinders and manifolds 4 Fuel and hydraulic tanks 4 Drive and turntable motors and drive hubs 4 Boom wear pads 4 Tires and wheels 4 Engine and related components Operator s Manual PRE OPERATION INSPECTION
35. tor s Manual Test the Tilt Sensor 9 Pull out the platform red Emergency Stop button to the on position Turn the key switch to platform control 10 Open the tank side turntable cover and locate the tilt sensor next to the control box 11 Press down one side of the tilt sensor Result The alarm located in the platform should sound Test Auxiliary Controls 12 Turn the key switch to ground control and shut the engine off 13 Pull out the red Emergency Stop button to the ON position 14 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions should operate Part No 43648 FUNCTION TESTS At the Platform Controls Test Emergency Stop 15 Turn the key switch to platform control and restart the engine 16 Push in the platform red Emergency Stop button to the oFF position Result The engine should turn off and all functions should not operate 17 Pull out the red Emergency Stop button and restart the engine Test the Hydraulic Oil Return Filter 18 Move the engine idle select switch to high idel rabbit symbol Filter condition indicator 19 Locate and check the hydraulic filter condition indicator Result The filter should be operating with the plunger in the green area 20 Move the engine idle select switch to foot switch activ
36. trol handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn Genie S 60 amp Genie S 65 23 Operators Manual Second Edition e Fifth Printing OPERATING INSTRUCTIONS To Drive 1 Move the lift drive select switch to the drive position if equipped Press down the foot switch Increase speed Slowly move the drive control handle off center Decrease speed Slowly move the drive control handle toward center Stop Return the drive control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the boom is raised or extended Drive Enable Light on indicates that the boom has moved just past either non steering wheel and drive function has been interrupted To drive hold the drive enable switch to either side and slowly move the drive control handle off center Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Generator To operate the generator move the generator toggle switch to the generator position The engine will continue to run but no drive or platform f
37. unctions will operate Plug power tool into the power to platform GFCI outlet To resume machine functions move the generator toggle switch to machine functions position All functions will operate 24 Genie S 60 amp Genie S 65 Engine Idle Select rpm Select engine idle rpm using the symbols on the control panel o Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle Check Engine Light if equipped Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Stopping the Engine Push in the red Emergency Stop button and turn the key switch to the oFF position 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 the non steering wheels 4 Turn the key switch to the oFF position and remove the key to secure from unauthorized use 5 Chock the wheels Part No 43648 Second Edition e Fifth Printing Operator s Manual Transport Instructions Observe and Obey M Transport vehicle must be parked on a level surface MI Transport vehicle must be secured to prevent rolling while machine is being loaded M Be sure vehicle capacity loading surfaces and Straps or lines are suffic
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