Operator`s Manual - Genie Industries
Contents
1. 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 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 Ibs 227 kg Maximum platform capacity S 60 with 6 Ft Platform with proper counterweight configuration 750 Ibs 340 kg Maximum occupants 2 2 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second 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 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 is2. Wheelbase 8 ft 2 in 2 48 m Turning radius outside 18 ft 7 in 5 66 m Turning radius inside 7 ft 10 in 2 39 m Turntable rotation degrees continuous Turntable tailswing 3 ft 11 in 1 19 m Drive speeds Drive speed stowed 2WD 4 4 mph 7 1 km h 40 ft 6 2 sec 12 2 m 6 2 sec Drive speed stowed 4WD 3 5 mph 5 6 km h 40 ft 7 8 sec 12 2 m 7 8 sec Drive speed raised or extended 0 6 mph 1 0 km h 40 ft 40 sec 12 2 m 40 sec Gradeability 2WD 4WD 30 50 Controls 12V DC proportional AC outlet in platform standard Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Platform dimensions 72 in x 30 in 1 8 m x 76cm 6 foot length x width Platform dimensions 96 in x 36 in 2 4m x 91 cm 8 foot length x width Platform leveling self leveling Platform rotation 160 Hydraulic pressure maximum 3000 psi 207 bar Boom functions System voltage 12V IN355 55 D625 41 18LL x 22 5 14 ply Tire size High flotation tire size Ground clearance 12 in 30 cm Fuel tank capacity 151 liters Weight See Serial Plate Machine weights vary with option configurations 40 gallons Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Floor Loading Information GVW Rated Load 21 060 Ibs 9553 kg Axle load maximum 16 28
3. 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 Il 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 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 Chevron Rykon Premium MV equivalent Part No 82407 Genie S 60 amp Genie S 65 15 Operator s Manual Third Edition Second Printing
4. Genie T Third Edition Operator s Manual Ee N with Maintenance Information Part No 82407 60 65 Operator s Manual Third Edition Second Printing Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Safety Rules ie ee dee ee ee RA AA Ee ee ee 1 GONUOIS ek se Ee Ne AE RE AA AN ne Ee ee EE 9 Pre operation Inspection ee ee Re ee 12 Maintenance ee ee ER EA Re AA AA AA ee ee ee 14 Function AE EE EE EE 18 Workplace Inspection ee ee ee Re ee 23 Operating Instructions ee ee ee 24 Transport and Lifting Instructions ees see ee 29 BIER ER EE a E 32 ee eie AR N aac 36 Contact us Copyright 1995 by Genie Industries First Edition Third Printing October 1996 Internet http www genielift com Seana Els HA ES OR e mail techpub genieind com EE Ee ee 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 These machines comply with ANSI SIA 92 5 1992 Z Printed on recycled paper S Printed in U S A G
5. Maintenance section a Check for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications a 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 a Tires and wheels u Engine and related components PRE OPERATION INSPECTION 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 a Cracks in welds or structural components 4 Dents or damage to machine a Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened a After you complete your inspection be sure that all compartment covers are in place and latched Part No 82407 Genie S 60 amp Genie S 65 13 Operator s Manual Third Edition Second Printing Maintenance Observe and Obey M 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 Ma
6. 20 ft 6 0 m oft 20 ft 40 ft 60 ft 6 0 m oft 20 ft 40 ft 60 ft 0 m 6 0 m 12 2 m 18 3 m Om 6 0 m 12 2m 18 3m 38 Genie S 60 amp Genie S 65 PartNo 82407 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 Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 5511 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 10 220 7911 Fax 31 10 220 6642
7. 27204 Arrow Blue 1 44981 Label Air Line to Platform 2 27205 Arrow Yellow 1 44986 Notice Maximum Manual Force 27206 Triangle Blue 2 pone ca Oui l 27207 Triangle Yellow g ADAD a LOMERA EE l 27564 Danger Electrocution Hazard AE pomel ARA d 28158 Label Unleaded 2 62076 Cosmetic Genie S 60 1 28159 Label Diesel By See SOM ES EA 28160 Label Liquid Petroleum Gas i ai ML seas 28161 Warning Crushing Hazard 4 62073 ES S982 1 28163 Notice Maximum Side Force 82283 Notice Operating Instructions 2 150 Ibs 667 N 1 82366 Label Chevron Rykon 1 28164 Notice Hazardous Materials 1 82455 Ground Control Panel 1 28165 Notice Foot Switch 1 82456 Platform Control Panel 1 28171 Label No Smoking 2 82549 Label Wheel Load S 60 4 28174 Label Power to Platform 230V 2 82550 Label Wheel Load S 65 4 28175 Caution Compartment Access 1 82644 Notice Perkins Diesel Engine Specs 1 28176 Notice Missing Manuals 1 82645 Notice Deutz Diesel Engine Specs 1 28177 Warning Platform Rotate 2 82677 Danger Notice Tire Specifications 4 28181 Warning No Step or Ride 1 82678 Danger Notice High Flotation Tire 28235 Label Power to Platform 115V 2 Spocmeangns t 28236 Warning Failure To Read q eSa SNotee GM Engine specs l 30080 Notice Maximum Load 500 Ibs 227 kg 1 82686 Danger Tip over Hi Capacity l 31060 Danger Tip over Hazard Interlock 3 97548 Notice Deutz Diesel Engine Specs 1 32700 Bangers Solely PUIS 2 97571 No
8. 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 18 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual Test the Machine Functions 7 Donothold 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 Test the Tilt Sensor 9 Pullout 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 fuel tank 11 Press down one side of the tilt sensor Result The alarm located in the platform should sound FUNCTION TESTS Test Auxiliary Controls 12 Turn the key switch to ground control and shut the engine off 13 Pull out the r
9. 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 coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap 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 Besure 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 Chec
10. 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 Di gt ca gt gt ao if 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 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 pi a CSA gt Ek ll 150 Ibs 667 N R Maximum allowable Ww manual force CE 1 S 90 Ibs 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 replace standard factory installed tires with high flotation tires Do not modify or alter an aerial work platform without prior written permission from t
11. the platform guard rails Maintain a firm footing on the platform floor at all times ss F 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 4 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual 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 the use of personal protective equipment Observe and use color coded direction arrows on the platform controls and drive chassis for drive and steer functions SAFETY RULES 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 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 No stunt driving or horseplay while operating a machine Part No 824
12. this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation from factory delivered condition is 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 repairs are completed the operator must perform a pre operation inspection again before going on to 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 12 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual Pre operation Inspection 4 Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform 4 Be sure that all decals are legible and in place See Decals section a Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section a Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section a Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section a Check for battery fluid leaks and proper fluid level Add distilled water if needed See
13. 0 lbs 7384 kg Wheel load maximum 10 800 Ibs 4899 kg Localized pressure per tire 70 psi 4 92 kg cm2 483 kPa Occupied pressure 232 psf 1600 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors 36 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual Model S 65 Height working maximum 71 ft4 in 21 7m Height platform maximum 65 ft 4 in 19 9 m Height stowed maximum 8 ft 10 in 2 49 m Horizontal reach maximum 55 ft 3 in 16 8 m Width 8 ft2in 2 49m Length stowed 31 ft 9 45 m Maximum load capacity 500 Ib 227 kg Wheelbase 8 ft 2 in in 2 48 m Turning radius outside 18 ft 7 in 5 66 m Turning radius inside 7 ft 10 in 2 39 m Turntable rotation degrees continuous Turntable tailswing 3 ft 11 in 1 18 m Drive speeds Drive speed stowed 2WD 4 4 mph 7 1 km h 40 ft 6 2 sec 12 2 m 6 2 sec Drive speed stowed 4WD 3 5 mph 5 6 km h 40 ft 7 8 sec 12 2 m 7 8 sec Drive speed raised or extended 0 6 mph 1 0 km h 40 ft 40 sec 12 2 m 40 sec Gradeability 2WD 4WD 30 50 Controls 12V DC proportional AC outlet in platform standard Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation SPECIFICATIONS Platform dimensions 72 in x 30
14. 07 Genie S 60 amp Genie S 65 5 Operator s Manual Third Edition Second Printing SAFETY RULES 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 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 in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Do not spray either into engine equipped with glow plugs Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conducta 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 be
15. 6 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual To Drive 1 Press down the foot switch 2 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 steer 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 OPERATING INSTRUCTIONS Engine Idle Select rpm Select engine idle rpm using the symbols on the control panel m amp When the foot switch is not pressed the engine will idle at the lowest rpm Turtle symbol Foot switch activated low idle Rabbit symbol Foot switch activated high idle Generator if equipped To operate the generator move the generator toggle sw
16. e 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 Test the Lift Drive Select Function if equipped 50 Press down the foot switch 51 Move the drive control handle off center 52 Activate each boom function toggle switch Result No boom functions should operate The machine will move in the direction indicated on the control panel 22 Genie S 60 amp Genie S 65 PartNo 82407 Third Edition Second Printing Operator s Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations 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 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspectthe workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operati
17. e engine should not start oe that the blue triangles point on the rive chassis 22 Do not press down the foot switch and restart 28 Press the thumb rocker switch in the direction hesngine indicated by the yellow triangle on the control 23 Do not press down the foot switch Test each panel OR slowly move the drive steer handle in machine function the direction indicated by the yellow triangle Result The machine functions should not Result The steer wheels should turn in the operate direction that the yellow triangles point on the drive chassis Test Machine Functions Test Drive and Braking 24 Press down the foot switch 29 Press down the foot switch 25 Activate each machine function control handle or toggle switch 30 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 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 Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 31 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begi
18. ed 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 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 Horn 18 Push the horn button Result The service horn should sound Part No 82407 Genie S 60 amp Genie S 65 19 Operator s Manual Third Edition Second Printing FUNCTION TESTS Test the Foot Switch Test the Steering 19 Push in the platform red Emergency Stop button 26 Press down the foot switch he off position a 27 Press the thumb rocker switch on top of the 20 Pull out the red Emergency Stop button to drive control handle in the direction indicated by the on position but do not start the engine the blue triangle on the control panel OR slowly move the drive steer control handle in the 21 Press down the foot switch and attempt to start direction indicated by the blue triangle the engine by moving the start toggle switch to either side Result The steer wheels should turn in the Result Th
19. elect switch to the desired position 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 Operation from Platform 1 Turn the key switch to platform control 2 Pull out 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 Press down the foot switch 2 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 Press down the foot switch 2 Turn the steer wheels with the thumb rocker switch located on top of the drive control handle Use the color coded direction triangles on the platform controls and the drive chassis to identify the direction the wheels will turn 2
20. en 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 storage container located on the platform 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 6 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual EES EE EE EE EE EE EE SAFETY RULES 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 Hazard Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas Electrocution Hazard Avoid contact with electrical terminals Part No 82407 Genie S 60 amp Genie S 65 7 Operator s Manual Third Edition e Second Printing BEE EE EE EE SAFETY RULES Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminen
21. enie S 60 amp Genie S 65 Part No 82407 Third Edition Second 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 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Part No 82407 Genie S 60 amp Genie S 65 1 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 oe ad lt A S amp S Pe amp Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart
22. er for control electrical circuits 18 20A breaker for oil cooler and options 19 Platform level switch 20 S 65 only Jib boom up down switch PartNo 82407 Genie S 60 amp Genie S 65 9 Operator s Manual Third Edition Second Printing CONTROLS eo O amp D Platform Control Panel 7 Glow plug switch 1 Horn button 8 Engine start switch 2 Platform level switch 9 Engine idle rpm select switch Turtle foot switch activated low idle NE N Rabbit foot switch activated high idle 4 S 65 only Jib boom up down switch 10 Gasoline LPG models Fuel select switch 5 Auxiliary power switch 11 Red Emergency Stop button 6 Drive speed select switch 10 Genie S 60 amp Genie S 65 PartNo 82407 Third Edition Second Printing Operator s Manual CONTROLS STOP DRIVE ENABLE OPERATION Light on indicates that boom has moved past a non steer tire and drive function is turned off To drive hold drive enable switch to si and slowly move drive control handle Machine may drive in opposite direction that drive and steer controls are moved O se color coded direction arrows on his panel and drive chassis to identify he direction machine will travel 12 Dual axis proportional control handle for drive 16 Drive enable switch and steer functions OR Proportional control handle for drive function and thumb rocker for s
23. everse the procedures described to re engage the brakes Note The pump free wheel valve should always remain closed Part No 82407 Genie S 60 amp Genie S 65 29 Operator s Manual Third Edition Second Printing TRANSPORT AND LIFTING INSTRUCTIONS Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 5 chains Adjust the rigging to prevent damage to the chains x 4 Truck bed Securing the Platform S 60 Place a block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed through the lower platform support Do not use excessive downward force when securing the boom section Securing the Platform S 65 Place a block under the jib knuckle Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed over the jib Knuckle Do not use excessive downward force when securing the boom section Fully raise the jib for transport 30 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual TRANSPORT AND LIFTING INSTRUCTIONS Lifting Instruct
24. he 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 Part No 82407 Genie S 60 amp Genie S 65 Operator s Manual Third Edition Second Printing SAFETY RULES 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 in the platform LN 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 are properly inflated and lug nuts are properly tightened Models with 750 Ib 340 kg Capacity Do not attach a platform rated at 750 Ibs 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 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 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
25. in 1 8 m x 76 cm 6 foot length x width Platform dimensions 96 in x 36 in 2 4m x 91 cm 8 foot length x width Platform leveling self leveling Platform rotation 160 Hydraulic pressure maximum 2900 psi 204 bar Boom functions System voltage 12V IN355 55 D625 41 18LL x 22 5 14 ply Tire size High flotation tire size Ground clearance 12 in 30 cm Fuel tank capacity 151 liters Weight See Serial Plate Machine weights vary with option configurations 40 gallons Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Floor Loading Information GVW Rated Load 22 000 Ibs 9979 kg Axle load maximum 18 129 lbs 8223 kg Wheel load maximum 11 600 Ibs 5262 kg Localized pressure per tire 70 psi 4 92 kg cm2 483 kPa Occupied pressure 246 psf 1696 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Part No 82407 Genie S 60 amp Genie S 65 37 Operator s Manual Third Edition Second Printing SPECIFICATIONS S 60 Range of Motion Chart S 65 Range of Motion Chart 60 ft 60 ft H s 18 3 m 18 3 m 40 ft 40 ft 12 2 m 122m i 20 tt 20 ft 6 1m 6 1m O oft oft Om Om aq 20 ft
26. intenance 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 required to SA perform this procedure Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level candamage engine components Check the oil level with the engine off 1 Check the oil dipstick Add oil as needed GM Models Result The oil level should be within the app and FULL marks on the dipstick Deutz Models Result The oil level should be within the two marks on the dipstick Perkins Models Result The oil level should be within the two notches on the dipstick Ford Models Result The oil level should be within the SAFE zone 14 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual GM 3 0L EFI Engine 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
27. ion for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Decal Description Quantity Part No Decal Description Quantity 27204 Arrow Blue 1 82472 Warning Crushing Hazard 4 27205 Arrow Yellow 1 82473 Caution Compartment Access 1 27206 Triangle Blue 2 82487 Notice Operating Instructions 2 27207 Triangle Yellow 2 82455 Ground Control Panel 1 28158 Label Unleaded 2 82456 Platform Control Panel 1 28159 Label Diesel 2 82544 Danger Electrocution Hazard 3 28160 Label Liquid Petroleum Gas 1 82545 Notice Maximum Load 227 kg 1 28171 Label No Smoking 2 82547 Notice Maximum Load 340 kg 1 28174 Label Power to Platform 230V 2 82548 Warning Platform Rotate 2 28235 Label Power to Platform 115V 2 82549 Label Wheel Load S 60 4 32728 Label Generator option 1 82550 Label Wheel Load S 65 4 40434 Label Lanyard Anchorage 4 82551 Label Tire Pressure 4 44981 Label Air Line to Platform 2 82552 Label Hi Flotation Tire Pressure 4 52966 Cosmetic 4 x 2 1 82602 Danger Max Manual Force 667 N 1 52967 Cosmetic 4 x 4 1 82604 Danger Max Manual Force 400 N 1 62076 Cosmetic Genie S 60 1 Please reference the Specifications section or the chart on 62077 BESEER 1 page 2 to determine the ca
28. ions Fully lower and retract the boom Move the jib boom parallel with the ground Remove all loose items on the machine Use the turntable rotation lock to secure the turntable Observe and Obey Determine the center of gravity of your machine lM Only qualified riggers should rig and lift the using the table and the picture on this page machine Attach the rigging only to the designated lifting MT Be sure the crane capacity loading surfaces points on the machine There are two lifting points and straps or lines are sufficient to withstand on the chassis and two on the turntable the machine weight See serial plate Adjust the rigging to prevent damage to the machine and to keep the machine level X Axis Y Axis S 60 4 13 ft 50 6 in 1 25 m 1 28 m S 65 4 18 ft 51 5 in 1 27 m 1 30 m Turntable S Lifting Points 2 we Chassis Lifting Points 2 Part No 82407 Genie S 60 amp Genie S 65 31 Operator s Manual Third Edition Second Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Decal Description Quantity Part No Decal Description Quantity
29. itch to the on position The engine will continue to run but no drive or platform functions will operate Plug a power tool into the power to platform GFCI outlet To resume machine functions move the generator toggle switch to the off position All functions will operate Part No 82407 Genie S 60 amp Genie S 65 27 Operator s Manual Third Edition Second Printing OPERATINGINSTRUCTIONS Check Engine Light qh Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Machine Not Level Indicator Light if equipped A Light on indicates machine is not level The tilt alarm will be sounding when this light is on Move the machine to a firm level surface Machine Malfunction Indicator Light A 1 Light on indicates all functions have stopped Push in and then pull out the red Emergency Stop button Lower and retractthe boom Tag the machine and remove from service Functions will not operate Fall Protection Personal fall protection equipment PFPE is regured when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance
30. k 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 16 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual Check the Tire Pressure This procedure does not need to be performed on machines equipped with foam filled tires Bodily injury hazard 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 pressure 70 psi 60 psi 4 92 bar High flotation tire pressure 4 21 bar MAINTENANCE Scheduled Maintenance Maintenance performed quarterly annually and every two years 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 Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Part No 82407 Genie S 60 amp Ge
31. ng the machine drop offs or holes bumps floor obstructions or debris sloped surfaces unstable or slippery surfaces 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 Part No 82407 Genie S 60 amp Genie S 65 23 Operator s Manual Third Edition Second Printing Operating Instructions 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 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 Fundamentals The Operating Instructions 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 along with their tools and materials 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 o
32. nie S 65 17 Operator s Manual Third Edition Second Printing Function Tests 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 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests 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 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 repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service 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
33. ns 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 20 Genie S 60 amp Genie S 65 PartNo 82407 Third Edition Second Printing Operator s Manual Test the Oscillating Axle if equipped 32 Start the engine from the platform controls 33 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 34 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 35 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 36 Press down the foot switch and lower the boom to the stowed position 37 Rotate the turntable until the boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 38 Move the drive control handle off center Result The drive function should not operate FUNCTION TESTS 39 Move and hold the drive enable toggle switch to either side and slowly move the drive con
34. ow machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 0 F 18 C may require the use of a booster battery Gasoline LPG models In cold conditions 20 F 6 C and below the machine should be started on gasoline and warmed for 2 minutes then switched to LPG Warm engines can be started on 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 red Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform red Emergency Stop button 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 Press down the foot switch when operating the auxiliary controls from the platform 4 Simultaneously hold the auxiliary power switch and activate desired 4 function The drive function will not operate with auxiliary power Part No 82407 Genie S 60 amp Genie S 65 25 Operator s Manual Third Edition Second Printing OPERATINGINSTRUCTIONS 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 the fuel s
35. pacity of your machine 62078 Cosmetic Genie S 65 1 62079 Cosmetic S 65 1 34 Genie S 60 amp Genie S 65 PartNo 82407 Third Edition Second Printing Operator s Manual 82487 Serial Plate 28158 or 28159 EI 82455 wo Co DECALS 28171 82544 28160 82472 40434 82551 a a or 82552 eae 82549 82548 or 82550 82551 or 82552 62077 or 62079 27204 27206 32728 82456 82487 IN or 28235 82545 27207 d or 82547 27206 27205 es 59966 44981 or 92967 or 95604 40434 82544 82548 62076 or 62078 28174 82551 82677 82551 82549 82472 or 28235 or 82552 or 82678 82473 or 82552 or 82550 Part No 82407 Genie S 60 amp Genie S 65 35 Operator s Manual Third Edition Second Printing Specifications Model S 60 Height working maximum 66 ft 2 in 20 2 m Height platform maximum 60 ft 2 in 18 3 m Height stowed maximum 8 ft 10 in 2 49 m Horizontal reach maximum 50 ft 4 in 15 3 m Width 8 ft2in 2 49m Length stowed 27 ft 4 in 8 33 m Maximum load capacity 500 Ib 227 kg Maximum load capacity 750 Ib 340 kg 6 foot platform with proper counterweight configuration
36. perators 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 workplace inspection before using the machine 24 Genie S 60 amp Genie S 65 PartNo 82407 Third Edition Second Printing Operator s Manual Starting the Engine 1 Atthe ground controls turn the key switch to the desired position 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position Gasoline LPG models 3 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 Diesel models 3 Move the glow plug switch if equipped to either side and hold for 3 to 5 seconds 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 All models If engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again In cold conditions 20 F 6 C and below warm the engine for 5 minutes before operating to prevent hydraulic system damage OPERATING INSTRUCTIONS In extreme cold conditions 0 F 18 C and bel
37. teer function 17 Proportional control handle for boom extend retract 13 Platform overload indicator light if equipped 18 Machine malfunction indicator light 14 Machine not level indicator light if equipped 19 used for optional equipment 20 Dual axis proportional control handle for boom 15 Dri le indi ligh l 9 Drive enameinaicator igni up down and turntable rotate left right functions Part No 82407 Genie S 60 amp Genie S 65 11 Operator s Manual Third Edition Second Printing Pre operation Inspection 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 2 Always perform a pre operation inspection Know and understand the pre 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 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
38. tice Ford Engine Specs 1 32728 Label Generator option 1 97602 Warning Explosion Hazard 1 Please reference the Specifications section or the chart on 33952 Danger Tilt Alarm 1 page 2 to determine the capacity of your machine 40434 Label Lanyard Anchorage 4 43594 Notice Maximum Load 750 Ibs 340 kg 1 32 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual 31060 82366 38149 28158 or 28159 82455 MT 5 82677 or 82678 82549 or 82550 82677 or 82678 62077 4 op N 27204 52966 or 52967 28181 40434 28177 62076 or 62078 28174 82283 Serial Plate 28171 27564 28161 28160 DECALS mt 1 28177 33952 32728 82456 82283 32700 al 28174 or 28235 28236 82686 28176 30080 or 43594 28165 44981 28163 or 44986 31060 82679 or 82644 or 82645 or 97548 82549 826 77 28161 or 28235 or 82550 or 82678 28175 or 97571 97602 82549 or 82678 or 82550 27564 PartNo 82407 Genie S 60 amp Genie S 65 33 Operator s Manual Third Edition Second Printing E DECALS Inspect
39. tly hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury gt Yellow with safety alert symbol ACAUTION used to indicate the presence of a A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION 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 or maintenance information 8 Genie S 60 amp Genie S 65 PartNo 82407 Third Edition Second Printing Operator s Manual N OE BO l OO DWA FN O N OX cf P A M rO Ground Control Panel Platform rotate switch Turntable rotate switch Boom up down switch Boom extend retract switch Platform overload indicator light if equipped Machine malfunction indicator light Check engine light Auxiliary power switch Key switch for platform off ground selection 10 Red Emergency Stop button OMAN OA POND Controls 11 Hourmeter 12 Gasoline LPG models Fuel select switch 13 Function enable switch 14 Diesel models Glow plug switch 15 15A breaker for engine electrical circuits 16 Engine start switch 17 15A break
40. trol 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 drive and steer control handle is moved Use the color coded direction Bi t arrows on the platform controls and the drive chassis to identify the direction of travel Yellow Test Limited Drive Speed 40 Press down the foot switch 41 Raise the boom to just above horizontal 42 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 30 cm per second 43 Lower the boom to the stowed position Part No 82407 Genie S 60 amp Genie S 65 21 Operator s Manual Third Edition Second Printing FUNCTION TESTS 44 Extend the boom 1 foot 30 cm 45 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 30 cm per second If the drive speed with the boom raised or extended exceeds 1 foot 30 cm per second immediately tag and remove the machine from service Test Auxiliary Controls 46 Shut off the engine 47 Pull out the red Emergency Stop button to the on position 48 Press down the foot switch 49 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch Note To conserv
41. with the PFPE manufacturer s instructions After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic Retract and lower the boom to the stowed position Rotate the turntable so that the boom is between the non steer wheels Turn the key switch to the off position and remove the key to secure from unauthorized use Chock the wheels 28 Genie S 60 amp Genie S 65 Part No 82407 Third Edition Second Printing Operator s Manual Transport and Lifting Instructions Observe and Obey M The transport vehicle must be parked on a level surface KI The transport vehicle must be secured to prevent rolling while the machine is being loaded M Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling 2WD models Release the non steer wheel brakes by turning over the drive hub disconnect caps Disengage 4WD models Release the wheel brakes by turning over all four drive hub disconnect caps Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions R
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