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Operator's Manual

Second Edition • First Printing

Maintenance

64 S-60X

Part No. 1261735

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.

Summary of Contents for S-60X

Page 1: ...Operator s Manual S 60X ANSI CSA North America South America Asia with Maintenance Information Second Edition First Printing Part No 1261735 ...

Page 2: ...fety 13 Legend 21 Controls 22 Inspections 30 Operating Instructions 44 Towing Instructions 57 Transport and Lifting Instructions 58 Maintenance 61 Specifications 65 Copyright 2010 by Terex Corporation Second Edition First Printing January 2015 Genie and S are registered trademarks of Terex South Dakota Inc in the U S A and many other countries These machines comply with ANSI SIA A92 5 CAN B 354 4 ...

Page 3: ... This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Bulletin Distribution and Compliance Safety of product users is of paramount importance to Genie Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners The information contained in the bulletins is tied to specifi...

Page 4: ...o your machine Please register your machine by visiting us on the web at www genielift com or by calling us toll free at 1 800 536 1800 Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Kn...

Page 5: ...use symbols color coding and signal words to identify the following Safety alert symbol used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or seri...

Page 6: ... equipped with glow plugs No smoking No flame Stop engine Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Tip over hazard Tip over hazard Replace tires with tires of same specification Wheel load Wind speed Maximum capacity Side force Weight of welder reduces capacity 1000 lbs 454 kg 1000 lbs 454 kg 500 lbs 227 kg 500 l...

Page 7: ...orage points Corrosive acid Color Coded Direction Arrows Runaway Hazard Collision hazard Collision hazard Electrocution hazard Avoid contact Disconnect battery Voltage rating for power to platform Pressure rating for air line to platform Recovery procedure if tilt alarm sounds while elevated Platform downhill 1 Retract boom 2 Lower boom Platform uphill 1 Lower boom 2 Retract boom Read the operator...

Page 8: ... ft lbs 225 Nm Lubricated bolts 130 ft lbs 176 Nm Tip over Hazard Failure to replace tires with tires of same specification will result in death or serious injury Tires are critical to machine stability Do not replace factory installed tires with high flotation tires Only replace factory installed tires with tires of same specification and ply rating Tire Size 355 55 D625 14 ply 82677 C DANGER DAN...

Page 9: ...consult your supervisor the owner or the manufacturer 28236 D WARNING Improper operation or maintenance can result in serious injury or death DANGER 82862 Tip over Hazard Welder power supply reduces rated platform capacity and must be factored into total platform load DANGER Do not overload platform Welder power supply weighs 75 lbs 34 kg 97579 114390 DANGER 218559 218559 A Keep away from overhead...

Page 10: ...ed and secured during operation 28175 G WARNING 82677 Tire Pressure 70 psi 4 92 bar Lug Nut Torque Dry bolts 170 ft lbs 225 Nm Lubricated bolts 130 ft lbs 176 Nm Tip over Hazard Failure to replace tires with tires of same specification will result in death or serious injury Tires are critical to machine stability Do not replace factory installed tires with high flotation tires Only replace factory...

Page 11: ... 82473 114251 133205 114252 114249 133067 82487 114252 82487 82487 1256425 114252 82487 114251 133067 114249 114249 A 114252 A 82487 B 114251 A 133067 A 0 to 50KV 3 0 m 50 to 200KV 4 6 m 200 to 350KV 6 1 m 350 to 500KV 7 6 m 500 to 750KV 10 6 m 750 to 1000KV 13 7 m 82473 82473 B 133205 82481 1256425 ...

Page 12: ... Safety 10 S 60X Part No 1261735 1261414 1262343 114473 219958 133067 82487 114473 82487 82487 B 114473 A 133067 133067 A 0 to 50KV 3 0 m 50 to 200KV 4 6 m 200 to 350KV 6 1 m 350 to 500KV 7 6 m 500 to 750KV 10 6 m 750 to 1000KV 13 7 m 1261414 1262343 219958 ...

Page 13: ...5 S 60X 11 82473 133067 114252 114249 114249 114251 114252 1256425 114252 82487 114251 133067 114249 114249 A 114252 A 82487 B 114251 A 133067 A 0 to 50KV 3 0 m 50 to 200KV 4 6 m 200 to 350KV 6 1 m 350 to 500KV 7 6 m 500 to 750KV 10 6 m 750 to 1000KV 13 7 m 82473 82473 B 1256425 ...

Page 14: ...ccupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchor provided in the platform Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s...

Page 15: ...uring 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 for the restricted or unrestricted range of motion Maximum platform capacity Unrestricted range of motion 500 lbs 227 kg Maximum occupants 2 Maximum platform capacity Restricted range of motion 1000 lbs 454 kg Maximum occupants 3...

Page 16: ...boom Do not raise the boom when wind speeds may exceed 28 mph 12 5 m s If wind speeds exceed 28 mph 12 5 m s when the boom is raised lower the boom and do not continue to operate the machine Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Use extreme care and slo...

Page 17: ...ny part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Do not use the platform controls to free a platform that is caught snag...

Page 18: ...loor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of the boom position and tailswing when rotating the turntable Check the work area fo...

Page 19: ...on monoxide poisoning Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed an...

Page 20: ...ce and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located on the machine Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine Do not use the machine as a ground for welding Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when work...

Page 21: ...connector at the turntable and platform Clamp the negative lead to the ground post at the turntable and platform Pipe Cradle Safety Read understand and obey all warnings and instructions provided with the pipe cradles Do not exceed the rated platform capacity The pipe cradle assembly and the weight in the pipe cradles will reduce rated platform capacity and must be factored into total platform loa...

Page 22: ...th lifting panels Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Maximum vertical height of panels 4 ft 1 2 m Maximum wind speed 15 mph 6 7 m sec Maximum panel area 32 sq ft 3 m2 Tow Package Safety Read understand and obey all warnings and instructions provided with the tow package When vehicle is in free wheel configuration there are no ...

Page 23: ...ator s Manual Legend Part No 1261735 S 60X 21 Legend 1 Non steer tire 2 Steer tire 3 Ground controls 4 Boom 5 Platform controls 6 Platform 7 Lanyard anchorage points 8 Sliding mid rail 9 Manual storage container 10 Foot switch 7 8 9 10 ...

Page 24: ...Operator s Manual Second Edition First Printing Controls 22 S 60X Part No 1261735 Controls 1 2 3 4 5 6 25 24 23 20 21 22 19 ...

Page 25: ...Second Edition First Printing Operator s Manual Controls Part No 1261735 S 60X 23 STOP 7 8 9 10 11 12 13 18 14 17 16 15 ...

Page 26: ...ange operation for maximum drive speed 6 Emergency power switch Use emergency power if the primary power source engine fails Simultaneously hold the emergency power switch to either side and activate the desired function 7 Machine not level indicator light Light is on when the tilt alarm is sounding Move the machine to level ground 8 Generator switch if equipped Move the generator switch up to act...

Page 27: ...e will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards Press the left side of the thumb rocker and the machine will steer to the left Press the right side of the thumb rocker and the machine will steer to the right 15 Drive enable switch To drive when the drive enable light is on hold the drive enable switch to either side a...

Page 28: ... See the instructions in the Operating Instructions section 23 Not used 24 Thumb rocker switch for boom extend retract function Push the top of the rocker switch and boom will retract Push the bottom of the rocker switch and the boom will extend 25 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions Move the control handle up and the primary boo...

Page 29: ...round control panel The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels unless specifically noted 1000 lbs 454 kg 500 lbs 227 kg STOP 12 11 9 7 17 13 10 13 2 8 19 15 18 23 16 5 22 14 21 4 20 1 1000 lbs 454 kg 500 lbs 227 kg 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 8 18 19 ...

Page 30: ...esired function 8 Turntable rotate switch Move the turntable rotate switch to the right and the turntable will rotate to the right Move the turntable rotate switch to the left and the turntable will rotate to the left 9 Boom up down switch Move the boom up down switch up and the boom will raise Move the boom up down switch down and the boom will lower 10 Machine malfunction indicator light Light o...

Page 31: ...perate the machine 17 Not used 18 Platform level switch Move the platform level switch up and the level of the platform will raise Move the platform level switch down and the level of the platform will lower 19 Platform rotate switch Move the platform rotate switch to the right and the platform will rotate to the right Move the platform rotate switch to the left and the platform will rotate to the...

Page 32: ...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 If damage or any unauthorize...

Page 33: ...ction 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 Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine ...

Page 34: ...the machine as it was intended Function Test 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 onl...

Page 35: ...itch Attempt to activate each boom and platform function toggle switch Result No boom and platform functions should operate 8 Move and hold the platform capacity select function enable switch to select 500 lbs 227 kg platform capacity Activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm should sound whil...

Page 36: ...ngine off 17 Pull out the red Emergency Stop button to the on position 18 Simultaneously hold the emergency 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 19 Enter the platform and pull out the red Emergency Stop button Start...

Page 37: ...e and then fully extend the boom to full height Lower the boom Result The boom should stop part way down and the 500 lbs 227 kg capacity indicator light should flash 27 Retract the boom to continue and then fully retract and lower the boom Test the Foot Switch 28 Push in the platform red Emergency Stop button to the off position 29 Pull out the red Emergency Stop button to the on position and do n...

Page 38: ...t The steer wheels should turn in the direction that the yellow triangles point on the drive chassis Test Drive and Braking 36 Press down the foot switch 37 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...

Page 39: ...he Drive Enable System 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 steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 45 Move the drive control handle off center Result The drive function should not operate 46 Move and hold the dr...

Page 40: ...chine from service Test Emergency Controls 53 Shut off the engine 54 Pull out the red Emergency Stop button to the on position 55 Press down the foot switch 56 Simultaneously hold the emergency 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 ...

Page 41: ...or 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 operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situations ...

Page 42: ...ng Panel Cradle option 2 82677 Danger Tire Specifications 4 82862 Danger Fire Extinguisher Welder option 1 Part No Decal Description Qty 97548 Instructions Deutz Engine Specifications F3L 2011 D2011 L03i 1 97579 Danger Tip over Welder option 1 97602 Warning Explosion Hazard 1 97815 Label Lower Mid rail 1 97875 Warning Weld Line to Platform 2 114258 Danger Explosion Hazard 2 114390 Danger Electrocu...

Page 43: ...5 28160 114258 97865 826345 or 133278 52475 31060 52475 82677 229743 72086 147755 or 823658 114390 114390 825579 72086 1262344 31060 52607 82366 72168 72169 52865 1255581 1255582 52475 82677 229743 52475 52475 82677 229743 72086 114258 1260107 72086 822004 or 215527 or 822131 or 133238 or 97548 or 128953 215526 97602 44981 28174 or 28235 97875 147658 97875 31060 31060 1255581 82237 82237 ...

Page 44: ...artment Access 2 82481 Label Battery Charger Safety 1 82487 Label Read the Manual 2 Part No Decal Description Qty 82487 Label Read the Manual Panel Cradle 2 82487 Label Read the Manual Pipe Cradle 2 82551 Label Tire Pressure 4 97815 Label Lower Mid rail 1 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 2 114252 Label Tip over Hazard Limit Switches 5 114473 Label Tilt Alarm 1 133...

Page 45: ...81 28158 or 28159 82473 82473 28160 114251 133205 52475 114252 52475 114249 229743 72086 147755 or 823658 133067 133067 72086 82487 114252 1255581 1255582 52475 114249 229743 52475 52475 114249 229743 72086 114251 1260107 72086 215526 44981 28174 or 28235 147658 114252 114252 1255581 1256425 82487 82487 219958 133067 82487 133387 82551 82551 82551 82551 1256425 ...

Page 46: ... 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 m...

Page 47: ... At the 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 Models with glow plug toggle switch 3 Move the glow plug switch 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 ...

Page 48: ...e red Emergency Stop button to the on position 3 Press down the foot switch when using the controls from the platform 4 Simultaneously hold the emergency power switch to either side and activate the desired function The drive and steer functions will not operate with emergency power Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on pos...

Page 49: ...ency Stop button is pushed in and pulled back out the platform capacity will need to be selected again To Steer 1 Press down the foot switch 2 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to id...

Page 50: ...etermine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the...

Page 51: ...on incline symbol Low range operation for inclines or rough terrain Machine on level surface symbol High range operation for maximum drive speed Engine Idle Select rpm Select engine idle rpm using the symbols on the control panel 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 Gene...

Page 52: ...e Functions will not operate 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 Engine Shut down indicator light if equipped Light on Tag and remove the machine from service Aircraft Protection Package if equipped If the platform bumpers come into contact with aircraft compon...

Page 53: ...eneration mode is running No service required Right side amber light on or flashing Regeneration is required 1 Push in red Emergency Stop button to turn the machine off 2 Restart the engine The regeneration mode should run automatically Left amber light on and no high temperature text box present Regeneration mode is turned off To turn the regeneration mode on 1 Push in red Emergency Stop button t...

Page 54: ...dicates that the capacity has not been selected Determine the weight of all occupants equipment and materials in the platform Refer to the load chart on this page or on the machine to determine the available working range of motion Move and hold the platform capacity select function enable switch to select the platform capacity Less than 501 lbs 227 kg The range of motion is unrestricted 501 1000 ...

Page 55: ...e and Obey Pipe cradles must be installed on the inside of the platform Pipe cradles must not obstruct the platform controls or the platform entrance The bottom of the pipe cradle tube must rest on the platform floor Be sure the platform is level before installing a pipe cradle Pipe Cradle Installation 1 Install a pipe cradle on each side of the platform Refer to the illustration on the left Make ...

Page 56: ... may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 200 lbs 90 7 kg Pipe Cradle Assembly Weight 21 lbs 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to the front of each panel cradle if needed 2 Install rubber bumper 1 in the panel cradle base See the illustration 3 Secure the bumper with 2 high profile lock nuts and 2 washers Panel Cradle In...

Page 57: ...ne side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly end plate should be able to slide on the platform rail Panel Cradle Operation 1 Secure both panel cradles to the platform 2 Place the load so that it rests in both panel cradles 3 Center the load on t...

Page 58: ...h 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 steer wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use ...

Page 59: ...ront drive torque hubs by turning over the drive disconnect caps 5 Turn the steering bypass valve counterclockwise to hydraulically release the steering Do not exceed recommended maximum towing speed or maximum towing times Maximum tow speed 8 mph 12 87 km h Maximum towing time at 8 mph 13 km h 30 minutes Maximum towing time at 6 mph 10 km h 60 minutes After Towing 1 Immediately after towing chock...

Page 60: ...g surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Do not drive the machine on a slope that exceeds the uphill downhill or side slope rating See D...

Page 61: ...pin Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items For diagram refer to the Lifting Instructions Securing the Platform S 60X 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 us...

Page 62: ...ine weight Lifting Instructions Fully lower and retract the boom Remove all loose items on the machine Use the turntable rotation lock to secure the turntable Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine All four of the lifting points are on the turntable Adjust the rigging to pr...

Page 63: ...will be required to perform this procedure Indicates that new parts will be required to 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 can damage engine components Note Check th...

Page 64: ...ons Hydraulic oil type Chevron Rando HD equivalent 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 prob...

Page 65: ...d eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold down brackets are in place and secure Note Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel...

Page 66: ...ly 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 ...

Page 67: ...asoline 30 gallons 114 liters Fuel tank capacity diesel 35 gallons 132 liters Hydraulic pressure maximum boom functions 3000 psi 207 bar System voltage 12V Weight 20 742 lbs 9408 kg Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating stowed position 2WD Counterweight uphill 30 17 Counterweight downhill 10 6 Side slope 25 14 Maximum slop...

Page 68: ...Operator s Manual Second Edition First Printing Specifications 66 S 60X Part No 1261735 S 60X Range of Motion S 60X Part No 1261735 Operator s Manual Second Edition First Printing ...

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