Genie S®-60 FE launch DC & hybrid telescopics Instruction Manual

S®-60 FE launch DC & hybrid telescopics

Operator’s Manual
Serial Number Range

S®-60 FE S®-60 DC

from S60EM-101

CE

with Maintenance Information
Original Instructions First Edition First Printing Part No. 1299606GT

Operator’s Manual
Front Matter
Manufacturer: Terex South Dakota, Inc. 500 Oakwood Road Watertown, SD 57201, USA Authorized representative: Genie Industries B.V. Boekerman 5 4751 XK OUD GASTEL The Netherlands

First Edition · First Printing
Contents
Introduction ………………………………………………….. 1 Symbol and Hazard Pictorials Definitions …………. 5 General Safety ……………………………………………… 8 Personal Safety…………………………………………… 14 Work Area Safety ………………………………………… 15 Legend ………………………………………………………. 25 Controls……………………………………………………… 26 Inspections …………………………………………………. 35 Operating Instructions………………………………….. 51 Transport and Lifting Instructions ………………….. 64 Maintenance ………………………………………………. 67 Specifications ……………………………………………… 70

Copyright © 2021 by Terex Corporation
First Edition: First Printing, March 2021
Genie and “S” are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries.
Complies with EC Directive 2006/42/EC See EC Declaration of Conformity

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Operator’s Manual
Introduction

Introduction
About this manual
Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. This book is an operation and daily maintenance manual for the user or operator of a Genie machine.
This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, contact Genie.

Product Identification
The machine serial number is located on the serial label.

Serial number stamped on chassis

Serial label (located under cover)

Intended Use and Familiarization Guide
The intended use of this machine is to lift personnel, including tools, and materials to an aerial work site. Before operating the machine, it’s the operator’s responsibility to read and understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s instructions and safety rules provided in the Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

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Operator’s Manual
Introduction
Platform controls symbology and related machine movement:
Platform level Platform rotate
Jib boom up/down Boom up/down
Boom extend/retract
Turntable rotate Drive forward/reverse

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Ground controls symbology and related machine movement:
Platform level, jib boom up/down, boom extend/retract,and boom up/down, platform overload indicator light
Turntable rotate and platform rotate
Sequential functions and movement: · Drive and steer. Interlocked functions: · Elevated drive speed. · Elevated drive in an off-level condition. · Drive enable when the boom is rotated past the
non-steer wheels, or non-steer tracks. · All platform and ground controls. Limitations of use: · The intended use of this machine is to lift
personnel, including tools, and materials to an aerial work site. · Do not elevate the platform unless the machine is on firm level ground.

Steer right/left

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Operator’s Manual
Introduction

Bulletin Distribution and Compliance
Safety of product users is of paramount importance to Genie. Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners.
The information contained in the bulletins is tied to specific machines using the machine model and serial number.
Distribution of bulletins is based on the most current owner on record along with their associated dealer, so it is important to register your machine and keep your contact information up to date.
To ensure safety of personnel and the reliable continued operation of your machine, be sure to comply with the action indicated in a respective bulletin.
To view any open bulletins for your machine, visit us on the web at www.genielift.com.

Contacting the Manufacturer
At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and safety
Standards and regulatory compliance information
Current owner updates, such as changes in machine ownership or changes in your contact information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information will ensure that you receive important safety, maintenance and operating information that applies to your machine.
Please register your machine by visiting us on the web at www.genielift.com or by calling us toll free at 1-800-536-1800.

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Introduction

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Danger
Failure to obey the instructions and safety rules in this manual will result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s manual.
1 Avoid hazardous situations.
Know and understand the safety rules before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety rules– safety and operator’s manuals and machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Safety Sign Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent- based cleaners because they may damage the safety sign material.
Hazard Classification
Decals on this machine use symbols, color coding, and signal words to identify the following:
Safety alert symbol–used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Indicates a property damage message.

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Symbol and Hazard Pictorials Definitions

Symbol and Hazard Pictorials Definitions

Fire hazard

Explosion hazard

Explosion hazard

Do not use ether or other high energy starting aids on machines equipped with glow plugs.

No smoking. No flame. Stop engine.

Battery box torque No smoking

Explosion hazard

Electrocution hazard

Maintain required clearance

Tip-over hazard

Tip-over hazard

Tip-over hazard

Tip-over hazard

Tire specifications

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Symbol and Hazard Pictorials Definitions

Wheel load

Wind speed

Maximum capacity Manual force

Machine not level

Tie-down point

Lifting point

Platform tie-down instructions

Lifting & tie down instructions

Lanyard anchorage points

Burn hazard

Color coded direction arrows

Runaway hazard

Collision hazard

Overhead obstruction

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Operator’s Manual

Symbol and Hazard Pictorials Definitions

Electrocution hazard

Avoid contact

Recovery procedure if tilt alarm sounds while elevated.

Disconnect battery

Voltage rating for power to platform

Pressure rating for air line to platform

Platform downhill: Platform uphill:

1 Retract boom.

1 Lower boom.

2 Lower boom.

2 Retract boom.

Read the operator’s manual

Access by trained and authorized personnel only

Read the service manual

Emergency lowering

Crush hazard

Support the platform or boom during maintenance

Grounded AC 3-wire only

Replace damaged wires and cords

Batteries used as counterweights

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General Safety
General Safety
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Operator’s Manual
Personal Safety
Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is required when operating this machine.
Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.
All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions.

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Operator’s Manual
Work Area Safety

Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.
Obey all local and governmental regulations regarding required clearance from electrical power lines. At a minimum, the required clearance contained in the chart below must be followed.

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.

Line Voltage 0 to 50KV 50 to 200KV 200 to 350KV 350 to 500KV 500 to 750KV 750 to 1000KV

Required Clearance

10 ft

3.05 m

15 ft

4.60 m

20 ft

6.10 m

25 ft

7.62 m

35 ft 10.67 m

45 ft 13.72 m

Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds.

Tip-over Hazards
Occupants, equipment and materials shall not exceed the maximum platform capacity.

Maximum platform capacity Maximum occupants

660 lbs 300 kg 2

The weight of options and accessories such as pipe cradles and welders will reduce the rated platform capacity, and must be subtracted from the platform capacity. See the decals with the options and accessories.
If using accessories, read, understand and obey the decals, instructions and manuals with the accessory.

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Operator’s Manual
Work Area Safety
Do not raise or extend the boom unless the machine is on a firm, level surface.

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If the tilt alarm sounds with the platform uphill: 1 Lower the boom. 2 Retract the boom.
If the tilt alarm sounds with the platform downhill: 1 Retract the boom. 2 Lower the boom.

Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds in the platform only when the machine is on a severe slope.
If the tilt alarm sounds when the platform is raised, use extreme caution. The machine not level indicator light will come on and the drive function in one or both directions will not operate. Identify the condition of the boom on the slope as shown below. Follow the steps to lower the boom before moving to a firm, level surface. Do not rotate the boom while lowering.
The recovery mode should be used only by trained and authorized personnel.

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.

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Operator’s Manual
Work Area Safety

Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.
Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended.
Do not use the machine as a crane.
Do not push the machine or other objects with the boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent structures.
Do not place loads outside the platform perimeter.
Do not push off or pull toward any object outside of the platform.
Maximum allowable side force ­ 90 lbs/400 N

Do not alter or disable machine components that in any way affect safety and stability.
Do not replace items critical to machine stability with items of different weight or specification.
Do not replace factory-installed tires with tires of different specification or ply rating.
Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight is critical to 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.
Do not modify or alter a mobile elevated work platform without prior written permission from the manufacturer. Mounting attachments for holding tools or other materials onto the platform, toeboards, or guard rail system can increase the weight in the platform and the surface area of the platform or the load.

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Work Area Safety

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Do not place or attach fixed or overhanging loads to any part of this machine.
Do not place ladders or scaffolds in the platform or against any part of this machine.

Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds the maximum uphill, downhill or side slope rating of the machine. Slope rating applies only to machines in the stowed position.

Maximum slope rating, stowed position, 4WD

Platform downhill

45% (24°)

Platform uphill

30% (17°)

Side slope

25% (12°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating. See Driving on a Slope in the Operating Instructions section.

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 the tires are in good condition and the lug nuts tightened.

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Work Area Safety

Fall Hazards
Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform.
Do not sit, stand, or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

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.

Do not climb down from the platform when raised.

Be aware of crushing hazards when grasping the platform guard rail.

Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry gate before operating.
Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level.
Hazards related with the specific product application of exiting at height have been considered in the design of the machine, for further information contact Genie (see section Contacting the Manufacturer).

Operators must comply with employer, job site, and governmental rules regarding use of personal protective equipment.

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Work Area Safety

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Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.
Do not lower the boom unless the area below is clear of personnel and obstructions.
Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any 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.

Bodily Injury Hazard
Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.
Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin.
Improper contact with components under any cover will cause serious injury. Only trained maintenance personnel should access compartments. Access by the operator is only advised when performing a pre-operation inspection. All compartments must remain closed and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect diesel fuel or other explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the batteries only in an open, well-ventilated area away from sparks, flames and lighted tobacco.
Do not operate the machine or charge the batteries in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.
Do not spray ether into engine.

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Operator’s Manual
Work Area Safety

Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine.
Be sure all maintenance has been performed as specified in this manual and the appropriate Genie service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety, and responsibilities manuals are complete, legible, and in the storage container located on the machine.
Component Damage Hazards
Do not use any battery or charger greater than 12V to jump-start the engine.
Do not use the machine as a ground for welding.
Do not operate the machine in locations where extremely high magnetic fields may be present.

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.
Do not expose the batteries or the charger to water or rain during charging.
Explosion Hazards
Keep sparks, flames, and lighted tobacco away from batteries. Batteries emit explosive gas.
The battery pack covers should remain open during the entire charging cycle.
Do not contact the battery terminals or the cable clamps with tools that may cause sparks.

Component Damage Hazard
Do not use any battery charger greater than 48V to charge the function batteries.
Disconnect the battery pack plug before removing the battery pack.

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Electrocution/Burn Hazards
Connect the battery charger to a grounded, AC 3-wire electrical outlet only.
Inspect daily for damaged cords, cables and wires. Replace damaged items before operating.
Avoid electrical shock from contact with battery terminals. Remove all rings, watches and other jewelry.
Do not operate when generator is submerged in water.
Tip-over Hazard
Do not use batteries that weigh less than the original equipment. Batteries are used as counterweight and are critical to machine stability. Machines with standard batteries, each battery must weigh 106 lbs / 48 kg. Each battery pack including batteries must weigh a minimum of 1156 lbs / 524 kg.
Lifting Hazard
Use a forklift to remove or install a battery pack.

Contact Alarm Safety
Read, understand and obey all warnings and instructions provided with the contact alarm.
Do not exceed the rated platform capacity. The weight of the contact alarm assembly will reduce the rated platform capacity and must be subtracted from the total platform load.
The contact alarm assembly weighs 10 lbs/4.5 kg.
Be sure the contact alarm is securely installed.

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Work Area Safety

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 load.
The pipe cradle assembly weighs 21 lbs/9.5 kg.
The maximum capacity of the pipe cradle assembly is 200 lbs/91 kg.
The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in platform.
Center the load within the perimeter of the platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the platform.
Do not obstruct the ability to operate the platform controls or the red Emergency Stop button.
Do not operate unless you are adequately instructed and are aware of all of the hazards associated with movement of the platform with an overhanging load.
Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load.
Electrocution Hazard: Keep pipes away from all energized electrical conductors.

Panel Cradle Safety
Read, understand and obey all warnings and instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The combined weight of the cradles, panels, occupants, tools and any other equipment must not exceed rated capacity.
The panel cradle assembly weighs 30 lbs/13.6 kg.
The maximum capacity of the panel cradles is 250 lbs/113 kg.
The weight of the panel cradles and the load in the panel cradles may limit the maximum number of occupants in platform to one person.
Secure the cradles to the platform. Secure the panel (s) to the platform railing using the straps provided.
Do not operate unless you are adequately instructed and are aware of all hazards associated with 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.

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Operator’s Manual
Work Area Safety
Lockout 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-steer wheels.
4 Turn the key switch to the off position and remove the key to secure from unauthorized use.

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Legend

Operator’s Manual
Legend

1 Non-steer tire 2 Steer tire 3 Ground controls 4 Boom 5 Jib boom 6 Platform controls

7 Swing gate 8 Platform 9 Lanyard anchorage points 10 Sliding mid-rail 11 Manual storage container 12 Foot switch

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Controls

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Controls
The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform. When the ground control station is selected, the platform controls are inoperable, including the E-stop switch.

Ground Control Panel

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Controls

Ground Control Panel
1 Function enable button
Press and hold the function enable button to enable the functions on the ground control panel to operate.
2 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.
3 Boom extend/retract switch
Move the boom extend/retract switch to the right and the boom will extend. Move the boom extend/retract switch to the left and the boom will retract.
4 LCD display
At machine start up the LCD screen displays pitch and roll angles of the machine, the number of hours the machine has operated, the battery charge level and the alarm beeps 4 seconds. The screen also displays fault codes and other service information.

5 Key switch for off/ground/platform selection
Turn the key switch to the off position and the machine will be off. Turn the key switch to the ground position and the ground controls will operate. Turn the key switch to the platform position and the platform controls will operate.
6 DC mode light: FE models
Light on indicates the machine is in DC mode
7 Red Emergency Stop button
Push in the red Emergency Stop button to the off position to stop all functions and turn the engine off. Pull out the red Emergency Stop button to the on position to operate the machine.

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8 Hybrid mode light: FE models
Light on indicates the machine is in Hybrid mode
9 Machine mode select switch: FE Models
Move the switch to the left to select DC mode
Move the switch to the right to select Hybrid mode
10 Jib boom up/down switch
Move the jib boom switch up and the jib boom will raise. Move the jib boom switch down and the jib boom will lower.
11 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.

12 Platform overload indicator light
Light flashing indicates the platform is overloaded and no functions will operate. Remove weight until the light goes off.
13 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.
14 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 left.

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15 Auxiliary power switch Use auxiliary power if the primary power source (engine) is not available. Simultaneously hold the auxiliary power switch to either side and activate the desired function.
16 Recovery switch Recovery switch should be used only by trained and authorized personnel. Be sure all maintenance has been performed as specified in this manual and the appropriate service manual.

Operator’s Manual
Controls

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Platform Control Panel

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Platform Control Panel

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Platform Control Panel
1 Horn button
Press this button and the horn will sound. Release the button and the horn will stop.
2 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.
3 Jib boom up/down switch
Move the jib boom switch up and the jib boom will raise. Move the jib boom switch down and the jib boom will lower.
4 Platform rotate switch
Move the platform rotate switch to the left and the platform will rotate left. Move the platform rotate switch to the right and the platform will rotate right.

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5 Boom extend/retract switch
Move the boom extend/retract switch to the right and the boom will extend. Move the boom extend/retract switch to the left and the boom will retract.
6 Function speed control switch
Move the switch to the left and the function speeds for jib up/down, platform rotate and primary boom extend/retract will decrease. Move the switch to the right and the function speeds for jib up/down, platform rotate and primary boom extend/retract will increase.
Note: Function speeds will increase or decrease by 5% each time the speed control switch is moved. The speed control switch can also be held in either direction to increase or decrease function speed.
7 Auxiliary power switch
Use auxiliary power if the primary power source fails. Simultaneously hold the auxiliary power switch up or down and activate the desired function.
8 Inverter switch (if equipped)
Move the inverter switch up to activate the inverter. Move the switch down to turn off the inverter.
9 Aircraft protection override switch (if equipped)
Move and hold the aircraft protection override switch to operate the machine when the platform bumper is against an object.
10 Red Emergency Stop button
Push in the red Emergency Stop button to the off position to stop all functions and turn the engine off. Pull out the red Emergency Stop button to the on position to operate the machine.

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Controls

11 Dual axis proportional control handle for drive and steer functions. OR Proportional control handle for drive function and thumb rocker for steer function.
Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward. Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards. Move the control handle in the direction indicated by the blue triangle and the machine will steer to the left. Move the control handle in the direction indicated by the yellow triangle and the machine will steer to the right. OR Move the control handle in the direction indicated by the blue arrow on the control panel and the machine 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.

12 Drive enable indicator light
Light on indicates that the boom has moved just past either non-steer wheel and drive function has been interrupted.
13 Drive enable switch
To drive when the drive enable light is on, 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.
14 Drive speed select switch
Machine on incline symbol: Low range for improved throttle control at reduced drive speed. Machine on level surface symbol: High range operation for maximum drive speed.
15 Machine not level indicator light
The machine not level indicator light will come on when the tilt alarm sounds.
16 LCD readout screen

a see operator’s manual b contact maintenance c hazard d hybrid mode e DC mode

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Controls
17 Platform overload indicator light
Light flashing indicates the platform is overloaded. The engine will stop and no functions will operate. Remove weight until the light goes off and then restart the engine.
18 Machine mode select switch: FE Models
Move the switch to the left to select DC mode
Move the switch to the right to select Hybrid mode
19 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions
Move the control handle up and the boom will raise. Move the control handle down and the boom will lower.
Move the control handle to the right and the turntable will rotate to the right. Move the control handle to the left and the turntable will rotate to the left.

First Edition · First Printing

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S®-60 DC · S®-60 FE

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Operator’s Manual
Inspections

Inspections
Do Not Operate Unless:
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.

Pre-operation Inspection 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.
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 preoperation 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.

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Inspections

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Pre-operation Inspection
Verify the operator’s manual, safety manual, responsibilities manual and any necessary supplements are complete, legible and in the storage container located in the platform.
FE Models – Check for engine oil leaks and proper oil level. Add oil if needed. See Maintenance section.
FE Models – Check for engine coolant leaks and proper level of coolant. Add coolant if needed. See Maintenance section.
Be sure that all decals are legible and in place. See Inspections section.
Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section.
Check for battery fluid leaks and proper fluid level. Add distilled water 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
FE Models – Engine and related components
Limit switches, angle sensors and horn
Contact alarm
Alarms and beacons (if equipped)
Nuts, bolts and other fasteners
Platform entry mid-rail and gate
Platform load cell
Lanyard anchorage points
Check entire machine for:
Cracks in welds or structural components
Dents or damage to machine
Excessive rust, corrosion or oxidation
Verify that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened.
Be sure the hydraulic tank valves are in the open position.
After you complete your inspection, be sure that all compartment covers are in place and latched.
Be sure that the battery pack is in place and properly connected.

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Operator’s Manual
Inspections

Do Not Operate Unless:
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.

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 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.

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Operator’s Manual
Inspections

First Edition · First Printing

At the Ground Controls
1 Select a test area that is firm, level and free of hazards.
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 FE models: Start the engine. See Operating Instructions section.
Test Emergency Stop
5 Push in the red Emergency Stop button to the off position.
Result FE models The engine will shut off after 2 to 3 seconds.
6 Press and hold the function enable button and activate each boom and platform function toggle switch.
Result: No functions should operate.
7 Pull out the red Emergency Stop button to the on position.
Test Machine Functions
8 Do not push and hold the function enable button. Attempt to activate each boom and platform function toggle switch.
Result: No boom and platform functions should operate.
9 Press and hold the function enable button and 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 while the boom is lowering.

Test Auxiliary Power
FE Models:
10 Turn the key switch to ground control.
11 Pull out the red Emergency Stop button to the on position.
12 Select hybrid mode.
13 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 functions should operate.
DC Models:
14 Turn the key switch to ground control.
15 Pull out the red Emergency Stop button to the on position.
16 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 functions should operate.

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Operator’s Manual
Inspections

Test the Tilt Sensor
FE Models:
17 Select a test area that is firm, level and free of hazards.
18 Turn the key switch to ground control.
19 Pull out the red Emergency Stop button to the on position.
20 Select hybrid mode.
21 Start the engine. See Operating Instructions section.
Result At machine start up the ground control meter displays pitch and roll angles of the machine and the alarm will beep 4 seconds.
DC Models:
22 Select a test area that is firm, level and free of hazards.
23 Turn the key switch to ground control.
24 Pull out the red Emergency Stop button to the on position.
Result At machine start up the ground control meter displays pitch and roll angles of the machine and the alarm will beep 4 seconds.

At the Platform Controls
25 Turn the key switch to platform control. 26 Pull out the red Emergency Stop button to the
on position. 27 FE models: Start the engine. See Operating
Instructions section.
Test Emergency Stop 28 Push in the platform red Emergency Stop
button to the off position. Result FE models The engine should turn off. 29 Activate each function control handle, toggle switch or thumb rocker switch. Result: No functions should operate. 30 Pull out the platform red Emergency Stop button to the on position.
Test the Horn 31 Press the horn button.
Result: The horn should sound.

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Inspections

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Test the Foot Switch
DC Models:
32 Do not press down the foot switch. Test each machine function.
Result: No functions should operate.
FE Models:
33 Push in the platform red Emergency Stop button to the off position.
34 Pull out the red Emergency Stop button to the on position and do not start the engine.
35 Do not press down the foot switch and attempt to start the engine by moving the machine mode select switch to hybrid mode.
Result: The engine should not start.
36 Move the machine mode select switch to hybrid mode.
37 Press and hold the foot switch.
Result: The engine should start.
38 Do not press down the foot switch and test each machine function.
Result: No functions should operate.

Test Machine Functions
39 Press down the foot switch.
40 Activate each machine function control handle or toggle switch.
Result: All boom and platform functions should operate through a full cycle.
Test the Steering
41 Press down the foot switch.
42 Press the thumb rocker switch on top of the drive control handle in the direction indicated by the blue triangle on the control panel OR slowly move the control handle in the direction indicated by the blue triangle.
Result: The steer wheels should turn in the direction that the blue triangles point on the drive chassis.
43 Press the thumb rocker switch in the direction indicated by the yellow triangle on the control panel OR slowly move the control handle in the direction indicated by the yellow triangle.
Result: The steer wheels should turn in the direction that the yellow triangles point on the drive chassis.

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Inspections

Test Drive and Braking
44 Press down the foot switch.
45 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.
46 Slowly move the 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.

Test the Drive Enable System
47 Press down the foot switch and lower the boom to the stowed position.
48 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.
49 Move the drive control handle off center.
Result: The drive function should not operate.
50 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 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.

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Inspections

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Test Limited Drive Speed
51 Press down the foot switch.
52 Raise the boom approximately 5° above the horizontal.
53 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 ft/30 cm per second.
54 Lower the boom to the stowed position.
55 Extend the boom approximately 18inches/46cm.
56 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 ft/30 cm per second.
If the drive speed with the boom raised or the boom extended exceeds 1 ft/30 cm per second, immediately tag and remove the machine from service.

Test Drive Tilt Cutout
57 Press down the foot switch.
58 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is greater than 4.5°.
Result: The machine should continue to drive.
59 Return to level ground and raise the boom to an out of stowed position (approximately 10° above horizontal).
60 Drive the machine onto a slope where the chassis pitch angle is greater than 4.5°.
Result: The machine should stop once the machine reaches 4.5° of chassis tilt and the alarm should sound at the platform controls.
61 Lower the boom to the stowed position.
Result: The machine should drive.
62 Return to level ground and extend the boom approximately 1.6 ft / 0.5 m.
63 Drive the machine onto a slope where the chassis pitch angle is greater than 4.5°.
Result: The machine should stop once the machine reaches 4.5° of chassis tilt and the alarm should sound at the platform controls.
64 Retract the boom to the stowed position.
Result: The machine should drive.
65 Return to level ground and stow the boom.

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Inspections

66 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is greater than 4.5°.
Result: The machine should continue to drive.
67 Return to level ground and raise the boom to an out of stowed position (approximately 10° above horizontal).
68 Drive the machine onto a slope where the chassis roll angle is greater than 4.5°.
Result: The machine should stop once the machine reaches 4.5° of chassis tilt and the alarm should sound at the platform controls.
69 Lower the boom to the stowed position or drive in the opposite direction.
Result: The machine should drive.
70 Return to level ground and extend the boom approximately 1.6 ft / 0.5 m.
71 Drive the machine onto a slope where the chassis roll angle is greater than 4.5°.
Result: The machine should stop once the machine reaches 4.5° of chassis tilt and the alarm should sound at the platform controls.
72 Retract the boom to the stowed position or drive in the opposite direction.
Result: The machine should drive.
73 Return to level ground and stow the boom.
74 With the boom fully stowed, drive the machine onto a slope where the chassis roll angle is greater than 4.5°.
Result: The machine should continue to drive.

Test the Oscillating Axle (if equipped)
75 Drive the right steer tire up onto a 6 in/15 cm block or curb.
Result: The three remaining tires should stay in firm contact with the ground.
76 Drive the left steer tire up onto a 6 in/15 cm block or curb.
Result: The three remaining tires should stay in firm contact with the ground.
77 Drive both steer tires up onto a 6 in/15 cm block or curb.
Result: The non-steer tires should stay in firm contact with the ground.
Test Auxiliary Power
78 Push in the red Emergency Stop button to the off position.
79 Pull out the red Emergency Stop button to the on position.
80 Press down the foot switch.
81 Simultaneously move and hold the auxiliary power switch and activate each function control handle, toggle switch or thumb rocker 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.

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Inspections

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Test the Lift/Drive Select Function (if equipped)
82 Press down the foot switch.
83 Move the drive control handle off center and activate a boom function toggle switch.
Result: No boom functions should operate. The machine will move in the direction indicated on the control panel.
Repair any malfunctions before operating the machine.

88 Operate each machine function. Result: All machine functions should not operate.
89 Insert the actuator into the switch socket. Result: The lights and horn will turn off.
90 Operate each machine function. Result: All machine functions should operate.

Test the Contact Alarm (if equipped)
84 Do not activate the foot switch and press on the contact alarm cable to release the actuator from the switch socket.
Result: The contact alarm lights will not flash and the machine horn will not sound.
85 Activate the foot switch by pressing the foot switch down.
Result: The contact alarm lights will flash and the machine horn will sound.
86 Insert the actuator into the switch socket.
Result: The lights and horn will turn off.
87 Activate the foot switch by pressing the foot switch down and press on the contact alarm cable to release the actuator from the switch socket.
Result: The contact alarm lights will flash and the machine horn will sound.

1 actuator 2 contact alarm cable 3 flashing alarm 4 switch socket

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Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 91 Extend the boom approximately 1 ft/30 cm. 92 Move the yellow bumper at the bottom of the
platform 4 inches/10 cm in any direction. 93 Activate each function control handle or toggle
switch. Result: No boom and steer functions should operate. 94 Move and hold the aircraft protection override switch.
95 Activate each function control handle or toggle switch. Result: All boom and steer functions should operate.

Operator’s Manual
Inspections

Part No. 1299606GT

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Operator’s Manual
Inspections

First Edition · First Printing

Do Not Operate Unless:
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.
Know and understand the workplace inspection before going on to the next section.
5 Only use the machine as it was intended.

Workplace Inspection Checklist
Be aware of and avoid the following hazardous situations:
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

Workplace Inspection 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 operating the machine.

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Operator’s Manual
Inspections

Inspection for Decals with Symbols – S-60 DC
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.
Below is a numerical list with quantities and descriptions.

Part No. Decal Description

Qty

27204 Arrow ­ Blue

1

27205 Arrow ­ Yellow

1

27206 Triangle ­ Blue

2

27207 Triangle ­ Yellow

2

28174 Label ­ Power to Platform, 230V

2

28235 Label ­ Power to Platform, 115V

2

44981 Label ­ Air Line to Platform (option)

2

52475 Label ­ Transport Tie Down

8

65278 Caution ­ No Step

2

72086 Label ­ Lifting Point

4

82481 Label ­ Battery/Charger Safety

2

82487 Label ­ Read the Manual

3

82487 Label ­ Read the Manual (panel

2

cradle)

82487 Label ­ Read the Manual (pipe cradle)

2

97815 Label ­ Lower Mid-rail

2

114236 Label ­ CB Symbol

3

114249 Label ­ Tip-over Hazard, Tires

4

114252 Label ­ Tip-over Hazard, Limit

3

Switches

114334 Label ­ Electrocution Hazard, Plug

1

114473 Label ­ Tilt Alarm

1

133067 Label ­ Electrocution Hazard

3

133205 Label ­ Electrocution/Burn Hazard

2

133286 Label ­ Power to Charger

1

219956 Label ­ Platform Overload

1

219958 Label ­ Tip-over, Crush Hazard

1

1256425 Label ­ Danger, Electrocution Hazard

1

1263542 Label ­ Compartment Access

2

1265361 Label ­ Battery Charger Indicator

1

1271943 Label – AC Inverter Power, 115V

1

1271944 Label – AC Inverter Power, 220V

1

1272242 Label ­ Machine Registration/Owner

1

Transfer

1278542 Label ­ Contact Alarm Weight

1

1278982 Label ­ Actuator Switch Socket

1

1281169 Label ­ Recovery Switch

1

1281175 Label ­ Lanyard Anchorage Point, Fall

8

Restrained

1281184 Label ­ Runaway Machine Hazard, S-

1

80/85 XC

1281188 Label ­ Emergency Lowering

1

1283878 Label ­ Tech Pro Link

2

1286362 Label ­ Crush Hazard, Service

2

1294857 Label ­ Tip Over Hazard, CE Z-45

1

FE/DC

1303758 Label ­ Ground Control Box, S-Boom

1

1303760 Label ­ Platform Control Box, S-

1

Boom

1304629 Label ­ Wheel Load S60FE/DC

4

1304630 Label ­ Transport/Lifting, S60FE/DC

2

1304632 Label ­ Swing Lock S-60FE

1

1304633 Label ­ Battery Weight/Tip Over,

1

ANSI, Symbol

1304634 Label ­ Battery Fastening Danger

1

T112773 Tape, Protective Mask

4

Shading indicates decal is hidden from view, i.e. under covers

• These decals are model, option or configuration specific.

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Operator’s Manual
Inspections

First Edition · First Printing

48

S®-60 DC · S®-60 FE

Part No. 1299606GT

First Edition · First Printing

Operator’s Manual
Inspections

Inspection for Decals with Symbols – S-60 FE
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.
Below is a numerical list with quantities and descriptions.

Part No. Decal Description

Qty

27204 Arrow ­ Blue

1

27205 Arrow ­ Yellow

1

27206 Triangle ­ Blue

2

27207 Triangle ­ Yellow

2

28159 Label ­ Diesel

1

28174 Label ­ Power to Platform, 230V

2

28235 Label ­ Power to Platform, 115V

2

44981 Label ­ Air Line to Platform (option)

2

52475 Label ­ Transport Tie Down

8

65278 Caution ­ No Step

2

72086 Label ­ Lifting Point

4

82240 Label ­ 105 dB

1

82481 Label ­ Battery/Charger Safety

2

82487 Label ­ Read the Manual

3

82487 Label ­ Read the Manual (panel

2

cradle)

82487 Label ­ Read the Manual (pipe cradle)

2

97815 Label ­ Lower Mid-rail

2

114236 Label ­ CB Symbol

3

114249 Label ­ Tip-over Hazard, Tires

4

114251 Label ­ Explosion Hazard

2

114252 Label ­ Tip-over Hazard, Limit

3

Switches

114334 Label ­ Electrocution Hazard, Plug

1

114473 Label ­ Tilt Alarm

1

133067 Label ­ Electrocution Hazard

3

Part No. Decal Description

Qty

133205 Label ­ Electrocution/Burn Hazard

2

133286 Label ­ Power to Charger, Universal

1

219956 Label ­ Platform Overload

1

219958 Label ­ Tip-over, Crush Hazard

1

1256425 Label ­ Danger, Electrocution Hazard

1

1263542 Label ­ Compartment Access

2

1265361 Label ­ Battery Charger Indicator

1

1271943 Label – AC Inverter Power, 115V

1

1271944 Label – AC Inverter Power, 220V

1

1272242 Label ­ Machine Registration/Owner

1

Transfer

1278542 Label ­ Contact Alarm Weight

1

1278982 Label ­ Actuator Switch Socket

1

1281169 Label ­ Recovery Switch

1

1281175 Label ­ Lanyard Anchorage Point, Fall

8

Restrained

1281184 Warning ­ Runaway Machine Hazard

1

1281188 Label ­ Emergency Lowering

1

1283878 Label ­ Tech Pro Link

2

1294857 Label ­ Tip Over Hazard, CE Z-45

1

FE/DC

1303758 Label ­ Ground Control Box, S-Boom

1

1303760 Label ­ Platform Control Box, S-

1

Boom

1304629 Label ­ Wheel Load S60FE/DC

4

1304630 Label ­ Transport/Lifting, S60FE/DC

2

1304632 Label ­ Swing Lock S-60FE

1

1304633 Label ­ Battery Weight/Tip Over,

1

ANSI, Symbol

1304634 Label ­ Battery Fastening Danger

1

T112773 Tape, Protective Mask

4

Shading indicates decal is hidden from view, i.e. under covers

• These decals are model, option or configuration specific.

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Operator’s Manual
Inspections

First Edition · First Printing

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S®-60 DC · S®-60 FE

Part No. 1299606GT

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Operator’s Manual
Operating Instructions

Operating Instructions
Do Not Operate Unless:
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 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 preoperation inspection, function tests, and a workplace inspection before using the machine.

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Operator’s Manual
Operating Instructions

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Machine Operation
FE models can be operated with or without the engine running.
1 Turn the key switch to ground or platform control.
2 Be sure both battery packs are connected before operating the machine.
3 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position.

Emergency Stop
Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions.
Repair any function that operates when either red Emergency Stop button is pushed in.
Selecting and operating the ground controls will override the platform red Emergency Stop button.

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Operator’s Manual
Operating Instructions

Auxiliary Power
Use auxiliary power if the primary power source 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 using the controls from the platform.
4 Simultaneously hold the auxiliary power switch to either side and activate the desired function.

FE Models: Starting the Engine
From the ground control panel:
1 Turn the key switch to ground control.
2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position.
3 Move the machine mode select switch to hybrid mode.
4 Push the function enable button to start the engine.
From the platform control panel:
5 Turn the key switch to platform control.
6 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position.
7 Move the machine mode select switch to hybrid mode.
8 Press down the foot switch to start the engine.
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 again.
In cold conditions, 20°F/-6°C and below, warm the engine for 5 minutes before operating to prevent hydraulic system damage.
In extreme cold conditions, 0°F/-18°C and below, 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.

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Operating Instructions

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Operation from Ground
1 Turn the key switch to ground control. 2 Pull out the red Emergency Stop button to the
on position. 3 FE Models: Select DC mode or Hybrid mode. 4 FE Models: Start the engine.
To Position Platform 1 Press and hold a function enable
button.
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.

Operation from Platform
Note: When operating the machine from the platform, the following foot switch messages may appear on the platform control LCD screen.
· FOOT SWITCH POWER UP FAULT. RELEASE FOOT SWITCH AND REPOWER.
· FOOT SWITCH MUST BE APPLIED BEFORE FUNCTION IS ACTIVATED.
· FOOT SWITCH TIMED OUT. RELEASE FOOT SWITCH TO RESET.
If any of these messages appear, follow the message instructions to resume machine operation.
1 Turn the key switch to platform control.
2 Pull out the red Emergency Stop button to the on position.
3 FE Models: Select DC mode or Hybrid mode.
4 FE Models: Start the engine.
To Position Platform
1 Press down the foot switch.
2 Slowly move the appropriate function control handle or toggle switch or press the appropriate button according to the markings on the control panel.
Note: If the up functions become disabled and the following message is displayed on the platform control LCD screen, UP FUNCTIONS DISABLED DUE TO LOW VOLTAGE CHARGE BATTERIES, charge the batteries to enable full use of the up functions.

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Operator’s Manual
Operating Instructions

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 identify the direction the wheels will turn.

To Drive
1 Press down the foot switch.
2 Increase speed: Slowly move the control handle off center.
Decrease speed: Slowly move the control handle toward center.
Stop: Return the control handle to center or release the function enable 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.
Note: For 4WD machines, the overall drive speed will be reduced to 2.5 mph / 4 km/h when an off level condition > 11.3 degrees (> 20% grade) is measured by the level sensor. The following message will also be displayed on the platform control LCD screen, DRIVE SPEED REDUCED DUE TO SLOPE.
Note: In very hot environments, operators may notice slower drive and/or charging performance. This is the machine protecting itself from the effects of heat and is a functional design of the machine.

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Operating Instructions

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Driving on a slope
Determine the uphill, downhill and side slope ratings for the machine and determine the slope grade.
Maximum slope rating, platform downhill (gradeability):
4WD: 45% (24°)
Maximum slope rating, platform uphill:
4WD: 30% (17°)
Maximum side slope rating:
25% (14°)
Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating. The term gradeability applies to the counterweight uphill configuration only.
Be sure the boom is below horizontal and the platform is between the circle- end wheels.
Move the drive speed select switch to machine on incline symbol.
To determine 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 vertical distance from the bottom of the piece of wood to the ground. Divide the tape measure distance (rise) by the length of the piece of wood (run) and multiply by 100. Example:
Piece of wood = 144 inches (3.6 m) Run = 144 inches (3.6 m) Rise = 12 inches (0.3 m) 12 in ÷ 144 in = 0.083 x 100 = 8.3% grade 0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade If the slope exceeds the maximum slope or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section.

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Operator’s Manual
Operating Instructions

Drive Enable
Light flashing indicates that the boom has moved just past either non-steer wheel and the 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.
Drive Speed Select
· Machine on incline symbol: Low range operation for inclines or rough terrain
· Machine on level surface symbol: High range operation for maximum drive speed

Function Speed Control
1 Move the switch to the left to decrease the function speeds for jib up/down, platform rotate and boom extend/retract.
2 Move the switch to the right to increase the function speeds for jib up/down, platform rotate and boom extend/retract.
Note: Function speeds will increase or decrease by 5% each time the function speed control switch is moved. The speed control switch can also be held in either direction to increase or decrease function speed.
AC Inverter (if equipped)
The inverter supplies power to the platform when external AC power is removed.
Plug the power to platform cable on the machine into the the inverter power cable.
Move the inverter switch up to activate the inverter. Move the switch down to turn off the inverter. All boom functions will operate while the inverter is in use.

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Machine Not Level Indicator Light
If the tilt alarm sounds when the platform is raised, the Machine Not Level indicator light will come on and the drive function in one or both directions will not operate. Identify the condition of the boom on the slope as shown below. Follow the steps to lower the boom before moving to a firm, level surface. Do not rotate the boom while lowering.
If the tilt alarm sounds with the platform uphill:
1 Lower the boom.
2 Retract the boom.
If the tilt alarm sounds with the platform downhill:
1 Retract the boom.
2 Lower the boom.

Platform Overload Indicator Light
Light flashing indicates the platform is overloaded and no functions will operate. The platform control LCD screen will also display the following message, PLATFORM IS OVERLOADED.
Remove weight from the platform until the light goes off and the message in no longer displayed.

Overload Recovery
If the ground controls LCD screen displays OVERLOAD RECOVERY, the emergency lowering system has been used while the platform was overloaded. For information on how to reset this message, please consult the appropriate Genie Service Manual.

Tilt Sensor Activation Settings

Model

Chassis Angle

S-60 FE/DC

4.5°

When the Machine On Incline indicator light is on and the tilt alarm sounds, the following functions are affected; drive functions are disabled.
Follow the Boom lowering procedure (see Operating Instructions) to restore drive function.
When the machine is stowed, on a slope, and the tilt alarm sounds, the following functions are affected; lift functions are disabled.
Return the machine to level ground to restore lift functions.

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Operator’s Manual
Operating Instructions

Contact Alarm (if equipped)
The contact alarm is designed to alert ground personnel when an operator makes contact with the platform control panel, interrupting boom movement, sounding an alarm and flashing warning lights.
When the contact alarm cable is tripped, the lift and drive functions are disabled at the platform. The audio and visual warnings will activate alerting others that assistance may be needed. These notifications will continue until the system is reset.
1 The contact alarm cable is tripped, releasing the actuator from the switch socket.
2 Insert the actuator into the switch socket to turn off flashing lights and audio alarm.

Aircraft Protection Package (if equipped)
If the platform bumper comes into contact with an object, the machine will shut down and no functions will operate.
1 Start the engine.
2 Press down the foot switch.
3 Move and hold the aircraft protection override switch.
4 Move the appropriate function control handle or toggle switch to move the machine away from aircraft components.

a actuator b contact alarm cable c flashing alarm d switch socket

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-steer wheels.
4 Turn the key switch to the off position and remove the key to secure from unauthorized use.

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Battery and Charger Instructions
Observe and Obey:
Do not use an external charger or booster
battery.
Charge the battery in a well-ventilated area. Use proper AC input voltage for charging as
indicated on the charger.
Use only a Genie authorized battery and
charger.
To Charge Battery
FE Models: Use the engine or an external power source to recharge the batteries.
DC Models: Use an external power source to recharge the batteries.
Be sure the batteries are connected before charging the batteries.
If machine is equipped with flooded lead acid batteries, check the battery acid level when the charging cycle is complete. Replenish with distilled water to the bottom of the fill tube. Do not overfill.
If the batteries are not charged weekly the following message will appear on the platform control LCD screen, FULL PLUG-IN CHARGE ADVISED WEEKLY FOR BEST BATTERY LIFE.

FE Models: Charging Batteries with Engine
Running the engine will automatically charge the batteries.
The engine will automatically shut off when the battery charge cycle reaches 85%.
After the charge cycle reaches 85% the platform control panel LCD screen will display the following message, HYBRID CHARGE COMPLETE. PLUG IN FOR 100% CHARGE.
Charging Batteries with External Power
1 Connect the battery charger to a grounded AC circuit.
The charger will automatically shut off when the charging cycle is complete.
If machine is equipped with flooded lead acid batteries, check the battery acid level when the charging cycle is complete. Replenish with distilled water to the bottom of the fill tube. Do not overfill.

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Operator’s Manual
Operating Instructions

Dry Battery Filling and Charging Instructions
This procedure applies to flooded lead acid batteries only.
1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings.
2 Fill each cell with battery acid (electrolyte) until the level is sufficient to cover the plates.
Do not fill to maximum level until the battery charge cycle is complete. Overfilling can cause the battery acid to overflow during charging. Neutralize battery acid spills with baking soda and water.
3 Install the battery vent caps.
4 Charge the battery.
5 Check the battery acid level when the charging cycle is complete. Replenish with distilled water to the bottom of the fill tube. Do not overfill.

Pipe Cradle Instructions
The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform and mounted to the guardrails with U-bolts.

a strap b U-bolts c pipe cradle mount d upper platform railing e pipe cradle weldment f middle platform railing g flat washers h nylock nuts

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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 Installation
1 Insert the hook piece through the slots in the panel cradle base.
2 Hook the panel cradle to the bottom platform tube in the desired location.
3 Install rubber bumper 2 through the panel cradle base and the hook piece. See the illustration.
4 Secure with 2 low profile lock nuts.
5 If the panel cradle is installed at a platform floor support tube, insert the U-bolt through the floor, around the tube and into the panel cradle base.
6 Secure the U-bolt with 2 nuts and 2 washers. Proceed to step 9.
7 If the panel cradle is not installed at a platform floor support tube, use the aluminum tube provided.
8 Place the tube between the panel cradle and the platform floor. Insert the U-bolt through the floor, around the tube and into the panel cradle base.
9 Repeat above for the second set of parts.

Installation of Padding
1 Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails.
Installation of Strap
1 Open the clamp and install it around a vertical platform rail tube.
2 Insert a bolt with a washer through one 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 overtighten. The strap assembly end plate should be able to slide on the platform rail.

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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 the platform. 4 Secure the load to the platform using the
strap. Tighten the strap.

Operator’s Manual
Operating Instructions

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Transport and Lifting Instructions

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Transport and Lifting Instructions
Observe and Obey:
Genie provides this securement information as
a recommendation. Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations, other localized regulations, and their company policy.
Genie customers needing to containerize any
lift or Genie product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment.
Only qualified mobile elevating work platform
operators should move the machine on or off the truck.
The transport vehicle must be parked on a
level surface.
The transport vehicle must be secured to
prevent rolling while the machine is being loaded.
Be sure the vehicle capacity, loading 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. See the inspections section for the serial label location.

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 Driving on a Slope in the Operating Instructions section.
If the slope of the transport vehicle bed
exceeds the uphill or downhill maximum slope rating, the machine must be loaded and unloaded using a winch as described in the brake release operation. See the Specifications section for the slope ratings.

Free-wheel Configuration for Winching
Chock the wheels to prevent the machine from rolling.

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.

Disengage

Engage

Reverse the procedures described to re-engage the brakes.

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Operator’s Manual
Transport and Lifting Instructions

Securing to Truck or Trailer for Transit
Always use the turntable rotation lock pin each time the machine is transported.
1 Turntable rotation lock pin Turn the key switch to the off position and remove the key before transporting. Inspect the entire machine for loose or unsecured items. Note: Set the turntable rotation lock pin to 3° for efficient, multiple machine transportation.

Securing the Chassis Use chains of ample load capacity.
Use a minimum of 6 chains.
Adjust the rigging to prevent damage to the chains.
For diagram, refer to the Lifting Instructions.
Securing the Platform Make sure the jib and platform are in the stowed position.
Secure the platform with a nylon strap placed parallel to the strap guides. Do not use excessive downward force when securing the boom section.

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Observe and Obey:
Only qualified riggers should rig the machine.
Only certified crane operators should lift the
machine and only in accordance with the applicable crane regulations.
Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand the machine weight. See the serial label for the machine weight.

Lifting Instructions
Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine.
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.
Adjust the rigging to prevent damage to the machine and to keep the machine level.

Center of gravity S-60 FE/DC

X Axis 152.4 cm

Y Axis 124.5 cm

1 – X Axis 2 – Y Axis
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Maintenance

Operator’s Manual
Maintenance
Check the Engine Oil Level

Observe and Obey:
Only routine maintenance items specified in
this manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians, according to the manufacturer’s specifications and the requirements specified in the responsibilities manual.
Dispose of material in accordance with
governmental regulations.
Use only Genie approved replacement parts.
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 a maintenance procedure, it conveys the meaning below.
Indicates that tools will be required to perform this procedure.
Indicates that new parts will be required to perform this procedure.

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 the oil level with the engine off.

1 Check the oil level dipstick. Add oil as needed.

Kubota D1105-E4B Engine Oil type

SAE10W or 10W-30

Diesel Fuel Requirements

Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following result: long engine life and acceptable exhaust emissions levels.
Minimum diesel fuel requirements for each engine are listed below.

Kubota D1105-E4B Engine

Fuel Type

Low Sulfur Diesel (LSD) or
Ultra Low Sulfur Diesel (ULSD)

Indicates that a cold engine is required before performing this procedure.

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Maintenance

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Check the Hydraulic Oil Level

Check the Engine Coolant Level ­ Liquid Cooled Models

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.
2 Visually inspect the sight gauge located on the side of the hydraulic oil tank.
Result: The hydraulic oil level should be within the top 5 cm of the sight gauge.
3 Add oil as needed. Do not overfill.

Hydraulic oil specifications

Hydraulic oil type

Shell Tellus S4 VX 32 equivalent

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 parts and coolant. Contact with hot engine parts and/or coolant may cause severe burns.
Burn hazard. Do not remove the radiator cap if the engine has been running. Contact with pressurized coolant may cause severe burns. Allow engine to cool before removing the radiator cap.
1 Check the fluid level in the coolant recovery tank. Add fluid as needed.
Result: The fluid level should be at the FULL mark on the tank or visible in the sight gauge.

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Operator’s Manual
Maintenance

Check the Batteries
Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions.
Electrocution hazard. Contact with hot or live circuits may result in death or serious injury. Remove all rings, watches and other jewelry.
Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are tight and free of corrosion.
3 Be sure that the battery hold-down brackets are in place and secure.
Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables.

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 and maintenance manuals 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.

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Specifications

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Specifications
Model

S-60 FE/DC

Height, working maximum

67 ft 2 in 20.6 m

Height, platform maximum

61 ft 2 in 18.6 m

Horizontal reach, platform maximum

40 ft 6 in 12.3 m

Maximum load capacity

660 lbs 300 kg

Maximum wind speed

28 mph 12.5 m/s

Platform rotation

160°

Platform leveling

self-leveling

Turntable rotation (degrees)

353° non-continuous

Turntable tailswing, Riser down

5 ft 2 in 1.57 m

Turntable tailswing, Riser up

4 ft 1 in 1.24 m

Height, stowed maximum

8 ft 12 in 2.73 m

Length, stowed

31 ft 8 in 9.65 m

Width, standard tires

8 ft 2 in 2.49 m

Wheelbase

8 ft 2in 2.48 m

Ground clearance, center

18.3 in 46.4 cm

Ground clearance, axle (Middle)

10.7 in 27.1 cm

Ground clearance, axle (End)

8.8 in 22.3 cm

Turning radius (inside)

10 ft 0 in 3.06 m

Turning radius (outside)
Platform dimensions, 6 foot (length x width)
Platform dimensions, 8 foot (length x width)

17 ft 3 in 5.25 m 72 in x 30 in 182 cm x 76 cm
96 in x 36 in 244 cm x 91 cm

Weight (8ft Platform) Hybrid

17750 lbs

8051 kg

Weight (8ft Platform) DC

17600 lbs

7983 kg

(Machine weights vary with option configurations. See serial label for specific machine weight.)

Airborne noise emissions

Sound pressure level at ground workstation 83 dBA

Sound pressure level at platform workstation

76 dBA

Guaranteed sound power level

105 dBA

Total vibration value to which the hand/arm system is subjected does not exceed 2.5 m/s2.
Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0.5 m/s2.

Ambient operating temperature
Controls AC outlet in platform System voltage Hydraulic pressure, maximum (boom functions) Tire size Fuel tank capacity Hydraulic tank capacity

-20° F to 120° F -29° C to 49° C 24V DC proportional
Standard 48V
3000 psi 207 bar
355/55 D625, FF 17 gallons 64 liters 18 gallons 68 liters

Maximum slope rating, stowed position, 4WD

Platform uphill

30% (17°)

Platform downhill

45% (24°)

Side slope

25% (14°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating.

Drive speeds Drive speed, stowed
Drive speed, raised or extended

4 mph 5.9 ft/sec
0.68 mph 1 ft/sec

6.4 km/h 1.8 m/sec
1.1 km/h 0.30 m/sec

Floor loading information

Tire load maximum

10454 lbs

4742 kg

Tire contact pressure

73 psi

5.10 kg/cm2 500 kPa

Occupied floor pressure

203 psf

993 kg/m2 9.74 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

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Operator’s Manual
Specifications

Maximum platform capacity

1

660 lbs

Horizontal Values

2

-10 ft

3

0 ft

4

10 ft

5

20 ft

6

30 ft

300 kg
-3 m 0 m 3 m 6.1 m 9.1 m

Vertical Values

7

40 ft

8

50 ft

9

60 ft

10

70 ft

12.2 m 15.2 m 18.3 m 21.3 m

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Contents of EC Declaration of Conformity
<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives:
1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate issued by:
Kuiper Certificering B.V. Van Slingelandtstraat 75, 7331NM Apeldoorn Netherlands NB number 2842

2. EC Directive EMC: 2014/30/EU, under consideration of harmonized European standard EN 61000-62 and EN 61000-6-4

3. EC Directive 2000/14/EC, Noise Directive, under consideration of Annex V and harmonized standard EN ISO 3744, internal combustion engine only.

Test Report: This machine has been tested and passed the following categories per EN 280:2013+A1:2015 clause 6.3 prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse. 2. OVERLOAD: Overload tested at XXX% rated load. 3. FUNCTIONAL: Smooth operation at XXX% rated load. 4. FUNCTIONAL: All safety devices working correctly. 5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type:

Manufacture Date:

Description:

Country of Manufacture:

Model:

Net Installed Power:

Serial Number:

Guaranteed Sound Power Level:

VIN:

Manufacturer: <Manufacturer’s name>

Authorized Representative:
Genie Industries B.V Boekerman 5, 4751 XK Oud Gastel, The Netherlands

Empowered signatory:

Place of Issue:

S®-60 DC · S®-60 FE

Part No. 1299606GT

Date of Issue:
Operator’s Manual

First Edition · First Printing

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References

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