Genie S60X Manual de Operación

Operator's Manual
Serial Number Range
S-60X From S6010-21001

ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
First Edition
Fifth Printing
Part No. T107102
Operator's Manual First Edition Fifth Printing
Front Matter
Important Contents
Read, understand and obey these safety rules Introduction ........................................................... 1
and operating instructions before operating this Symbol and Hazard Pictorials Definitions ............. 3
machine. Only trained and authorized personnel
General Safety ...................................................... 5
shall be permitted to operate this machine. This
manual should be considered a permanent part of Personal Safety................................................... 11
your machine and should remain with the machine Work Area Safety ................................................ 12
at all times. If you have any questions, contact us. Legend ................................................................ 21
Controls ............................................................... 22
Contact Us: Inspections .......................................................... 30
Operating Instructions ......................................... 44
Internet: www.genielift.com
Towing Instructions ............................................. 56
E-mail: awp.techpub@terex.com Transport and Lifting Instructions ....................... 57
Maintenance ....................................................... 60
Specifications ...................................................... 64
Copyright 2010 by Terex Corporation

First Edition: Fifth Printing, July 2013
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
S-60X Part No. T107102

First Edition Fifth Printing Operator's Manual
Introduction
Introduction
Owners, Users and Operators:

Thank you for choosing our machine for your
application. Our number one priority is user safety,
which is best achieved by our joint efforts. We feel
that you make a major contribution to safety if you,
as the equipment users and operators:
1 Comply with employer, job site and Danger
governmental rules.
Failure to obey the instructions and
2 Read, understand and follow the instructions
in this and other manuals supplied with this safety rules in this manual will result
machine. in death or serious injury.
3 Use good safe work practices in a
commonsense way.
Do Not Operate Unless:
4 Only have trained/certified operators,
directed by informed and knowledgeable You learn and practice the principles of safe
supervision, running the machine. machine operation contained in this operators
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
manufacturers instructions and safety
rulessafety and operators manuals and
machine decals.
You read, understand and obey employers
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Part No. T107102 S-60X 1

Introduction
Hazard Classification Intended Use

Decals on this machine use symbols, color coding This machine is intended to be used only to lift
and signal words to identify the following: personnel, along with their tools and materials to
an aerial work site.
Safety alert symbolused to alert
you to potential personal injury
hazards. Obey all safety Safety Sign Maintenance
messages that follow this symbol Replace any missing or damaged safety signs.
to avoid possible injury or death. Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
DANGER Indicates a hazardous situation
which, if not avoided, will result in
solvent-based cleaners because they may damage
the safety sign material.
death or serious injury.
WARNING Indicates a hazardous situation

which, if not avoided, could result
in death or serious injury.
CAUTION Indicates a hazardous situation

which, if not avoided, could result
in minor or moderate injury.
NOTICE Indicates a property damage

message.
2 S-60X Part No. T107102

Symbol and Hazard Pictorials Definitions

Crush hazard Keep away from Explosion hazard No smoking. Electrocution hazard
moving parts No flame.
Stop engine.
Maintain required Crush hazard Keep away from path Fall hazard Keep off this surface.
clearance of moving platform
Tip-over hazard Platform downhill: Platform uphill: Tip-over hazard Replace tracks with
1 Retract boom. 1 Lower boom. same tracks.
2 Lower boom. 2 Retract boom.
Tip-over hazard Read the operators Only trained Tip-over hazard See serial label for
manual maintenance rated capacity.
personnel should
access
compartments
Part No. T107102 S-60X 3

Lanyard attachment Wheel load Voltage rating for Pressure rating for air Have fire
point power to platform line to platform extinguisher near.
Electrocution hazard Avoid contact Tie-down instructions Read the service

manual
Tie-down instructions Explosion / Burn Explosion hazard Do not use ether or

hazard other high energy
starting aids on
machines equipped
with glow plugs
4 S-60X Part No. T107102

General Safety
General Safety
Part No. T107102 S-60X 5

General Safety
6 S-60X Part No. T107102

General Safety
Part No. T107102 S-60X 7

General Safety
8 S-60X Part No. T107102

General Safety
Part No. T107102 S-60X 9

General Safety
10 S-60X Part No. T107102

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
manufacturers instructions.
Part No. T107102 S-60X 11

Work Area Safety

Work Area Safety
Electrocution Hazards Tip-over Hazards

This machine is not electrically insulated and will Occupants, equipment and materials shall not
not provide protection from contact with or exceed the maximum platform capacity for the
proximity to electrical current. restricted or unrestricted range of motion.
Obey all local and Maximum platform capacity 500 lbs 227 kg
governmental regulations Unrestricted range of motion
regarding required Maximum occupants 2
clearance from electrical
power lines. At a minimum, Maximum platform capacity 1000 lbs 454 kg
the required clearance Restricted range of motion
contained in the chart Maximum occupants 3
below must be followed.
If the restricted range of motion is selected for the
maximum platform capacity, do not move the
platform into the unrestricted range of motion zone.
Line Voltage Required Clearance Do not exceed the selected maximum platform
0 to 50KV 10 ft 3.05 m capacity.
50 to 200KV 15 ft 4.60 m Do not attach a platform rated at 500 lbs / 227 kg
200 to 350KV 20 ft 6.10 m (unrestricted range of motion) or 1000 lbs / 454 kg
350 to 500KV 25 ft 7.62 m (restricted range of motion) to machines with any
other rated load. See the serial label for the
500 to 750KV 35 ft 10.67 m
maximum rated load.
750 to 1000KV 45 ft 13.72 m
The weight of options and accessories, such as
Allow for platform movement, electrical line sway pipe cradles, panel cradles and welders, will
or sag, and beware of strong or gusty winds. reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
Keep away from the decals with the options and accessories.
machine if it contacts
energized power lines. If using accessories, read, understand and obey
Personnel on the ground the decals, instructions and manuals with the
or in the platform must accessory.
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.
12 S-60X Part No. T107102

Work Area Safety

Do not raise or extend the Do not raise the boom
boom unless the machine when wind speeds may
is on a firm, level surface. exceed 28 mph / 12.5 m/s.
If wind speeds exceed
28 mph / 12.5 m/s when
the boom is raised, lower
the boom and do not
continue to operate the
machine.
Do not operate the machine in strong or gusty

winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.
Use extreme care and

slow speeds while driving
the machine in the
stowed position across
uneven terrain, debris,
Do not depend on the tilt alarm as a level indicator. unstable or slippery
The tilt alarm sounds in the platform only when the surfaces and near holes
machine is on a severe slope. and drop-offs.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the Do not drive the machine on or near uneven terrain,
boom on the slope as shown below. Follow the unstable surfaces or other hazardous conditions
steps to lower the boom before moving to a firm, with the boom raised or extended.
level surface. Do not rotate the boom while
lowering. Do not use the machine as a crane.
Do not push the machine or other objects with the
If the tilt alarm sounds with the
boom.
platform uphill:
Do not contact adjacent structures with the boom.
1 Lower the boom.
2 Retract the boom. Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
If the tilt alarm sounds with the
platform downhill:
1 Retract the boom.
2 Lower the boom.
Part No. T107102 S-60X 13

Work Area Safety
Do not push off or pull Do not transport tools and materials unless they
toward any object outside are evenly distributed and can be safely handled
of the platform. by person(s) in the platform.
Do not use the machine on a moving or mobile
Maximum allowable
surface or vehicle.
side force ANSI & CSA
150 lbs / 667 N Be sure all tires are in good condition, air-filled
tires are properly inflated and lug nuts are properly
tightened.
Do not alter or disable machine components that in Do not use the platform controls to free a platform
any way affect safety and stability. that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
Do not replace items critical to machine stability personnel must be removed from the platform
with items of different weight or specification. before attempting to free the platform using the
ground controls.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Do not modify or alter an aerial work platform
Operation on Slopes Hazards
without prior written permission from the Do not drive the machine on a slope that exceeds
manufacturer. Mounting attachments for holding the maximum uphill, downhill or side slope rating of
tools or other materials onto the platform, the machine. Slope rating applies only to machines
toeboards or guard rail system can increase the in the stowed position.
weight in the platform and the surface area of the
platform or the load. Maximum slope rating, stowed position, 2WD
Platform downhill 30% (17)
Do not place or attach
fixed or overhanging loads Platform uphill 10% (6)
to any part of this Side slope 25% (14)
machine. Maximum slope rating, stowed position, 4WD
Platform downhill 45% (24)
Platform uphill 30% (17)
Side slope 25% (14)
Note: Slope rating is subject to ground conditions

Do not place ladders or and adequate traction. See Driving on a Slope in
scaffolds in the platform or the Operating Instructions section.
against any part of this
machine.
14 S-60X Part No. T107102

Work Area Safety
Fall Hazards Collision Hazards

Occupants must wear a Be aware of limited sight
safety belt or harness in distance and blind spots
accordance with when driving or operating.
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform. Be aware of the boom position and tailswing when
rotating the turntable.
Do not sit, stand or climb
on the platform guard Check the work area for
rails. Maintain a firm overhead obstructions or
footing on the platform other possible hazards.
floor at all times.
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 Operators must comply with employer, job site and
gate before operating. governmental rules regarding use of personal
protective equipment.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform Observe and use the color-coded direction arrows
is at ground level. on the platform controls and drive chassis for drive
and steer functions.
Part No. T107102 S-60X 15

Work Area Safety
Do not lower the boom Bodily Injury Hazard

unless the area below is
clear of personnel and Always operate the machine in a well-ventilated
obstructions. 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
Limit travel speed
maintenance personnel should access
according to the
compartments. Access by the operator is only
condition of the ground
advised when performing a pre-operation
surface, congestion,
inspection. All compartments must remain closed
slope, location of
and secured during operation.
personnel, and any other
factors which may cause
collision. Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
Do not operate a boom in the path of any crane petroleum gas (LPG), gasoline, diesel fuel or other
unless the controls of the crane have been locked explosive substances.
out and/or precautions have been taken to prevent
any potential collision. Do not refuel the machine with the engine running.
No stunt driving or horseplay while operating a Refuel the machine and charge the battery only in
machine. an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.
16 S-60X Part No. T107102

Work Area Safety
Damaged Machine Hazards Battery Safety

Do not use a damaged or malfunctioning machine.
Burn Hazards
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work Batteries contain acid.
shift. Immediately tag and remove from service a Always wear protective
damaged or malfunctioning machine. clothing and eye wear when
working with batteries.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie Avoid spilling or contacting
service manual. battery acid. Neutralize
battery acid spills with
Be sure all decals are in place and legible. baking soda and water.
Be sure the operators, safety and responsibilities
manuals are complete, legible and in the storage Explosion Hazards
container located on the platform.
Keep sparks, flames and
lighted tobacco away from
Component Damage Hazards batteries. Batteries emit
Do not use any battery or charger greater than 12V explosive gas.
to jump-start the engine.
Do not use the machine as a ground for welding.
Electrocution Hazard
Avoid contact with electrical terminals.
Part No. T107102 S-60X 17

Work Area Safety
Welder Safety Weld Line to Platform Safety

Read, understand and obey all warnings and Read, understand and obey all warnings and
instructions provided with the welding power unit. instructions provided with the welding power unit.
Do not connect weld leads or cables unless the Do not connect weld leads or cables unless the
welding power unit is turned off at the platform welding power unit is turned off at the platform
controls. controls.
Do not operate unless the weld cables are properly Do not operate unless the weld cables are properly
connected and the welder is properly grounded. connected.
The weight of the welder will reduce the rated Connect the positive lead to the twist-lock
platform capacity and must be factored into the connector at the turntable and platform.
total platform load. The welder power supply
weighs 75 lbs / 34 kg. Clamp the negative lead to the ground post at the
turntable and platform.
Do not operate the welder unless a fire
extinguisher is immediately available for instant
use, per OSHA regulation 1926.352(d).
18 S-60X Part No. T107102

Work Area Safety
Pipe Cradle Safety Panel Cradle Safety

Read, understand and obey all warnings and Read, understand and obey all warnings and
instructions provided with the pipe cradles. instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe combined weight of the cradles, panels, occupants,
cradles will reduce rated platform capacity and tools and any other equipment must not exceed
must be factored into total platform load. rated capacity.
The pipe cradle assembly weighs 21 lbs / 9.5 kg. The panel cradle assembly weighs 30 lbs /
13.6 kg.
The maximum capacity of the pipe cradle
assembly is 200 lbs / 91 kg. The maximum capacity of the panel cradles is
250 lbs / 113 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum The weight of the panel cradles and the load in the
number of occupants in platform. panel cradles may limit the maximum number of
occupants in platform to one person.
Center the load within the perimeter of the
platform. Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
Secure the load to the platform. provided.
Do not obstruct the entrance or the exit of the Do not operate unless you are adequately
platform. instructed and are aware of all hazards associated
Do not obstruct the ability to operate the platform with lifting panels.
controls or the red Emergency Stop button. Do not cause a horizontal force or side load to
Do not operate unless you are adequately machine by raising or lowering a fixed or
instructed and are aware of all of the hazards overhanging load.
associated with movement of the platform with an Maximum vertical height of panels: 4 ft / 1.2 m
overhanging load.
Maximum wind speed:15 mph / 6.7 m/sec
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or Maximum panel area: 32 sq ft / 3 m2
overhanging load.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.
Part No. T107102 S-60X 19

Work Area Safety
Tow Package Safety Lockout After Each Use

Read, understand and obey all warnings and 1 Select a safe parking locationfirm level
instructions provided with the tow package. surface, clear of obstruction and traffic.
When vehicle is in free-wheel configuration, there 2 Retract and lower the boom to the stowed
are no brakes and machine may move, resulting in position.
death, serious injury or property damage. 3 Rotate the turntable so that the boom is
Do not exceed maximum towing speed, or between the non-steer wheels.
maximum towing time. 4 Turn the key switch to the off position and
remove the key to secure from unauthorized
Maximum tow speed 8 mph / 12.87 km/h use.
Maximum towing time at
30 minutes 5 Chock the wheels.
8 mph / 13 km/h
Maximum towing time at
60 minutes
6 mph / 10 km/h
20 S-60X Part No. T107102

Legend
Legend
10
1 Non-steer tire 6 Platform

2 Steer tire 7 Lanyard anchorage point
3 Ground controls 8 Sliding mid-rail
4 Boom 9 Manual storage container
5 Platform controls 10 Foot switch
Part No. T107102 S-60X 21

Controls
Controls
1 2 3 4 5 6
25 24 23 22 21 20 19
22 S-60X Part No. T107102

Controls
7 8 9 10 11 12 13
STOP
18 17 16 15 14
Part No. T107102 S-60X 23

Controls
Platform Control Panel 6 Emergency power switch

Use emergency power if the primary power
1 Horn button
source (engine) fails.
Press this button and the horn will sound. Simultaneously hold the emergency power
Release the button and the horn will stop. switch to either side and activate the desired
function.
2 Platform level switch
7 Machine not level indicator light
Move the platform level
switch up and the level of Light is on when the tilt alarm is sounding.
the platform will raise. Move the machine to level ground.
Move the platform level 8 Generator switch (if equipped)
switch down and the level
of the platform will lower. Move the generator switch up to activate the
generator. Move the switch down to turn off
3 Platform rotate switch the generator.
Move the platform rotate 9 1000 lbs / 454 kg capacity indicator light
switch to the left and the Light on indicates that the selected platform
platform will rotate left. capacity is 1000 lbs / 454 kg. The range of
Move the platform rotate motion is restricted.
switch to the right and the
platform will rotate right. 10 Platform capacity select switch
Move the platform capacity select switch to the
4 Jib boom up/down switch
left to select 1000 lbs / 454 kg platform
Move the jib boom switch capacity. Move the platform capacity select
up and the jib boom will switch to the right to select 500 lbs / 227 kg
raise. Move the jib boom platform capacity.
switch down and the jib 11 500 lbs / 227 kg capacity indicator light
boom will lower.
Light on indicates that the selected platform
5 Drive speed select switch capacity is 500 lbs / 227 kg. The range of
motion is unrestricted.
Machine on incline symbol: Low range
operation for inclines. 12 Used for optional equipment
Machine on level surface symbol: High range
operation for maximum drive speed.
24 S-60X Part No. T107102

Controls
13 Red Emergency Stop button 15 Drive enable switch
Push in the red Emergency Stop button to the To drive when the drive enable light is on, hold
off position to stop all functions and turn the the drive enable switch to either side and
engine off. Pull out the red Emergency Stop slowly move the drive control handle off center.
button to the on position to operate the Be aware that the machine may move in the
machine. opposite direction that the drive and steer
controls are moved.
14 Dual axis proportional control handle for drive
and steer functions 16 Drive enable indicator light
OR Proportional control handle for drive
Light on indicates that the boom has moved
function and thumb rocker for steer function.
just past either non-steer wheel and drive
Move the control handle in the direction function has been interrupted.
indicated by the blue arrow on the control
17 Deutz Diesel Models: Glow plug switch (if
panel and the machine will drive forward.
equipped)
Move the control handle in the direction
indicated by the yellow arrow and the machine Move the glow plug switch to either side and
will drive backwards. Move the control handle hold for 3 to 5 seconds.
in the direction indicated by the blue triangle
Perkins Models: Glow plug indicator light.
and the machine will steer to the left. Move the
control handle in the direction indicated by the 18 Engine idle (rpm) select switch
yellow triangle and the machine will steer to
the right. Move the engine idle select switch to the turtle
OR position for foot switch activated low idle.
Move the control handle in the direction Move the engine idle select switch to the rabbit
indicated by the blue arrow on the control position for foot switch activated high idle.
panel and the machine will drive forward. 19 Models with LCD screen: Engine shut-down
Move the control handle in the direction indicator light
indicated by the yellow arrow and the machine
will drive backwards. Press the left side of the Light on indicates that the engine has shut
thumb rocker and the machine will steer to the down. Contact service personnel.
left. Press the right side of the thumb rocker
and the machine will steer to the right.
Part No. T107102 S-60X 25

Controls
20 Gasoline/LPG models: Fuel select switch 25 Dual axis proportional control handle for
primary boom up/down and turntable rotate
Move the fuel select switch to the gasoline
left/right functions
position to select gasoline. Move the fuel
select switch to the LPG position to select Move the control handle up
LPG. and the primary boom will
21 Engine start switch raise. Move the control
handle down and the
Move the engine start switch to either side to primary boom will lower.
start the engine.
Move the control handle to
22 Machine malfunction indicator light the right and the turntable
Light on indicates all functions have stopped. will rotate to the right. Move
See the instructions in the Operating the control handle to the left
Instructions section. and the turntable will rotate
to the left.
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.
26 S-60X Part No. T107102

Controls
The S-60X machines will have one of these two 21
styles of ground control panel. The descriptions in
14
this section and the instructions in the Function Test
and Operating Instructions apply to both panels, 22
unless specifically noted. 5
20 16
13 14 15 16 STOP
23
4
1000 lbs / 500 lbs /

454 kg 227 kg
12
18
12 1100 lbs /
500 kg
660 lbs /
300 kg
17 11
11 15
9
10 18
9 19
19
8
7
8
!
6
5
17 13 10 13 2
4
Part No. T107102 S-60X 27

Controls
Ground Control Panel 8 Turntable rotate switch

Move the turntable rotate switch to the right
1 LCD readout screen
and the turntable will rotate to the right. Move
Screen displays hour meter, voltage, oil the turntable rotate switch to the left and the
pressure and coolant temperature. Screen turntable will rotate to the left.
also displays fault codes and other service
9 Boom up/down switch
information.
Move the boom up/down switch up and the
2 Not used
boom will raise. Move the boom up/down
3 Not used switch down and the boom will lower.
4 Engine start switch 10 Machine malfunction indicator light
Move the engine start switch to either side to Light on indicates all functions have stopped.
start the engine. See the instructions in the Operating
Instructions section.
5 Engine idle (rpm) select switch
11 Boom extend/retract switch
Move the engine idle select switch to the turtle
position for foot switch activated low idle. Move the boom extend/retract switch to the
Move the engine idle select switch to the rabbit right and the boom will extend. Move the boom
position for foot switch activated high idle. extend/retract switch to the left and the boom
will retract.
6 Not used
12 Platform capacity select/function enable switch
7 Emergency power switch
Move and hold the platform capacity
Use emergency power if the primary power
select/function enable switch to select the
source (engine) fails.
platform capacity and enable the ground
Simultaneously hold the emergency power
control panel functions to operate. The range
switch to either side and activate the desired
of motion is restricted if 1000 lbs / 454 kg
function.
platform capacity is selected.
13 Circuit breakers
14 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.
28 S-60X Part No. T107102

Controls
15 Jib boom up/down switch 21 Glow plug switch
Move the jib boom switch up and the jib boom Move the glow plug switch to either side and
will raise. Move the jib boom switch down and hold for 3 to 5 seconds.
the jib boom will lower.
22 Gasoline/models: Fuel select switch
16 Red Emergency Stop button
Move the fuel select switch to the gasoline
Push in the red Emergency Stop button to the position to select gasoline. Move the fuel
off position to stop all functions and turn the select switch to the LPG position to select
engine off. Pull out the red Emergency Stop LPG.
button to the on position to operate the
23 Check engine light
machine.
Light on and engine stopped: Tag the machine
17 Not used
and remove from service.
18 Platform level switch Light on and engine still running: Contact
service personnel within 24 hours.
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 left.
20 Hour meter
The hour meter displays the number of hours
the machine has operated.
Part No. T107102 S-60X 29

Inspections
Inspections
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.
Do Not Operate Unless: The inspection is designed to discover if anything
is apparently wrong with a machine before the
You learn and practice the principles of safe operator performs the function tests.
machine operation contained in this operators
manual. The pre-operation inspection also serves to
determine if routine maintenance procedures are
1 Avoid hazardous situations.
required. Only routine maintenance items specified
2 Always perform a pre-operation in this manual may be performed by the operator.
inspection.
Refer to the list on the next page and check each
Know and understand the pre-operation of the items.
inspection before going on to the next
section. If damage or any unauthorized variation from
factory delivered condition is discovered, the
3 Always perform function tests prior to use. machine must be tagged and removed from
4 Inspect the workplace. service.
5 Only use the machine as it was intended. Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturers specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturers specifications and
the requirements listed in the responsibilities
manual.
30 S-60X Part No. T107102

Inspections
Pre-operation Inspection Engine and related components

Limit switches and horn
Be sure that the operators, safety and
Alarms and beacons (if equipped)
responsibilities manuals are complete, legible
and in the storage container located in the Nuts, bolts and other fasteners
platform.
Platform entry mid-rail or gate
Be sure that all decals are legible and in place.
Check entire machine for:
See Inspections section.
Check for hydraulic oil leaks and proper oil Cracks in welds or structural components
level. Add oil if needed. See Maintenance Dents or damage to machine
section.
Excessive rust, corrosion or oxidation
Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See Be sure that all structural and other critical
Maintenance section. components are present and all associated
fasteners and pins are in place and properly
Check for engine oil leaks and proper oil level. tightened.
Add oil if needed. See Maintenance section.
After you complete your inspection, be sure
Check for engine coolant leaks and proper that all compartment covers are in place and
level of coolant. Add coolant if needed. See latched.
Maintenance section.
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
Part No. T107102 S-60X 31

Inspections
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
Do Not Operate Unless: tagged and removed from service. Repairs to the
You learn and practice the principles of safe machine may only be made by a qualified service
machine operation contained in this operators technician, according to the manufacturers
manual. specifications.
1 Avoid hazardous situations. After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.
3 Always perform function tests prior to
use.
Know and understand the function tests
before going on to the next section.
32 S-60X Part No. T107102

Inspections
At the Ground Controls Test the Machine Functions and the

Platform Capacity Selection
1 Select a test area that is firm, level and free of
obstruction. 7 Do not move and hold
the platform capacity
2 Turn the key switch to ground control.
select/function enable
3 Pull out the red Emergency Stop button to the switch. Attempt to
on position. activate each boom and
platform function toggle
Result: The beacons (if equipped) should
switch.
flash.
4 Start the engine. See Operating Instructions Result: No boom and platform functions should
section. operate.
8 Move and hold the platform capacity
Test Emergency Stop select/function enable switch to select 500 lbs /
5 Push in the red Emergency Stop button to the 227 kg platform capacity. Activate each boom
off position. and platform function toggle switch.
Result: The engine should shut off and no Result: All boom and platform functions should
functions should operate. operate through a full cycle. The descent
alarm should sound while the boom is
6 Pull out the red Emergency Stop button to the lowering.
on position and restart the engine.
select/function enable switch to select 1000 lbs
/ 454 kg platform capacity. Raise and extend
the boom.
/ 454 kg platform capacity. Lower the boom.
Result: The boom should stop part way down.
/ 454 kg platform capacity. Retract the boom.
12 Retract the boom to continue and then fully
retract and lower the boom.
Part No. T107102 S-60X 33

Inspections
Test the Tilt Sensor At the Platform Controls
13 Pull out the platform red Emergency Stop
button to the on position. Turn the key switch Test Emergency Stop
to platform control.
19 Enter the platform and pull out the red
14 Open the tank side turntable Emergency Stop button. Start the engine.
cover and locate the tilt 20 Push in the platform red Emergency Stop
sensor next to the fuel tank. button to the off position.
15 Press down one side of the Result: The engine should shut off and no
tilt sensor. functions should operate.
21 Pull out the red Emergency Stop button and
restart the engine.
Test the Horn

Result: The alarm, located in the platform,
should sound. 22 Press the horn button.
23 Result: The horn should sound.
Test Emergency Controls
16 Turn the key switch to ground control and shut
the engine 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.
34 S-60X Part No. T107102

Inspections
Test the Machine Functions and the Test the Foot Switch
Platform Capacity Selection 29 Push in the platform red Emergency Stop
Note: Perform this test with less than 500 lbs / button to the off position.
227 kg in the platform. 30 Pull out the red Emergency Stop button to the
24 Pull out the red Emergency Stop button to the on position and do not start the engine.
on position. 31 Press down the foot switch and attempt to start
Result: Both capacity indicator lights should the engine by moving the start toggle switch to
flash. either side.
25 Press down the foot switch. Test each Result: The engine should not start.
machine function. 32 Do not press down the foot switch and restart
Result: The boom raise and extend functions the engine.
should not operate. Result: The engine should start.
26 Move the platform capacity select switch to the 33 Do not press down the foot switch and test
left to select 1000 lbs / 454 kg capacity. each machine function.
27 First, fully raise and then fully extend the boom Result: No functions should operate.
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.
28 Retract the boom to continue and then fully
retract and lower the boom.
Part No. T107102 S-60X 35

Inspections
Test the Steering Test Drive and Braking
34 Press down the foot switch. 37 Press down the foot switch.
35 Press the thumb rocker switch on top of the 38 Slowly move the drive control handle in the
drive control handle in the direction indicated direction indicated by the blue arrow on the
by the blue triangle on the control panel OR control panel until the machine begins to
slowly move the control handle in the direction move, then return the handle to the center
indicated by the blue triangle. position.
Result: The steer wheels should turn in the Result: The machine should move in the
direction that the blue triangles point on the direction that the blue arrow points on the drive
drive chassis. chassis, then come to an abrupt stop.
36 Press the thumb rocker switch in the direction 39 Slowly move the control handle in the direction
indicated by the yellow triangle on the control indicated by the yellow arrow on the control
panel OR slowly move the control handle in panel until the machine begins to move, then
the direction indicated by the yellow triangle. return the handle to the center position.
Result: The steer wheels should turn in the Result: The machine should move in the
direction that the yellow triangles point on the direction that the yellow arrow points on the
drive chassis. 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.
36 S-60X Part No. T107102

Inspections
Test the Oscillating Axle (if equipped) Test the Drive Enable System
40 Start the engine from the platform controls. 44 Press down the foot switch and lower the
boom to the stowed position.
41 Drive the right steer tire up onto a 6 in / 15 cm
block or curb. 45 Rotate the turntable until the boom moves past
one of the non-steer wheels.
Result: The three remaining tires should stay
in firm contact with the ground. Result: The drive enable
42 Drive the left steer tire up onto a 6 in / 15 cm indicator light should come
block or curb. on and remain on while the
boom is anywhere in the
Result: The three remaining tires should stay range shown.
in firm contact with the ground.
46 Move the drive control handle off center.
43 Drive both steer tires up onto a 6 in / 15 cm
block or curb. Result: The drive function should not operate.
Result: The non-steer tires should stay in firm 47 Move and hold the drive enable toggle switch
contact with the ground. 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.
Part No. T107102 S-60X 37

Inspections
Test Limited Drive Speed Test Emergency Controls
48 Press down the foot switch. 54 Shut off the engine.
49 Raise the boom to just above horizontal. 55 Pull out the red Emergency Stop button to the
on position.
56 Press down the foot switch.
57 Simultaneously hold the emergency power
switch on and activate each function control
handle or toggle switch.
50 Slowly move the control handle to full drive
position. Note: To conserve battery power, test each
function through a partial cycle.
Result: The maximum achievable drive speed
with the boom raised should not exceed 1 ft / Result: All boom and steer functions should
30 cm per second. operate. Drive functions should not operate
with emergency power.
51 Lower the boom to the stowed position.
52 Extend the boom 18 inches / 46 cm.
53 Slowly move the control handle to 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
extended exceeds 1 ft / 30 cm per second,
immediately tag and remove the machine from
service.
38 S-60X Part No. T107102

Inspections
Workplace Inspection Checklist

Be aware of and avoid the following hazardous
situations:
drop-offs or holes
bumps, floor obstructions or debris
Do Not Operate Unless: sloped surfaces

unstable or slippery surfaces
You learn and practice the principles of safe
machine operation contained in this operators overhead obstructions and high voltage
manual. conductors
1 Avoid hazardous situations. hazardous locations
2 Always perform a pre-operation inspection. inadequate surface support to withstand all
load forces imposed by the machine
3 Always perform function tests prior to use.
wind and weather conditions
the presence of unauthorized personnel
Know and understand the workplace
inspection before going on to the next other possible unsafe conditions
section.
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 operators responsibility to read and
remember the workplace hazards, then watch for
and avoid them while moving, setting up and
operating the machine.
Part No. T107102 S-60X 39

Inspections
Inspection for Decals with Words Part No. Decal Description Qty
97548 Instructions Deutz Engine 1
Determine whether the decals on your machine
Specifications (F3L 2011 & D2011 L03i)
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in 97579 Danger Tip-over Welder (option)
place. 97602 Warning Explosion Hazard 1
97815 Label Lower Mid-rail 1
Below is a numerical list with quantities and
descriptions. 97875 Warning Weld Line to Platform 2
97887 Instructions Max Side Force, 150 lbs / 1
Part No. Decal Description Qty 667 N, ANSI
25994 Notice Component Damage Hazard 1 114099 Label Transport Diagram 2
27204 Arrow Blue 1 114169 Instructions Ford Engine Specifications 1
27205 Arrow Yellow 1 (DSG-423)
27206 Triangle Blue 2 114258 Danger Explosion Hazard 1
27207 Triangle Yellow 2 114277 Label Belt Routing (DSG-423) 1
28158 Label Unleaded 1 114389 Danger Safety Rules 2
28159 Label Diesel 1 114390 Danger Electrocution Hazard 2
28160 Label Liquid Petroleum Gas 1 114416 Danger Tip-over Hazard, Tilt Alarm 1
28161 Warning Crushing Hazard 4 133278 Label Low Sulfur Fuel (diesel models) 1
28165 Instructions Foot Switch 1 147575 Platform Control Panel 1
28174 Label Power to Platform, 230V 2 147605 Instructions Maximum Capacity Load 3
Chart
28175 Warning Compartment Access 1
147609 Instructions Operating Instructions, 1
28176 Label Missing Manuals 1 Platform
28177 Warning Collision Hazard 2 147658 Cosmetic Genie S-60X 1
28181 Warning No Step or Ride 1 147755 Ground Control Panel 1
28235 Label Power to Platform, 115V 2 147793 Danger Tip-over Hazard 2
28236 Warning Improper Operation 1 147795 Instructions Operating Instructions, 1
31060 Danger Tip-over Hazard, Limit Switch 3 Ground
31788 Danger Explosion/Burn Hazard 1 215526 Label Belt Routing (MSG 425) 1
40434 Label Lanyard Anchorage Point 8 215527 Instructions Ford Engine Specifications 1
44981 Label Air Line to Platform (option) 2 (MSG-425)
52865 Warning Annual Inspection Record 1 229743 Label Wheel Load, S-60X 4
52966 Cosmetic 4 x 2 1 822004 Instructions Perkins Engine 1
Specifications, (404F-22)
52967 Cosmetic 4 x 4 1
822131 Instructions - Deutz Engine 1
62077 Cosmetic S-60 1 Specifications (D2.9 L4)
72875 Warning Pipe Cradle (option) 2 823658 Ground Control Panel 1
82237 Danger Electrocution Hazard (option) 2 823764 Platform Control Panel 1
82366 Label Chevron Rando 1 825579 Instructions LCD Screen 1
82410 Warning Panel Cradle (option) 2 826345 Label Ultra Low Sulfur Fuel Only 1
82644 Instructions Perkins Engine 1 (diesel models)
Specifications (404C-22) 1000262 Danger Tip-over, Capacity 1
82677 Danger Tire Specifications 4
Shading indicates decal is hidden from view, i.e.
82862 Danger Fire Extinguisher, Welder 1 under covers
(option)
40 S-60X Part No. T107102

Inspections
31060 147795 28160 31788 52865 28161 31060

25994 28158 Serial
114390
Label
114258 or 28159
133278
147605 or 826345
114389
82366 72875
147755 or
823658 40434
147793
825579 82237
82677 28177
229743 28174
or 28235
114099
229743 114416
82677 1000262
147575 or 823764
147605
62077 147609
27204 114389
27206 97875
27207 or 97579
147793
97815
44981
82862
27207
28176
27206 147605
27205
28165
52966 28236
or 52967 97887
97875
31060
28181 114277
or 215526
82644
40434 or 97548
or 114169
or 215527
or 822004
82410 or 822131
97602
28177 28175
31060
114390
147658
28174 82677 82677
or 28235
114099
28161 44981 229743 229743
Part No. T107102 S-60X 41

Inspections
Inspection for Decals with Part No. Decal Description Qty
Symbols 82487 Label Read the Manual 2

82548 Label Platform Rotate 2
Determine whether the decals on your machine
82551 Label Tire Pressure 4
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in 82602 Label Max Manual Force, 667 N, 1
ANSI
place.
82671 Label Weld Line to Platform 2
Below is a numerical list with quantities and (option)
descriptions. 97815 Label Lower Mid-rail 1
114099 Label Transport Diagram 2
Part No. Decal Description Qty
114247 Label Fall Hazard 1
27204 Arrow Blue 1
114249 Label Tip-over Hazard, Tires 4
27205 Arrow Yellow 1
114251 Label Explosion Hazard 1
27206 Triangle Blue 2
114252 Label Tip-over Hazard, Limit 7
27207 Triangle Yellow 2 Switches
28158 Label Unleaded 1 114277 Label Belt Routing (DSG-423) 1
28159 Label Diesel 1 114473 Label Tilt Alarm 1
28160 Label Liquid Petroleum Gas 1 133067 Label Electrocution Hazard 1
28174 Label Power to Platform, 230V 2 133387 Drive Enable Patch 2
28235 Label Power to Platform, 115V 2 147575 Platform Control Panel 1
40434 Label Lanyard Anchorage Point 8 147658 Cosmetic Genie S-60X 1
44981 Label Air Line to Platform (option) 2 147755 Ground Control Panel 1
52966 Cosmetic 4 x 2 1 147788 Label Maximum Capacity 3
52967 Cosmetic 4 x 4 1 229743 Label Wheel Load, S-60X 4
62077 Cosmetic S-60 1 823658 Ground Control Panel 1
82472 Label Crushing Hazard 4 823764 Platform Control Panel 1
82473 Label Compartment Access 1
Shading indicates decal is hidden from view, i.e.
82481 Label Battery/Charger Safety 1 under covers
42 S-60X Part No. T107102

Inspections
82487 Serial 28158 82481 82472 114252

Label or 28159
114251 28160 133067
114252
147788
147755 or 147788
823658 40434
114252
114099
114249
82551
82548
229743
133387
229743 147575 or 823764
82551 114473
114249
114252
28174
62077 or 28235
82671
27204 97815
27206 82487
27207
44981
147788
27207 82602
27206
27205
52966 82671
or 52967
114252
82473
114247
114277
40434 or 215526
133067
82548
114252
147658 114249
28174
or 28235 229743 229743
114099
82472 44981 82551 82551 114249
Part No. T107102 S-60X 43

Operating Instructions
Fundamentals
The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operators responsibility to follow all the
safety rules and instructions in the operators,
safety and responsibilities manuals.
Using the machine for anything other than lifting
Do Not Operate Unless: personnel, along with their tools and materials, to
You learn and practice the principles of safe an aerial work site is unsafe and dangerous.
machine operation contained in this operators
Only trained and authorized personnel should be
manual.
permitted to operate a machine. If more than one
1 Avoid hazardous situations. 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
3 Always perform function tests prior to use. all safety rules and instructions in the operators,
safety and responsibilities manuals. That means
every new operator should perform a pre-operation
5 Only use the machine as it was inspection, function tests, and a workplace
intended. inspection before using the machine.
44 S-60X Part No. T107102

Starting the Engine Models with automatic glow plugs:

5 The LCD screen will display the glow
Gasoline/LPG models plug symbol when the automatic glow
plugs are on.
1 At the ground controls, turn the key switch to
the desired position. 6 When the automatic glow plug symbol turns
2 Be sure both ground and platform control red off, move the engine start toggle switch to
Emergency Stop buttons are pulled out to the either side. If the engine fails to start or dies,
on position. the restart delay will disable the start switch for
3 seconds.
3 Choose fuel by moving the fuel select switch to
the desired position.
4 Move the engine start toggle switch to either
Emergency Stop
side. If the engine fails to start or dies, the Push in the red Emergency Stop button to the off
restart delay will disable the start switch for position at the ground controls or the platform
3 seconds. controls to stop all machine functions and turn the
engine off.
Diesel models
Repair any function that operates when either red
1 At the ground controls, turn the key switch to Emergency Stop button is pushed in.
the desired position.
Selecting and operating the ground controls will
2 Be sure both ground and platform control red override the platform red Emergency Stop button.
Emergency Stop buttons are pulled out to the
on position.
Emergency Power
Models with glow plug toggle switch:
Use emergency power if the primary power source
3 Move the glow plug switch to either side and
(engine) fails.
hold for 3 to 5 seconds.
4 Move the engine start toggle switch to either 1 Turn the key switch to ground or platform
side. If the engine fails to start or dies, the control.
restart delay will disable the start switch for 2 Pull out the red Emergency Stop button to the
3 seconds. 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.
Part No. T107102 S-60X 45

Operation from Ground To Position Platform

1 Turn the key switch to ground control. 1 Select the platform capacity. See Platform
Capacity Selection section.
2 Pull out the red Emergency Stop button to the
on position. 2 Press down the foot switch.
3 Gasoline/LPG models: Choose fuel by moving 3 Slowly move the appropriate function control
the fuel select switch to the desired position. handle or toggle switch according to the
markings on the control panel.
4 Start the engine.
If the red Emergency Stop button is pushed in and
pulled back out, the platform capacity will need to
To Position Platform
be selected again.
1 Move and hold the
platform capacity To Steer
select/function enable 1 Press down the foot switch.
switch. See Platform
Capacity Selection 2 Slowly move the drive control handle in the
section. direction indicated by blue or yellow triangles
OR press the thumb rocker switch located on
2 Move the appropriate toggle switch according top of the drive control handle.
to the markings on the control panel.
Use the color-coded direction arrows on the
Drive and steer functions are not available from the platform controls and the drive chassis to identify
ground controls. the direction the wheels will turn.
Operation from Platform To Drive

1 Press down the foot switch.
1 Turn the key switch to platform control.
2 Increase speed: Slowly move the drive control
2 Pull out both ground and platform red
handle off center.
Emergency Stop buttons to the on position.
Decrease speed: Slowly move the drive
3 Gasoline/LPG models: Choose fuel by moving
control handle toward center.
the fuel select switch to the desired position.
Stop: Return the drive control handle to center
4 Start the engine. Do not press down the foot
or release the foot switch.
switch when starting the engine.
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 booms
are raised.
46 S-60X Part No. T107102

Driving on a slope Lay the piece of wood on the slope.
Determine the uphill, downhill and side slope At the downhill end, lay the level on the top edge of
ratings for the machine and determine the slope the piece of wood and lift the end until the piece of
grade. wood is level.
Maximum slope rating, While holding the piece of wood level, measure the
platform downhill vertical distance from the bottom of the piece of
(gradeability): wood to the ground.
2WD: 30% (17)
4WD: 45% (24) Divide the tape measure distance (rise) by the
length of the piece of wood (run) and multiply by
Maximum slope rating,
platform uphill:
100.
2WD: 10% (6) Example:
4WD: 30% (17)
Maximum side slope rating:
25% (14)
Note: Slope rating is subject to ground conditions

and adequate traction.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. Piece of wood = 144 inches (3.6 m)
Move the drive speed select switch to machine on Run = 144 inches (3.6 m)
incline symbol. Rise = 12 inches (0.3 m)
To determine the slope grade: 12 in 144 in = 0.083 x 100 = 8.3% grade

0.3 m 3.6 m = 0.083 x 100 = 8.3% grade
Measure the slope with a digital inclinometer OR
use the following procedure. If the slope exceeds the maximum slope or side
slope rating, then the machine must be winched or
You will need: transported up or down the slope. See Transport
carpenters level and Lifting section.
straight piece of wood, at least 3 feet / 1 m long

tape measure
Part No. T107102 S-60X 47

Drive Enable Engine Idle Select (rpm)
Light on indicates that the boom Select engine idle (rpm) using the symbols on the
has moved just past either control panel.
non-steer wheel and the drive
When the foot switch is not pressed, the engine
function has been interrupted.
will idle at the lowest rpm.
To drive, hold the drive enable switch to either side Turtle symbol: Foot
and slowly move the drive control handle off switch activated low idle
center.
Rabbit symbol: Foot
Be aware that the machine may move in the switch activated high idle
opposite direction that the drive and steer controls
are moved.
Always use the color-coded direction arrows on the Generator (if equipped)
platform controls and the drive chassis to identify To operate the generator, move the generator
the direction the machine will travel. toggle switch to the on position.
Drive Speed Select The generator will turn on and the engine will
continue to run. Pressing down on the foot switch
will turn the generator off. Releasing the foot
switch will turn the generator back on.
Plug a power tool into the power to platform GFCI
Machine on incline symbol: Low range outlet.
operation for inclines or rough terrain To stop the generator, move the generator toggle
Machine on level surface symbol: High range switch to the off position.
operation for maximum drive speed
Machine Not Level Indicator Light
(if equipped)
Light on indicates machine is not
level. The tilt alarm will be sounding
when this light is on. Move the
machine to a firm level surface.
48 S-60X Part No. T107102

Machine Malfunction Indicator Light LCD Screen (if equipped)
Light on indicates all functions have The LCD screen displays hour
stopped. meter, voltage, oil pressure and
coolant temperature. The
screen also displays fault codes
1 Push in and then pull out the red Emergency and other service information.
Stop button.
Perkins Engine
2 Lower and retract the boom.
3 Tag the machine and remove from service. Machines equipped with Perkins diesel engines
Functions will not operate. with an LCD screen have a regeneration mode that
should run automatically when needed.
Check Engine Light (if equipped) Left amber light on and high temperature text box
present: Regeneration mode is running. No service
Light on and engine stopped: Tag the
required.
machine and remove from service.
Right side amber light on or flashing: Regeneration
Light on and engine still running:
is required.
Contact service personnel within
24 hours. 1 Push in red Emergency Stop button to turn the
machine off.
Engine Shut-down indicator light 2 Restart the engine. The regeneration mode
(if equipped) should run automatically.
Light on: Tag and remove the machine Left amber light on and no high temperature text
from service. box present: Regeneration mode is turned off. To
turn the regeneration mode on:
1 Push in red Emergency Stop button to turn the
machine off.
2 Restart the engine
Flashing red lights: contact service personnel.
Flashing green lights: contact service personnel
within 24 hours.
Deutz engine
Flashing red lights: contact service personnel.
Flashing green lights: contact service personnel
within 24 hours.
Part No. T107102 S-60X 49

Platform Capacity Selection At the Platform Controls
At the Ground Controls

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 Two light blinking indicates that the capacity has
of motion. not been selected.
Move and hold the platform capacity Determine the weight of all occupants, equipment
select/function enable switch to select the platform and materials in the platform.
capacity.
Refer to the load chart on this page or on the
Less than 501 lbs / 227 kg: The range of motion is machine to determine the available working range
unrestricted. of motion.
501-1000 lbs / 227-454 kg: The range of motion is Move and hold the platform capacity
restricted. select/function enable switch to select the platform
capacity.
The machine will stop when the machine reaches
the limit of the restricted range of motion. Raise or Less than 501 lbs / 227 kg: The range of motion is
retract the boom to continue. unrestricted.
501-1000 lbs / 227-454 kg: The range of motion is
restricted.
60 ft
18.3 m The machine will stop when the machine reaches
the limit of the restricted range of motion. Raise or
500 lbs / retract the boom to continue.
227 kg
40 ft If the red Emergency Stop button is pushed in and
12.2 m
1000 lbs / pulled back out, the platform capacity will need to
454 kg be selected again.
20 ft If the machine is started when the platform is

6.1 m outside the restricted range of motion, the 500 lbs /
227 kg capacity light will flash. Select 500 lbs /
227 kg capacity to continue. Do not exceed the
platform capacity of 500 lbs / 227 kg.
0 ft
0m
0 ft 20 ft 40 ft 60 ft
0m 6.1 m 12.2 m 18.3 m
50 S-60X Part No. T107102

Pipe Cradle Instructions Observe and Obey:

The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of
cradles positioned at either side of the platform the platform.
and mounted to the guardrails with U-bolts.
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 sure the bottom of the pipe cradle tube
rests on the platform floor.
2 Install two U-bolts from the outside of the
platform rails through each pipe cradle mount.
3 Secure each U-bolt with 2 washers and 2 nuts.
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 3/8-inch nylock nuts
Part No. T107102 S-60X 51

Pipe Cradle Operation

1 Be sure the pipe cradle assembly and
installation instructions have been followed
properly and that the pipe cradles are secured
to the platform railings.
2 Place the load so that it rests in both pipe
cradles. The length of the load should be
parallel with the length of the platform.
3 Center the load in the pipe cradles.
4 Secure the load to each pipe cradle. Pass the
nylon strap over the load. Depress the buckle
and slide the strap through. Tighten the strap.
5 Gently push and pull on the load to make sure
the pipe cradles and load are secure.
6 Keep the load secured when the machine is
moving.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles will
reduce the rated platform capacity of the
machine and must be factored into the total
platform load.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles 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
52 S-60X Part No. T107102

Panel Cradle Assembly Installation of Padding

1 Apply the warning decal to the front of each 1 Install the 2 pieces of padding on the platform
panel cradle (if needed). rails. Position the padding to protect the panels
from contact with the platform rails.
2 Install rubber bumper 1 in the panel cradle
base. See the illustration.
3 Secure the bumper with 2 high profile lock nuts Installation of Strap
and 2 washers. 1 Open the clamp and install it around a vertical
platform rail tube.
Panel Cradle Installation 2 Insert a bolt with a washer through one side of
the clamp.
1 Insert the hook piece through the slots in the
panel cradle base. 3 Install the strap assembly end plate onto the
bolt.
2 Hook the panel cradle to the bottom platform
tube in the desired location. 4 Insert the bolt through the other side of the
clamp.
3 Install rubber bumper 2 through the panel
cradle base and the hook piece. See the 5 Secure with a washer and a nut. Do not
illustration. over-tighten. The strap assembly end plate
should be able to slide on the platform rail.
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.
Part No. T107102 S-60X 53

Panel Cradle Operation

1 Secure both panel cradles to the platform.
2 Place the load so that it rests in both panel rubber
bumper 2
cradles.
3 Center the load on the platform.
4 Secure the load to the platform using the strap. rubber
Tighten the strap. bumper 1
U-bolt
mounting
slots
decal
panel
cradle
base
hook piece
padding
clamp
hook
54 S-60X Part No. T107102

After Each Use

1 Select a safe parking locationfirm 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.
5 Chock the wheels.
Part No. T107102 S-60X 55

Towing Instructions
Towing Instructions
Using the Tow Package After Towing:

1 Immediately after towing, chock the wheels,
Before Towing:
detach the tow bar and reverse the drive hub
1 Position the machine on a level surface. Chock disconnect caps.
the wheels to prevent the machine from rolling.
2 Secure the tow bar back onto the machine.
2 Attach the tow bar securely to the machine.
3 Test steer, drive and brake functions on a level
Attach the tow bar securely to the towing
surface prior to returning the machine to
vehicle.
operation. See Function Tests.
3 Release the drive torque hubs by turning over
the drive hub disconnect caps.
4 4WD models: Release the front drive torque
hus by turning over the drive disconnect caps.
5 Turn the steering bypass valve
counterclockwise to hydraulically release the
steering.
WARNING Do not exceed recommended

maximum towing speed or
maximum towing times.
Maximum tow speed 8 mph / 12.87 km/h

Maximum towing time at 30 minutes
8 mph / 13 km/h
Maximum towing time at 60 minutes
6 mph / 10 km/h
56 S-60X Part No. T107102

Transport and Lifting Instructions

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 maximum slope rating, the
machine must be loaded and unloaded using a
Observe and Obey: winch as described in the brake release
Genie provides this securement information as operation.
a recommendation. Drivers are solely
responsible for making sure machines are
properly secured and the correct trailer is
Free-wheel Configuration for
selected pursuant to US Department of Winching
Transportation regulations, other localized
regulations, and their company policy. Chock the wheels to prevent the machine from
rolling.
Genie customers needing to containerize any
lift or Genie product should source a qualified 2WD models: Release the
freight forwarder with expertise in preparing, non-steer wheel brakes by
loading and securing construction and lifting turning over the drive hub
equipment for international shipment. disconnect caps.
Only qualified aerial lift operators should move 4WD models: Release the
the machine on or off the truck. wheel brakes by turning
over all four drive hub
The transport vehicle must be parked on a
disconnect caps.
level surface.
The transport vehicle must be secured to Be sure the winch line is properly secured to the
prevent rolling while the machine is being drive chassis tie points and the path is clear of all
loaded. obstructions.
Be sure the vehicle capacity, loading surfaces Reverse the procedures described to re-engage
and chains or straps are sufficient to withstand the brakes.
the machine weight. Genie lifts are very heavy
relative to their size. See the serial label for the Note: The pump free-wheel valve should always
machine weight. remain closed.
Be sure the turntable is secured with the

turntable rotation lock before transporting. Be
sure the unlock the turntable for operation.
Part No. T107102 S-60X 57

Securing to Truck or Trailer for Securing the Platform - S-60X

Transit Place a block under the platform rotator. Do not
allow the block to contact the platform cylinder.
Always use the turntable rotation lock pin each
time the machine is transported. Secure the platform with a nylon strap placed
through the lower platform support. Do not use
excessive downward force when securing the
boom section.
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.
Securing the Chassis

Use chains or straps of ample load capacity.
Use a minimum of 5 chains.
Adjust the rigging to prevent damage to the chains.
58 S-60X Part No. T107102

Lifting Instructions
Fully lower and retract the boom. Remove all loose
items on the machine.
Use the turntable rotation lock to secure the
turntable.
Observe and Obey: Determine the center of gravity of your machine
using the table and the picture on this page.
Only qualified riggers should rig and lift the
machine. Attach the rigging only to the designated lifting
Be sure the crane capacity, loading surfaces points on the machine. All four of the lifting points
and straps or lines are sufficient to withstand are on the turntable.
the machine weight. See the serial label for the Adjust the rigging to prevent damage to the
machine weight. machine and to keep the machine level.
Center of gravity X Axis Y Axis

S-60X 4.13 ft 50.6 in
1.25 m 1.28 m
Turntable
Lifting
Points (2)
Y Axis
Chassis
Lifting
Points (2)
X Axis
Part No. T107102 S-60X 59

Maintenance
Maintenance
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
Observe and Obey: can damage engine components.
Only routine maintenance items specified in Note: Check the oil level with the engine off.
this manual shall be performed by the
operator. 1 Check the oil level dipstick. Add oil as needed.
Scheduled maintenance inspections shall be Ford DSG-423 EFI Engine
completed by qualified service technicians,
Oil type 5W-20
according to the manufacturers specifications
and the requirements specified in the Ford MSG-425 EFI Engine
responsibilities manual. Oil type 5W-20
Use only Genie approved replacement parts. Perkins 404C-22 Engine
Oil type 15W-40
Maintenance Symbols Legend Oil type - cold conditions 5W-20

Perkins 404D-22 Engine
The following symbols have been used in this
manual to help communicate the intent of the Oil type 15W-40
instructions. When one or more of the symbols Oil type - cold conditions 5W-40
appear at the beginning of a maintenance Perkins 404F-22 Engine
procedure, it conveys the meaning below.
Oil type 15W-40
Indicates that tools will be required to Oil type - cold conditions 5W-40
perform this procedure. Deutz F3L 2011F Engine
Oil type 15W-40
Indicates that new parts will be required to Oil type - cold conditions 5W-30
perform this procedure.
Deutz D2.9 L4 Engine
Oil type 15W-40
Indicates that a cold engine is required Oil type - cold conditions 5W-30
before performing this procedure.
60 S-60X Part No. T107102

Maintenance
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
Maintaining the engine coolant at the proper level
oil levels can damage hydraulic components. Daily
is essential to engine service life. Improper coolant
checks allow the inspector to identify changes in oil
level will affect the engines cooling capability and
level that might indicate the presence of hydraulic
damage engine components. Daily checks will
system problems.
allow the inspector to identify changes in coolant
1 Be sure that the boom is in the stowed level that might indicate cooling system problems.
position.
Burn hazard. Beware of hot engine parts and
2 Visually inspect the sight gauge located on the coolant. Contact with hot engine parts and/or
side of the hydraulic oil tank. coolant may cause severe burns.
Result: The hydraulic oil level should be within Burn hazard. Do not remove the radiator cap if
the top 2 inches / 5 cm of the sight gauge. the engine has been running. Contact with
3 Add oil as needed. Do not overfill. pressurized coolant may cause severe burns.
Allow engine to cool before removing the
Hydraulic oil specifications radiator cap.
Hydraulic oil type Chevron Rando HD equivalent 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.
Part No. T107102 S-60X 61

Maintenance
Check the Batteries Diesel Fuel Requirements
Proper battery condition is essential to good Satisfactory engine performance is dependent on

machine performance and operational safety. the use of a good quality fuel. The use of a good
Improper fluid levels or damaged cables and quality fuel will give the following result: long
connections can result in component damage and engine life and acceptable exhaust emissions
hazardous conditions. levels.
Electrocution hazard. Contact with hot or live Minimum diesel fuel requirements for each engine
circuits may result in death or serious injury. are listed below.
Remove all rings, watches and other jewelry.
Perkins 404D-22 Engine
Bodily injury hazard. Batteries contain acid.
Fuel Type Low Sulfur Diesel (LSD)
Avoid spilling or contacting battery acid.
Neutralize battery acid spills with baking soda Perkins 404F-22 Engine
and water. Fuel Type Ultra Low Sulfur Diesel (ULSD)
1 Put on protective clothing and eye wear. Deutz D2011 L03i Engine
Fuel Type Low Sulfur Diesel (LSD)
2 Be sure that the battery cable connections are
tight and free of corrosion. Deutz D2.9 L4 Engine
Fuel Type Ultra Low Sulfur Diesel (ULSD)
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.
62 S-60X Part No. T107102

Maintenance
Scheduled Maintenance
Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on
this machine according to the procedures found in
the service manual for this machine.
Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.
Part No. T107102 S-60X 63

Specifications
Specifications
Model S-60X Maximum slope rating, stowed position, 2WD

Height, working maximum 64 ft 4 in 19.79 m Counterweight uphill 30% 17
Height, platform maximum 58 ft 4 in 17.79 m Counterweight downhill 10% 6
Height, stowed maximum 8 ft 11 in 2.72 m Side slope 25% 14
Horizontal reach, maximum 50 ft 10 in 15.5 m Maximum slope rating, stowed position, 4WD
Horizontal reach, restricted 40 ft 8 in 12.4 m Counterweight uphill 45% 24
Width 8 ft 6 in 2.59 m Counterweight downhill 30% 17
Length, stowed 27 ft 11 in 8.5 m Side slope 25% 14
Maximum load capacity, 500 lbs 227 kg Note: Slope rating is subject to ground conditions and
unrestricted range of motion adequate traction.
Maximum load capacity, 1000 lbs 454 kg
Drive speeds
restricted range of motion
Drive speed, stowed, 2WD 4.0 mph 6.4 km/h
Maximum wind speed 28 mph 12.5 m/s
40 ft/6.2 sec 12.2m/6.2 sec
Wheelbase 8 ft 2.5 in 2.5 m
Drive speed, stowed, 4WD 3.0 mph 4.8 km/h
Turning radius (outside) 22.3 ft 6.8 m 40 ft/7.2 sec 12.2m/7.2 sec
Turning radius (inside) 12 ft 3.66 m Drive speed, raised or 0.7 mph 1.1 km/h
Turntable rotation (degrees) Continuous extended all models 40 ft/40 sec 12.2 m/40 sec
Turntable tailswing 4 ft 1.22 m Floor loading information
Controls 12V DC proportional Track load maximum 11,640 lbs 5280 kg
Platform dimensions, 6 foot 72 x 30 in 182 x 76 cm Track contact pressure 70 psi 4.92 kg / cm2
(length x width) 483 kPa
Platform dimensions, 8 foot 96 x 36 in 244 x 91 cm Occupied floor pressure 234 psf 1140 kg / m2
(length x width) 11.195 kPa
Platform leveling self-leveling Note: Floor loading information is approximate and does
Platform rotation 160 not incorporate different option configurations. It should
be used only with adequate safety factors.
AC outlet in platform standard
Continuous improvement of our products is a Genie
Ground clearance, center 14.5 in 36.8 cm policy. Product specifications are subject to change
Ground clearance, axle 13 in 33 cm without notice or obligation.
Fuel tank capacity, gasoline 30 gallons 114 liters
Fuel tank capacity, diesel 35 gallons 132 liters
Hydraulic pressure, maximum 3000 psi 207 bar
(boom functions)
System voltage 12V
Weight 20,742 lbs 9408 kg
(Machine weights vary with option configurations. See
serial label for specific machine weight.)
64 S-60X Part No. T107102

Specifications
S-60X Range of Motion
60 ft
18.3 m
500 lbs /
227 kg
40 ft
12.2 m
1000 lbs /
454 kg
20 ft
6.1 m
0 ft
0m
0 ft 20 ft 40 ft 60 ft
0m 6.1 m 12.2 m 18.3 m
S-60X Part No. T107102 Operator's Manual First Edition Fifth Printing
Part No. T107102 S-60X 65

California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Distributed By:
www.genielift.com

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What safety precautions should be taken when operating this equipment?

What safety precautions should be taken when operating this equipment?

What are the main components and controls described in the manual?

What are the main components and controls described in the manual?

Operator's Manual

Serial Number Range

S-60X From S6010-21001

Copyright 2010 by Terex Corporation

S-60X Part No. T107102

Owners, Users and Operators:

Part No. T107102 S-60X 1

Hazard Classification Intended Use

WARNING Indicates a hazardous situation

CAUTION Indicates a hazardous situation

NOTICE Indicates a property damage

2 S-60X Part No. T107102

Symbol and Hazard Pictorials Definitions

Part No. T107102 S-60X 3

Symbol and Hazard Pictorials Definitions

Electrocution hazard Avoid contact Tie-down instructions Read the service

Tie-down instructions Explosion / Burn Explosion hazard Do not use ether or

4 S-60X Part No. T107102

Part No. T107102 S-60X 5

6 S-60X Part No. T107102

Part No. T107102 S-60X 7

8 S-60X Part No. T107102

Part No. T107102 S-60X 9

10 S-60X Part No. T107102

Personal Fall Protection

Part No. T107102 S-60X 11

Work Area Safety

Electrocution Hazards Tip-over Hazards

Do not operate the machine during lightning or

12 S-60X Part No. T107102

Work Area Safety

Do not operate the machine in strong or gusty

Use extreme care and

Part No. T107102 S-60X 13

Work Area Safety

Note: Slope rating is subject to ground conditions

14 S-60X Part No. T107102

Work Area Safety

Fall Hazards Collision Hazards

Do not climb down from

Keep the platform floor clear of debris.

Part No. T107102 S-60X 15

Work Area Safety

Do not lower the boom Bodily Injury Hazard

16 S-60X Part No. T107102

Work Area Safety

Damaged Machine Hazards Battery Safety

Part No. T107102 S-60X 17

Work Area Safety

Welder Safety Weld Line to Platform Safety

18 S-60X Part No. T107102

Work Area Safety

Pipe Cradle Safety Panel Cradle Safety

Part No. T107102 S-60X 19

Work Area Safety